Bw141ad-4 SM PDF
Bw141ad-4 SM PDF
Bw141ad-4 SM PDF
Catalogue number.
008 910 92 01/2008
Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 24
Maintenance 29
2.1 General notes on maintenance 30
2.2 Fuels and lubricants 31
2.3 Fuels, lubricants and filling capacities 33
2.4 Running-in instructions 34
2.5 Maintenance chart 35
Technical data 37
3.1 Technical data 38
Connection overview 45
4.1 Connection overview 46
Tests and adjustments 49
5.1 Special tools, tests and adjustments 50
5.2 Adjusting the angle sensor on travel control lever 54
5.3 Checking the rotation speeds 56
5.4 Pressure tests in the travel circuit 58
5.5 Checking / adjusting the neutral positions of the travel pump 60
5.6 Check the setting of the high pressure relief valves in the travel circuit 63
5.7 Pressure tests in the vibration circuit 65
5.8 Check the setting of the high pressure relief valves in the vibration circuit 66
5.9 Checking / adjusting the vibrator shaft speeds 68
5.10 Check the leakage rate of the vibration motor 69
5.11 Pressure test in steering circuit 70
Flushing and bleeding 73
6.1 Special tools for flushing 74
6.2 Flushing - general 79
6.3 Flushing schematic for front drum drive 82
6.4 Flushing the front drum drive 83
6.5 Flushing schematic for rear drum drive system 87
6.6 Flushing the rear drum drive 88
6.7 Flushing schematic for wheel drive motors, AC-machines 92
6.8 Flushing the rear wheel drive on AC machines 93
6.9 Flushing schematic for vibration drive on AD-machines 97
6.10 Flushing schematic for vibration circuit on AC-machines 98
6.11 Flushing the vibration circuit 99
6.12 Bleeding the travel circuit 103
6.13 Bleeding the vibration circuit 105
Fundamental electrics 107
7.1 Understanding circuit diagrams 108
7.2 Terminal designations 113
7.3 Current and voltage 117
7.4 CAN-Bus 120
Documentation
For the BOMAG machines described in this training
manual the following documentation is additionally
available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Wiring diagram*
4 Hydraulic diagram*
5 Service Information
Danger
!
Caution
! Danger
!
Paragraphs marked like this highlight possible Electric shock!
dangers for machines or parts of the machine.
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
i Note
eyes!
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine. Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
Environment grease or solvent residues, etc.!
Paragraphs marked like this point out practices ● Check welding equipment and cables for damage
for safe and environmental disposal of fuels and before use (also the validity of inspection stickers).
lubricants as well as replacement parts.
● Ensure good conductivity between earth cable and
Observe the regulations for the protection of the work piece.
environment.
● Start the extraction fan before starting work and
guide with the progressing work as required.
General
●
Always isolate the burner when laying it down (re-
●
Before starting repair work stand the machine on move possible electrode residues).
level and solid ground.
● Protect cables from being damaged, use cables
● Always secure the machine against unintended roll- with insulated couplings.
ing.
●
Ensure sufficient fire protection, keep a fire extin-
● Secure the engine reliably against unintentional guisher at hand.
starting.
● In case of welding work in fire or explosion endan- full face visor; a facility suitable for rinsing the eyes
gered environments, you should always ask for a should also be available.
welding permission. ● Avoid prolonged and repetitive contact with oil, es-
● Remove combustible parts from the vicinity or cover pecially with old oil. In case of open incisions and in-
such parts. juries seek medical advice immediately.
● Name a fire watch during and after welding work. ● Apply protective cream before starting work, so that
oil can be easier removed from the skin.
● Do not clamp the welding rod holder and the inert
gas welding gun under your arm and lay these parts ● Wash with soap and water to ensure that all oil has
only on an insulated top. been removed (a skin cleaning agent and a nail
brush will help). Lanolin containing agents will re-
● Place the inert gas bottles in a safe place and se-
place natural skin oils that were lost.
cure them against falling over.
● Do not use gasoline, kerosene, diesel, thinner or
● Use a protective screen or an arcing shield with
solvents to wash the skin.
welding glass, wear welding gloves and clothes,
this applies also for assisting persons. ● Do not put oil soaked cloths into your pockets.
● Switch the welding unit off before connecting weld- ● Avoid clothes, especially underpants, getting soiled
ing cables. by oil.
Synthetic rubber
Many O-rings, hoses and similar parts, which are ap-
parently made of natural rubber, are actually made of
Air conditioning system from April 1989). Paragraph 10 of the pressure ves-
sel directive demands that these pressure contain-
ers must be periodically inspected and tested by a
Caution
!
specialist, according to paragraph 32. In this case
Lines in the air conditioning system must only be periodically recurring inspections consist of external
loosened by trained and explicitly instructed ex- examinations, normally on containers in operation.
perts. The refrigerant container must be visually inspected
two times per year, within the frame work of major
● Wear safety goggles! Put on your safety goggles.
inspections. Special attention must thereby be paid
This will protect your eyes against coming into con-
to signs of corrosion and mechanical damage. If the
tact with refrigerant, which could cause severe
container is in no good condition, it should be re-
damage by freezing.
placed for safety reasons, in order to protect the op-
● Wear safety gloves and an apron! Refrigerant are erator or third parties against the dangers when
excellent solvents for greases and oils. In contact handling or operating pressure vessels.
with skin they will remove the protective grease film. ● Secure pressure vessels against tipping over or roll-
However, degreased skin is very sensitive against
ing away.
cold temperatures and germs.
● Do not throw pressure vessels. Pressure vessels
● Do not allow liquid refrigerants to come into contact
may thereby be deformed to such an extent, that
with skin! Refrigerant takes the heat required for
they will crack. The sudden evaporation and escape
evaporation from the environment. Very low tem-
of refrigerant releases excessive forces. This ap-
peratures may be reached. The results may be local
plies also when snapping off valves on bottles. Bot-
frost injuries (boiling point of R134a -26.5°C at am-
tles must therefore only be transported with the
bient pressure).
safety caps properly installed.
● Do not inhale higher concentrations of refrigerant ●
Refrigerant bottles must never be placed near heat-
vapours! Escaping refrigerant vapours will mix with
ing radiators. Higher temperatures will cause higher
the ambient air and displace the oxygen required for
pressures, whereby the permissible pressure of the
breathing.
vessel may be exceeded. The pressure vessel di-
● Smoking is strictly prohibited! Refrigerants may be rective therefore specifies that a pressure vessel
decomposed by a glowing cigarette. The resulting should not be warmed up to temperatures above 50
substances are highly toxic and must not be in- °C.
haled. ●
Do not heat up refrigerant bottles with an open
● Welding and soldering on refrigeration equipment! flame. Excessive temperatures can damage the
Before starting welding or soldering work on vehi- material and cause the decomposition of refriger-
cles, (in the vicinity ant.
of air conditioning components) all refrigerant must ●
Do not overfill refrigerant bottles, since any temper-
be drawn out and the rests removed by blowing out
ature increase will cause enormous pressures.
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a Environment
strong corrosive effect, so that pipes and system In operation, during maintenance and repair work
components may be attacked. The substance is and when taking refrigeration systems our of
mainly fluorohydrogen. service it is not permitted to let refrigerant escape
● Pungent smell! In case of a pungent smell the afore into the atmosphere, which would contradict the
mentioned decomposition products have already current status of technology.
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi- Battery
ratory system, the lungs and other organs may be ● Wear goggles and face protection (acid).
harmed.
● Wear suitable clothes to protect face, hands and
● When blowing out components with compressed air body (acid).
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
●
Work and store accumulators only well ventilated
facilities (workshop exhaust systems). rooms. (Development of oxyhydrogen gas).
● Do not lean over the battery while it is under load,
Handling pressure vessels being charged or tested. (Danger of explosion).
● Since the fluid container is pressurized, the manu- ● Burning cigarettes, flames or sparks can cause ex-
facture and testing of these pressure vessels is gov- plosion of the accumulator
erned by the pressure vessel directive. (New edition ● Keep ignition sources away from the battery.
General Electrics
1.3 General repair instructions
●
Before removing or disassembling and parts, hoses General
or components mark these parts for easier assem-
The electric and electronic systems in construction
bly.
equipment are becoming more and more extensive.
● Before assembly oil or grease all parts, as far as this Electronic elements are increasingly gaining impor-
is necessary. tance in hydraulic and mechanical vehicle systems.
General:
●
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
● Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
●
Perform trouble shooting in a systematic way. Do
not become confused by the high number and vari-
ety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
●
Do not disconnect or connect battery or generator
while the engine is running.
● Do not operate the main battery switch under load.
!Caution
Switch off the main battery switch, doisconnect
the generator and pull the plug out on the control
unit before starting welding work.
Fig. 2
●
Lubricate sealing lips 1 (Fig. 2) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
●
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve 1 (Fig. 2), to pro-
tect the lip from being damaged by sharp edges,
!Caution !Caution
Feather keys must only be reused if they show no Ball and roller bearings must only be reinstalled
differences to new feather keys, any notches must after it has been assured that they are in perfect
be considered as initial signs of wear. condition.
Fig. 4
● Clean and thoroughly examine the feather key.
● Debur and thoroughly clean the edges of the key-
way with a fine file before reassembling.
Fig. 5
● Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
●
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
●
Hold the bearing with you thumb and the index fin-
ger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
●
Move the outer race gently to and fro while holding
it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
● Lubricate the bearing with an appropriate lubricant
before reinstalling.
i Note
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.
● black oiled
● with surface protection A4C
● with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
1 Coefficient of friction μ tot. = 0,14
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
1 Coefficient of friction μ tot. = 0,14
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
1 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.
Tightening torques Nm
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
1 Coefficient of friction μ tot. = 0,14
2 These values result in a 90% utilization of the yield point
i Note
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°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
1 Coefficient of friction μ tot. = 0,14
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
1 Coefficient of friction μ tot. = 0,14
2.1 General notes on maintenance the engine's performance and temperature level as
well as the quality of the exhaust gas.
When servicing the machine pay careful attention to
If your machine has to work permanently in "thin air"
all applicable safety instructions.
(at high altitudes) and with full load you should consult
Thorough maintenance of the machine ensures max- or service department or the service department of the
imum reliability and prolongs the lifetime of important engine manufacturer.
components. The necessary effort can by no means
be compared with the faults which may occur when Notes on the hydraulic system
not observing these instructions.
When servicing the hydraulic system cleanliness if of
The terms left/right are always related to travel direc-
utmost importance. make sure that no dirt or other
tion forward.
contaminating systems can enter the system. Small
● Clean machine and engine thoroughly before start- particles can flute valves, cause pumps to seize and
ing maintenance work. block restrictors and pilot bores, thereby causing cost-
ly repairs.
● For maintenance work park the machine on level
ground. ● If during the daily oil level check the oil level is found
to have dropped, check all lines, hoses and compo-
● Maintenance work must generally be carried out
nents for leakages.
with the engine shut down.
● Seal leakages immediately. If necessary inform the
● Depressurize hydraulic lines before working on
responsible service department.
them.
●
Disconnect the battery and cover it with insulation
●
Always use the filling and filtering unit (BOMAG
material before starting to work on electrical compo- part-no. 007 610 01) to fill the hydraulic system.
This unit is equipped with a fine filter which cleans
nents.
the hydraulic oil and prolongs the lifetime of the fil-
●
Always attach the articulation lock (transport lock) ter.
before starting to work in the articulation area of the ●
Clean fittings, filler caps and their immediate sur-
machine.
rounding area before removing them, so that no dirt
can fall in.
Environment ●
Do not leave the tank opening unnecessarily open,
During maintenance work catch all oils and fuels cover it so that no dirt can fall in.
and do not let them seep into the ground or into
the sewage system. Dispose of oils and fuel envi-
ronmentally.
Store used filters in a special waste container and
dispose of environmentally.
Always catch biodegradable oil separately.
Oil quality
Preferably use oils of ACEA-classification E3-96/E5-
02. This enables utilization of the longest oil change
intervals. Oil of ACEA-classification E2-96 may also
when reducing the period between oil changes by 50
percent.
Oils of API-quality class CG-4/CH-4 enable utilization
of the longest oil change intervals. Oils of API-quality
classes CF/CF-4 may also be used when reducing the
period between oil changes by 50 percent.
ACEA
E2-96 = 250 operating hours
API
API CF/CF-4 = 250 operating hours
Fig. 10
ACEA
In order to assure perfect cold starting it is import to
chose the viscosity (SAE-class) of the engine oil ac- E3-96/E5-02 = 500 operating hours
cording to the ambient temperature. API
For winter operation below -10 °C the oil change inter- CG-4/CH-4 = 500 operating hours
vals must be shortened.
Lubrication oil with a too high viscosity index causes
! Caution
starting difficulties. The temperature when starting the
engine is therefore of highest importance when These intervals apply only when using a diesel
choosing the viscosity of engine oil for winter opera- fuel with maximum 0.5 % sulphur by weight and
tion. for ambient temperatures higher than -10 °C.
When using fuels with a sulphur content of more
Oil viscosity than 0.5% to 1% or under ambient temperatures
below -10 °C the oil change intervals specified in
Since lubrication oil changes its viscosity with the tem-
the table must be halved. When using fuels with a
perature, the ambient temperature at the operating lo-
sulphur content higher than 1% to 1.5% the engine
cation of the engine is of utmost importance when
oil must have a TBN of approx. 12 x the S-content
choosing the viscosity class (SAE-class) (Fig. 10).
in % by weight when halving the oil change inter-
Occasional falling short of the temperature limit (e.g. vals.
use of SAE 15W/40 down to -15 °C) may effect the
cold starting ability of the engine, but will not cause
Lubrication oil quality classes
any engine damage.
The oil manufacturer is solely responsible for assign-
Temperature related lubrication oil changes can be
ing a product to a certain quality class.
avoided by using multi-purpose oils. The following oil
change intervals apply also when using multi-purpose
oils. i Note
When changing to a higher alloyed oil quality after a
longer period of operation, it is recommended to per-
form the first oil change of the higher quality oil already
after 20 operating hours. The lubrication oil filter car- Lubrication grease
tridge must be changed at the same time.
For lubrication purposes use an EP-high pressure
grease, calcium and/or lithium saponified (penetration
Fuels 2), acc. to DIN 51502 KP 2G.
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and en-
sure strict cleanliness when filling in. A higher sulphur
content has a negative effect on the oil change inter-
vals. Use only winter-grade diesel fuel under low am-
bient temperatures. 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.
The following fuel specifications are permitted: DIN
51601; Nato Codes: F-54, F-75; BS 2869: A1 and A2;
ASTM D 975-78: 1-D and 2-D; VV-F-800 a: DF-A, DF-
1 and DF-2.
Winter fuel
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
Consult the engine manufacturer.
API: CG-4/CH-4
Fuel
Travel gear, drum SAE 80W-90, API GL5 approx. 1.5 litres
! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.
Special intervals
●
Switch the heating system1 on every month for
about 10 minutes.
●
Switch the air conditioning* on every month for
about 10 minutes.
1 Optional equipment
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection X
glass
5.10 Check the water level X
5.11 Checking the emulsion level X
5.12 Clean the cooling fins on engine X
and hydraulic oil cooler
5.13 Change the engine oil* see foot note X
5.14 Change the engine oil filter car- min. 1x per year X
tridge1
5.15 Service the air conditioning (sum- X
mer operation)
5.16 Service the battery Pole grease X
5.17 Change the fuel filter cartridge X
5.18 Change the fuel pre-filter cartridge X
5.19 Change the oil in the drum drive see foot note X
gear2
5.20 Check, tension, lubricate the steer- X
ing chain
5.21 Check the engine mounts X
5.22 Check, tension, replace the V-belt X
5.23 Checking, tensioning, replacing X
the refrigerant compressor V-belt
5.24 Change the oil in the vibrator shaft see foot note X
tube3
5.25 Check, adjust the valve clearance X
5.26 Change hydraulic oil and breather see foot note X
filter4
as required
5.27 Changing the hydraulic oil filter at least every 2 X
years
5.28 Grease the articulated joint at least every 2 X
years
5.29 Replace the injection valve X
5.30 Service the combustion air filter min. 1x per X
year,
safety cartridge
at least every 2
years
5.31 Clean the water tank X
5.32 Clean the water filter X
5.33 Water sprinkler system, mainte- X
nance in the event of frost
5.34 Cleaning the emulsion filter X
5.35 Fill the provision tank for the wind- X
screen washer system
5.36 Adjusting the scrapers X
5.37 Checking the tire pressure X
5.38 Tightening torques X
5.39 Engine conservation X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Oil change after 250 h, after 500 h, then every 1000 h
3 Oil change after 250 h, after 500 h, then every 1000 h
4 Also after repairs in the hydraulic system.
Fig. 11
Dimensions in A B C D H H2 K L O W
mm
BW 141 AD-4 3300 1660 710 1220 2320 3000 400 4520 80 1500
BW 151 AD-4 3300 1660 715 1220 2320 3000 400 4520 80 1680
Weights
Operating weight (CECE) kg 7500 7900
Operating weight (CECE) with kg 8000 8300
ROPS-cabin
Front axle load (CECE) kg 3700 3900
Rear axle load (CECE) kg 3800 4000
Static linear load front (CECE) kg/cm 24,7 23
Static linear load rear (CECE) kg/cm 25,3 24
Dimensions
Oscillation angle +/-° 6 6
Inner track radius mm 4490 4400
Travel characteristics
Travel speed (1) km/h 0-10,5 0-10,5
Max. gradability without/with vibra- % 40/35 40/35
tion (soil dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2011 BF4M 2011
Cooling Oil Oil
Number of cylinders 4 4
Rated power ISO 9249 kW (PS) 60 60
Rated speed rpm 2500 2500
Electrical equipment V 12 12
Battery V/AH 12/100 12/100
Drive system hydrost. hydrost.
Driven drum front + rear front + rear
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost.
Steering angle +/- degree 30 30
Crabwalk, lateral offsetting of mm 170 170
drum (right/left)
Vibration system
Drive system hydrost. hydrost.
Frequency 1/2 Hz 40/60 40/60
Amplitude 1/2 mm 0,64/0,28 0,64/0,28
Vibrating drum front + rear front + rear
Filling capacities
Fuel (diesel) l 160 160
Water l 800 800
Hydraulic oil l 60 60
Engine oil l approx. 10 approx. 10
1 The right for technical modifications remains reserved
Fig. 12
Dimensions in A B C D H H2 K L O W
mm
BW 151 AC-4 3300 1660 715 1220 2320 3000 400 4520 80 1680
BW 161 ADCV 3300 1660 715 1220 2320 3000 400 4520 80 1680
1
BW 151 AC-4 BW 161 ADCV
Weights
Operating weight (CECE) kg 8300 7900
Operating weight (CECE) with kg 8750 8300
ROPS-cabin
Front axle load (CECE), drum kg 4150 3900
Rear axle load, (CECE) wheels kg 4600 4000
Static linear load front (CECE) kg/cm 27,7 23
Static linear load rear (CECE) 24
Dimensions
Oscillation angle +/-° 6 6
Inner track radius mm 4400 4400
Travel characteristics
Travel speed (1) km/h 0-10,5 0-10,5
Max. gradability without/with vibra- % 40/35 40/35
tion (soil dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2011 BF4M 2011
Cooling Oil Oil
Number of cylinders 4 4
Rated power ISO 9249 kW (PS) 60 60
Rated speed rpm 2500 2500
Electrical equipment V 12 12
Battery V/AH 12/100 12/100
Drive system hydrost. hydrost.
Driven drum front + rear front + rear
Brakes
Service brake hydrost. hydrost.
Parking brake mechanical mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrost. hydrost.
Steering angle +/- degree 30 30
Crabwalk, lateral offsetting of mm 170 170
drum (right/left)
Vibration system
Drive system hydrost. hydrost.
Frequency 1/2 Hz 40/60 40/60
Filling capacities
Fuel (diesel) l 160 160
Water l 800 800
Hydraulic oil l 60 60
Engine oil l approx. 10 approx. 10
1 The right for technical modifications remains reserved
Travel pump
Manufacturer Bosch-Rexroth
Type A4VG 56 HW/32
System Axial piston/swash plate
Max. displacement cm3/rev. 56
Max. flow capacity l/min 136,1
High pressure limitation bar 440
Pressure override valve bar 400 ± 10
Charge pressure, high idle bar 25 +3/-1
Travel motors
Type A2 FE 32
System Axial piston
Displacement (stage 1) cm3/rev. 32
Permissible leakage rate l/min 2
Flushing quantity l/min 5
Vibration pump
Manufacturer Bosch-Rexroth
Type A10VG 45 EZ
System Axial piston/swash plate
Max. displacement cm3/rev. 45
Start up pressure bar 360 ± 20
Operating pressure, soil dependent bar approx. 100
Vibration motor
Type A4FM 22
Check steering/
Type HY/ZFFS11/16+8
System Tandem gear pump
Displacement cm3/rev. 11/ 8
Max. steering pressure bar 200 ± 5
Steering valve
Type OSPC 400 LS
System Rotary valve
were determined during conditions typical for this type of equipment and by application of harmonized
standards.
During operation these values may vary because of the existing operating conditions.
Noise value
sound pressure level on the operator’s stand:
BW 141 AD-4 LpA = 80 dB(A) BW 161 AD-4, determined acc. to ISO 11204 and EN 500
BW 151 AD-4 LpA = 82 dB(A) BW 161 AD-4, determined acc. to ISO 11204 and EN 500
BW 151 AC-4 LpA = 83 dB(A) determined acc. to ISO 11204 and EN 500
BW 161 ADCV LpA = 79,7 dB(A) determined acc. to ISO 11204 and EN 500
! Danger
Wear your personal noise protection means (ear defenders) before starting operation.
Vibration value
Vibration of the entire boy (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is <= 0.5m/sec2.
Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
BOMAG part-no.: 059 710 02
Fig. 2
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 °C
Fig. 3
4. Digital rpm-meter for petrol engines
Fig. 4
Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use
Fig. 6
7. Infrared manual thermometer, -18 to 275°C
Fig. 7
8. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 8
i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses
Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 11
12. Adapter for pressure test hose
Fig. 12
Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 14
Fig. 1
i Note
The setting applies for module 920 225 17 (Fig.
2).
Fig. 2
! Caution
The setting does not apply for module
920 225 24 (Fig. 3).
i Note
Neutral position of the travel control lever (mod-
ule 920 225 24) is automatically learned with the
brake applied.
Fig. 3
Fig. 4
3. Slightly slacken both screws (Fig. 5) for the angle
sensor.
Fig. 5
4. Keep turning the sensor, until LED 3 (Fig. 6) lights
up.
i Note
LED 2 serves as adjustment aid. If the flashing
frequency rises while turning, you are turning to
the wrong direction.
If LED 2 flashes in intervals of a second and LED
3 lights permanently, the correct setting is
achieved.
If the adjustment range for the sensor is not big
enough, you may extend or shorten the connect-
Fig. 6 ing linkage 2 (Fig. 5).
! Caution
In order to check the setting the travel lever
must be shifted back and forth in the brake
gate, whereby the LED on Pin 3 (travel lever
out of "Neutral") should not light up. Other-
wise repeat the adjustment procedure.
5. Retighten the angle sensor fastening screws.
! Caution
Perform measurements at operating tempera-
ture (40 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
Fig. 1
i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.
Nominal value
see technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.
Fig. 3
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
1. Block the drums with suitable chocks (Fig. 1).
Fig. 1
2. Pull the plug (Fig. 2) off the brake solenoid valve
to close the brake.
Fig. 2
3. Connect a 600 bar pressure gauge (Fig. 3) each
to test ports MA and MB.
Fig. 3
Nominal value
Charge pressure = see technical data "travel
pump, charge pressure high idle".
High pressure = see technical data "travel pump,
charge pressure high idle".
Evaluation of test
Fig. 4
If the nominal value is not reached, check the
steering/charge pump.
7. Move the travel lever quickly to forward and back-
ward, read the pressure gauges.
Nominal value
Charge pressure = see technical data "travel
pump, charge pressure high idle".
High pressure = see technical data "travel pump,
pressure override".
Evaluation of test
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
the high pressure test, check the components in-
dividually.
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
1. Block the drums with suitable chocks (Fig. 1).
Fig. 1
1. Unhook the travel cable (Fig. 2) from the travel
pump.
Fig. 2
2. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 3
Fig. 4
Fig. 5
3. Read the pressure gauges (Fig. 6).
i Note
For a more exact adjustment repeat the test with
60 bar pressure gauges
Nominal value
Both pressure gauges must show identical pres-
sure, if necessary correct the mechanical neutral
position.
Fig. 6
4. Adjust the neutral position (Fig. 7) so that both
pressure gauges show identical pressure (charge
pressure).
i Note
Equalize the dead range of the neutral position.
Fig. 7
Fig. 8
3. Read the pressure gauges (Fig. 9).
i Note
For a more exact adjustment repeat the test with
60 bar pressure gauges
Do not actuate the travel lever, since this may de-
stroy the pressure gauges.
Nominal value
Both pressure gauges must show identical pres-
sure (charge pressure), if necessary correct the
hydraulic neutral position ....
Fig. 9
4. ..... for this purpose loosen the clamping (Fig. 10).
! Caution
Do not adjust the eccentric beyond the ± 90°
position.
5. Adjust the neutral position on the eccentric (2), so
that both pressure gauges show identical pres-
sure (charge pressure).
6. Retighten the clamping.
Fig. 10
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
1. Block the drums with suitable chocks (Fig. 1).
Fig. 1
2. Pull the plug (Fig. 2) off the brake solenoid valve
to close the brake.
Fig. 2
3. Connect a 600 bar pressure gauge (Fig. 3) each
to test ports MA and MB.
Fig. 3
! Caution
Perform the following pressure test for max. 3
seconds, otherwise pump damage caused by
overheating.
6. Move the travel lever quickly to both travel direc-
tions and read the pressure gauges.
Fig. 4
Nominal value
Evaluation of test:
If the nominal value is only reached to one direc-
tion, clean or replace the valve (Fig. 5) if neces-
sary.
If the nominal value is not reached to both direc-
tions check the travel pump, replace if necessary.
Fig. 5
Adjusting the pressure override
! Caution
To assure a reliable function of the pressure
override, the pressure override valve must be
adjusted 10% lower than the high pressure re-
lief valve.
1. Turn the setscrew (Fig. 6) back out again, until
the high pressure is limited to its setpoint, when
the drums are blocked.
Nominal value
see technical data, "travel pump pressure over-
ride".
Fig. 6
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
2. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
Fig. 1
3. Connect a 600 bar pressure gauge (Fig. 2) each
to test ports MA and MB.
4. Connect a 60 bar pressure gauge to the charge
pressure test port.
5. Start the engine and run it with maximum speed.
6. Apply the brake.
7. Switch on vibration at high or low frequency and
read the pressure gauge.
Nominal value
Charge pressure = see technical data "travel
pump, charge pressure high idle".
Fig. 2
Start-up pressure = see technical data " vibration
pump, start-up pressure".
Operating pressure = see technical data "vibra-
tion pump, operating pressure soil dependent".
Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
8. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
Fig. 1
9. Connect a 600 bar pressure gauge (Fig. 2) each
to test ports MA and MB.
Fig. 2
10. Turn the setscrew (Fig. 3) of the pressure over-
ride completely in to block the valve.
11. Start the engine and run it with maximum speed.
12. Apply the brake.
! Caution
Perform the following pressure test for max. 3
seconds, otherwise pump damage caused by
overheating.
13. Switch on vibration at high or low frequency and
read the start-up pressure on the pressure
Fig. 3
gauge.
Fig. 4
! Caution
To assure a reliable function of the pressure
override, the pressure override valve must be
adjusted 10% lower than the high pressure re-
lief valves.
1. Turn the setscrew (Fig. 5) back out again, so that
the start-up pressure for the vibrator shafts is lim-
ited to the nominal value.
Fig. 5
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
2. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
3. Start the diesel engine and shift the throttle lever
to max. speed position.
4. Apply the brake.
5. Select the frequency and switch the vibration on.
Fig. 1
6. Measure the speed of the vibrator shaft (Fig. 2) by
letting the tester rest on your thumb.
Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit.
Fig. 2
7. Adjust the speed on the corresponding adjust-
ment screw (Fig. 3).
i Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.
Fig. 3
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Apply the brake.
Fig. 1
3. Disconnect leak and flushing oil lines (Fig. 2) and
join them together.
4. Connect a leak oil hose to the leak oil port of the
motor and hold it into a measuring vessel
5. Start the diesel engine and shift the throttle lever
to max. speed position.
6. Select the frequency and switch the vibration on.
7. Measure the leak oil over a period of one minute.
! Caution
This measurement detects only the external
Fig. 2 leak oil quantity.
Internal leaks, directly from the high to the
low pressure side, are not detected.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it with high idle speed.
3. Apply the brake.
! Danger
Danger of squashing!
Do not stand in the articulation area of the ma-
chine.
4. Turn the steering against an end stop.
5. Read the pressure gauge.
Fig. 1
Nominal value
approx. 196 bar
Evaluation of test
If the nominal value is reached, check the steer-
ing cylinder.
6. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) and (Fig. 3) the steering cylinders and
close them with plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.
Nominal value
approx. 170 bar
Evaluation of test
If the nominal value is reached, replace the steer-
Fig. 2 ing cylinder.
If the nominal value is not reached, check the
steering/charge pump.
10. Reconnect the hydraulic hoses to the steering
cylinders.
Fig. 3
11. Close the pump outlet (Fig. 4) with a 200 bar
pressure relief valve
Nominal value
approx. 200 bar
Evaluation of test
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
steering/charge pump.
Fig. 4
Fig. 1
3. Flushing filter (S connection)
Fig. 2
7. Flushing filter (L connection)
Fig. 3
11. SAE-flange 1“ - 20S
Fig. 4
Fig. 5
15. Reducing fitting 18L - 15L
Fig. 6
16. Reducing fitting 25S - 20S
Fig. 7
17. Reducing fitting 20S - 16S
Fig. 8
Fig. 9
19. Connecting socket 18L
Fig. 10
20. Connecting socket 16S
Fig. 11
21. Connecting fitting 20S
Fig. 12
Fig. 13
23. Angular fitting 18L
Fig. 14
24. Elbow fitting 16L
Fig. 15
25. Elbow 20S
Fig. 16
Fig. 17
27. Pipe connection 16S - 16S
Fig. 18
28. Connecting hose 15L
Fig. 19
Caution
!
Solid particles in the circuit will very quickly cause damage to machine components.
Environment
Environmental damage
Catch running out hydraulic oil and dispose of environmentally.
Changing a component
Caution
!
Always flush the complete oil circuit after you have replaced a component.
Before flushing
Change the filter element
Fig. 1
Fig. 2
Caution
!
Change the oil in case of excessive contamination, oil discoloration or if the oil change interval is
almost due.
● Filter the tank content with the filling and filtering unit and pump it into the oil bag.
● Mark all hoses and disconnect them from the hydraulic oil tank.
● Clean the oil tank thoroughly from inside, if necessary remove the complete tank cover.
● Reconnect all hoses.
● Fill the hydraulic oil tank again with the filling and filtering unit.
Bleeding
Fig. 3
● Always bleed closed hydraulic circuits if lines had been removed or connected.
Fig. 4
● Replace the filter element of the flushing filter when the red control pin of the contamination indicator
is pressed out during the filtering process.
● Clean hoses and connections and store the flushing kit in a clean and protected environment.
i Note
Observe the chapter "Flushing - General"
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
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.
With the connection shown in the illustration
the travel pump must therefore be actuated to
reverse direction.
1. Disconnect the high pressure hose 8 (Fig. 1) from
the travel pump and connect it with the flushing
hose 6 (flushing filter inlet "IN"), see chapter
"Flushing schematic for front drum drive".
2. Connect the flushing hose (5, flushing filter outlet
"OUT") to the high pressure port A on the travel
pump.
Fig. 1
Disconnecting the front drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the hoses together.
Fig. 2
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the front hoses
4. Block the drums with suitable chocks.
i Note
On AC-machines block drum and rubber wheels.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
! Caution
Move the travel lever only to travel direction
reverse, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction reverse.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the high pressure hoses to the drum
drive motor.
Fig. 6
!Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear drum with chocks.
i Note
On AC machines block the rubber wheels.
Fig. 7
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 8
! Caution
Move the travel lever only to travel direction
reverse, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
11. Start the engine, run it with maximum speed and
shift the travel lever to travel direction reverse.
12. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve reverse travel.
13. Shut down the engine.
Fig. 9 14. Remove the flushing filter and reconnect the high
pressure lines.
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Function test
16. Check the hydraulic oil level in the tank, fill up if
necessary.
17. Check all connections for leaks with the engine
running (visual inspection).
18. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
19. Check all ports and connections for leak tightness
(visual inspection).
Fig. 10
i Note
Observe the chapter "Flushing - General"
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
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.
With the connection shown in the illustration
the travel pump must therefore be actuated to
reverse direction.
1. Disconnect the high pressure hose (8) from the
travel pump and connect it with the flushing hose
(6) flushing filter inlet "IN" (see chapter "Flushing
schematic for rear drum drive").
2. Connect the flushing hose (5) flushing filter outlet
"OUT" to the high pressure port "A" on the travel
pump.
Disconnecting the rear drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the hoses together.
Fig. 11
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 12
Flushing the rear hoses
4. Block the drums with suitable chocks.
Fig. 13
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 14
! Caution
Move the travel lever only to travel direction
reverse, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction reverse.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the high pressure hoses to the drum
drive motor.
Fig. 15
!Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the rear of the machine, so that the drum
can rotate freely.
10. Secure the front drum with chocks .
Fig. 16
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 17
! Caution
Move the travel lever only to travel direction
reverse, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
11. Start the engine, run it with maximum speed and
shift the travel lever to travel direction reverse.
12. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve reverse travel.
13. Shut down the engine.
Fig. 18 14. Remove the flushing filter and reconnect the high
pressure lines.
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 19
i Note
Observe the chapter "Flushing - General"
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
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.
With the connection shown in the illustration
the travel pump must therefore be actuated to
reverse direction.
1. Disconnect the high pressure hoses (8 and 14)
from the travel pump and connect them with the
flushing hose (6) flushing filter inlet "IN" (see
chapter "Flushing schematic for wheel motors)".
2. Connect the flushing hose (5) flushing filter outlet
"OUT" to the high pressure port A on the travel
pump.
3. Close the rear high pressure port A on the travel
pump with a plug.
Disconnecting the wheel motors
4. Take the drum drive motors (9 and 11) out of the
hydraulic circuit and join the hoses together.
i Note
If necessary remove the rubber wheels.
Fig. 1
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 2
Flushing the rear hoses
5. Block drums and wheels with suitable chocks .
Fig. 3
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 4
! Caution
Move the travel lever only to travel direction
reverse, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
6. Start the engine and shift the travel lever to travel
direction reverse.
7. Perform the flushing process at various engine
speeds for approx. 10 minutes.
8. Shut down the engine.
9. Reconnect the high pressure hoses to the wheel
drive motors.
Fig. 5
! Danger
Danger of accident!
The rubber wheels must be able to rotate free-
ly.
10. Jack up the rear of the machine, so that the rub-
ber wheels can rotate freely.
i Note
If necessary remove the rubber wheels.
Fig. 6 11. Secure the front drum with chocks .
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 7
! Caution
Move the travel lever only to travel direction
reverse, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction reverse.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve reverse travel.
14. Shut down the engine.
Fig. 8 15. Remove the flushing filter and reconnect the high
pressure lines.
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Function test
17. Check the hydraulic oil level in the tank, fill up if
necessary.
18. Check all connections for leaks with the engine
running (visual inspection).
19. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
20. Check all ports and connections for leak tightness
(visual inspection).
Fig. 9
i Note
Observe the chapter "Flushing - General"
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
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.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
1. Disconnect the high pressure hose (13) from the
vibration pump and connect it with the flushing
hose (12) (flushing filter inlet "IN"), see chapter
"Flushing circuit vibration circuit".
2. Connect the flushing hose (5, flushing filter outlet
"OUT") to the high pressure port (14) on the vibra-
tion pump.
Disconnecting the vibration motors
3. Take the vibration motors (8 and 9) out of the hy-
draulic circuit, for this purpose join the hoses on
the vibration motors together.
i Note
AC-machines are fitted with a front vibration mo-
tor only.
Fig. 10
i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Fig. 11
Flushing the hoses
4. Block the drums with suitable chocks.
i Note
On AC-machines block drum and rubber wheels.
Fig. 12
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 13
5. Switch on vibration of front and rear drums.
i Note
Not available on AC-machines.
Fig. 14
i Note
AC-machines are fitted with a front vibration mo-
tor only.
Fig. 16
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 17
12. Switch on vibration of front and rear drums.
i Note
Not available on AC-machines.
Fig. 18
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
13. Start the engine and run it with maximum speed.
14. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
15. Shut down the engine.
16. Remove the flushing filter and reinstall the vibra-
tion motors.
Fig. 19
Bleeding the vibration circuit
17. Bleed the vibration circuit (see corresponding
chapter).
Fig. 20
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
! Danger
The engine should not start.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
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.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
Fig. 4
! Caution
With the flushing filter installed shift the travel
lever only to travel direction reverse, as other-
wise the flushing filter will be subjected to oil
flow from the wrong direction.
!Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to re-
verse direction.
Fig. 5 12. After approx. 1 to 2 minutes shut down the engine
for a minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeat-
ing this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
Fig. 4
10. Switch on vibration of front and rear drums.
i Note
Not available on AC-machines.
Fig. 5
! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
11. For bleeding switch on vibration with high fre-
quency (Fig. 6).
12. Start the engine.
13. After running the engine 1 to 2 minutes pause for
approx. one minute.
Fig. 6 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
14. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
Structure
● Table of contents
● Function groups
● List of components
Table of contents
The table of contents lists all function groups.
Example:
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.
Example:
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“.
Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is trig-
gered.
The changeover contact can be found on page no. 8 in current path "3".
Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 1) (0 ..... 20).
Graphic symbol
Graphic symbols are standardized representations for electrical appliances. They serve the purpose of a simpli-
fied representation of complete systems, from which, however, the function can be clearly identified. This stand-
ardization is in compliance with the globally valid regulations of the IEC (International Electrical Commission).
For Germany these symbols were included in the DIN-Standard. The standardization serves the purpose of glo-
bal understanding and fault free connection of appliances, especially in automobile repairs.
Since the wiring diagram is intended to show only the most essential aspects, the graphic symbol only shows
as much of the function, as is needed for easy recognition and for the avoidance of mistakes.
54 Trailer signals, trailer plug device and lamp combination, brake light
54g Trailer signals, compressed air valve for permanent brake in trailer, electromag-
netically operated
55 Fog light
56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light
57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right
61 Generator control
76 Loudspeaker
B+ Battery Plus
B- Battery Minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
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.
Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
The electric amperage (I) is measured in Ampere Direct current flows with steady voltage and amper-
(A). age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
The technical flow direction is specified from
tors or batteries.
PLUS to MINUS.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
i Note the consumers switched on, the voltage is not con-
Current actually flows from minus to plus, because the stant, but drops gradually according to the battery
current flow is made up of negatively charged elec- charge condition.
trons.
The internal resistance of the battery also causes per-
But since this was only discovered after the poles of a manent changes in the vehicle voltage, as soon as
current source had already been designated, the as- consumers are switched on or off.
sumption that current flows from plus to minus was
maintained for historic reasons. Alternating current (A.C.)
Circuit
Fig. 3 Circuit Alternating current not only changes its direction, but
also its amperage.
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring. Pulsating direct current
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).
Fig. 4 PWM
The PWM signal is in most cases generated by a con-
trol and can be used to trigger proportional valves.
The signal (square wave signal) is changed in its
pulse control factor, the period, however, remains un-
changed.
The following applies:
●
The signal voltage cannot be measured.
●
The current can be measured.
Caution
!
7.4 CAN-Bus
Development objectives:
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.
Fig. 1 CAN
Why CAN?
● Networking of control units for the realization of complex functions.
● Reduction of the extend of wiring and plug connections.
● Better diagnostic possibilities (central diagnostics socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are
required.
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.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
Bad
Symbol, R
Unit, Ohm Ω
Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
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.
Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.
Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3
Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3
Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3
Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.
Parallel connection ● In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
● All resistances (consumers) are supplied with the
same voltage.
● Plus and minus poles have the voltage of the single
battery applied.
● Each of the resistances (consumers) draws as
much current as required.
● The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.
Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3
Resistance
The total resistance is less than the lowest individual
resistance.
Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.
Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm Ω).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM Ω
Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere
Resistance, R Ohm Ω
Voltage, U Volt
Current, I Ampere
Power, P Watt
Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
●
the range selector switch must be correctly set for
the corresponding measurement.
! Caution ●
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- ●
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic ●
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp ●
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The ● In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.
Resistance and continuity measurement with mul-
timeter
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
● The component to be measured must not be con-
nected to the power supply during the measure-
ment.
● At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
● Polarity is of no significance.
Voltage and voltage drop measurement with mul- Clip-on measuring instrument
timeter
The clip-on measuring instrument can be used to
measure current, voltage and resistance.
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
Diodes
Fig. 1
Fig. 1 Magnet tester
A diode consists of two different semi-conductors,
The magnet tester is used to test solenoid valves and which are connected by a separating layer. The max.
magnetic coils. conducting state current must not be exceeded.
The test lamp responds to the magnetic fields of A.C- Plus-voltage on diode:
voltage, D.C.-voltage and permanent magnets. ● At 0.6 – 0.7 Volt (silicium diode) the diode becomes
●
The component to be tested does not need to be re- conductive.
moved.
Negative voltage on diode:
● The magnetic coil can also be tested under a pro-
tective cap.
● The diode does not allow current to pass through.
Fig. 4 LED
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-conduc-
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the
head. Light emitting diodes are available in various
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.
Fuses
Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
A free-wheeling diode prevents induction voltage from
flowing back from the coil into the vehicle wiring sys-
tem, which would cause interference with electronic
components (control units).
With the possibility of using breaker - maker contacts
the effect of an information can be reversed.
Fig. 1
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.
Caution
!
Battery – accumulator
i Note
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.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal 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 very sluggishly during
Fig. 1 a subsequent charging process.
In vehicles batteries are used to start the engine. The In the worst case the accumulator can only be dis-
ability to start the engine depends on the charge con- posed of after such an exhaustive discharge.
dition of the batteries. The following therefore applies for longer downtimes:
Lead collectors or accumulators are secondary ele- ● Remove the battery and store it in a cool, dry and
ments, i.e they can be recharged after discharging frost protected room.
electric current. ● Check the open circuit voltage on the battery at reg-
The basic element of a lead accumulator is the cell. It ular intervals (at least once every month).
contains the plate blocks consisting of positive and ● Recharge immediately if the open circuit voltage
negative plates. These plates are separated from has dropped to 12.25 Volt (no rapid charging).
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of i Note
the cells. The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.
! Danger
! Caution
Before removing the generator you must discon-
nect 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 run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be Fig. 6 Rotor with claw poles
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal 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 el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
When cleaning the generator with a steam or wa-
ter 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
deposits of water from the generator.
Fig. 7 Stator with 3 windings
The three stator windings (Fig. 7) are electrically offset
to each other by 120°. The excitation of the magnetic
field requires direct current, which is fed to the rotor
via two carbon brushes and slip rings.
This includes :
● Electric motors
● Relays
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
es work with alternating or three-phase current.
This includes :
● Accumulators
● Control units
● All electronics
● Communication equipment.
i Note
The rotor coils can only be measured in disassembled
state.
Fig. 11 Rotor
●
Remove the regulator with carbon brush.
Fig. 12 Stator
●
Contact the rotor slip ring with the tester points.
●
The resistance should be between 3 and 6 OHM Ω.
i Note
●
The rotor coils should not have continuity to ground. The stator coils can only be measured in disassem-
bled state.
● Measure the resistance of all three coils.
● The coils should not have contact among each oth-
er.
Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
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.
Fig. 14
● All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 13 ● The generator ground connection must be OK.
The generator test assesses the regulator voltage and ●
The battery should be in good condition – the idle
the ripple factor of the generator voltage. speed voltage of the battery should be at least 12.6
●
All plug-and-socket connectors must be free of cor- Volt.
rosion and intermittent contact. ●
If possible switch off all consumers.
●
The generator ground connection must be OK. ●
Perform the measurement at raised engine speed.
●
The battery should be in good condition – the idle ●
The voltage (B+) should adjust itself at 13 to 14 Volt.
speed voltage of the battery should be at least 12.6
Volt.
●
If possible switch off all consumers.
●
Perform the measurement at raised engine speed.
Fig. 17
Fig. 18
Fig. 15
The illustrations (Fig. 17) and (Fig. 18) show two dif-
● If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
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).
Fig. 1 Electric starter For purposes like e.g. purging the fuel systems,
1 Pinion starters may be operated for maximum 1 minute
2 Roller free-wheeling without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again.
3 Steep thread During the 1 minute starting period this process
4 Guide ring should not be interrupted.
5 Spring winding Starter motors must not be cleaned with high
6 Armature pressure steam cleaning equipment.
7 Pole shoe The contacts on starter terminals 30, 45, 50 must
8 Carbon brushes be protected against unintended shorting (jump
protection).
9 Armature brake
10 Collector When replacing the starter the ring gear on the en-
gine flywheel must be checked for damage and its
11 Magnetic switch number of teeth - if necessary replace the ring
12 Engagement lever gear.
Always disconnect the battery before starting as-
!Caution sembly work in the starter area of the engine or on
So-called jump starting (using an additional exter- the starter itself.
nal battery) without the battery connected is dan-
gerous. When disconnecting the cables from the
poles high inductivities (arcs, voltage peaks) may
occur and destroy the electrical installation.
Magnetic switch
The magnetic switch is normally arranged directly
above the starter. Fig. 3 Switching position during starting
With the starter switch switched on, both the pickup 1 Ground
winding and the holding winding are energized and 2 Battery
shift the iron core in axial direction. With a lever this
iron core pulls the starter pinion towards the engine 3 Starter switch
flywheel. 4 Pull-in winding
Once the gears are engaged the starter current is ap- 5 Holding winding
plied to the back through a large cross-section. At the 6 Exciter winding
same time the pickup winding is shorted via the starter 7 Restoring spring
current and thus switched off as a measure to reduce
8 Driver
the load on the energy household.
9 Pinion
10 Flywheel
i Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.
Fig. 2 Disassembly
● Lift up the interlock (5).
Assembly
Fig. 5 Assembly
● Insert the front element (3) into the bore in the con-
trol panel.
i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
●
Tighten the screw (1) with a tightening torque of 0.6
Nm.
General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 10 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.
Working principle
Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 11
This stray field leaks out from the active area of the Proximity switches are used as breaking or making
proximity switch. If metal or non-ferrous metal enters contacts. Depending on the design the switching dis-
into the response range energy is absorbed. The os- tances are 2 or 4 mm. The maximum amperage is 300
cillator is thus dampened and the resulting change in mA.
current consumption is evaluated. The LED (Fig. 11) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry
Fig. 1 Sensor
The the function of the angle sensor (Fig. 1) is based
on the so-called "Hall-Effect". Named after the Ameri-
can physicist E.H. Hall. Due to the fact that moving
electrons are deflected in a magnetic field, a voltage
transverse to the flow direction of the primary current
can be expected on a current conducting conductor in
the magnetic field. Since the electrons are deflected in
Fig. 12 Circuit diagram, making contact
transverse direction by the magnetic field, they must
The circuit diagram (Fig. 12) shows a proximity switch enrich on the one side and reduce on the opposite
with normally open contact. side. If a very thin circuit board is now subjected to a
Brown = voltage supply current that is uniformly distributed across its cross
section, no voltage will be measured between two
Blue = ground supply
points A and B, which have an identical distance to the
Black = switching output current supply lines and are connected by a highly
The initiator switches the relay (K05) sensitive galvanometer. When generating a magnetic
field vertical to the circuit board, voltage will be
present between A and B and a current will flow
through the galvanometer connected to these points.
This is referred to as "Hall-Effect". The cause for this
effect is the warping of the originally parallel electron
orbits in the board by the magnetic field.
General
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.
Fig. 2 DT Series
Caution
!
Fig. 4
● Insert the contacts through the rubber grommet until
they click into place.
● Insert the orange wedge in direction of arrow.
Caution
!
i Note
Use the same method when assembling the socket.
Disassembling DT contacts
Fig. 5
● Pull the orange wedge out with long nose pliers.
●
Slightly pull the lead and unlock the interlocking
hook with a screw driver.
● Pull the contact out of the socket.
i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
Fig. 4
●
Insert the contacts through the rubber grommet until
they click into place.
●
Insert the orange wedge, until it clicks into place.
Caution
!
i Note
Use the same method when assembling the socket.
Fig. 5
● Pull the orange wedge (interlock) out with long nose
pliers.
● Slightly pull the lead and unlock the interlocking
hook with a screw driver.
● Pull the contact out of the socket.
i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
7.20 Plugs and terminals in spring ventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.
clamping technology
! Caution
General
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!
Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration
resistant and maintenance-free connection of all con-
!Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.
!Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.
Measuring signals
On these terminal blocks the bridge slot is most suita-
ble 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 central electrics of
heavy equipment machines.
X-COM System for universal system wiring, ever since it was intro-
The X-COM-SYSTEM, a synthesis of plug connector duced in 1997. All the familiar series clamping func-
and series clamp, has grown up to a construction kit tions have thus become pluggable.
!Caution
Perform a pull test on each lead, each of the termi-
nals must withstand a pulling force of 45 N with-
out any difficulties.
Fig. 9
16. Multimeter
Fig. 10
17. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.
Fig. 11
19. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.
Fig. 12
Fig. 15
Fig. 16
33. Clip-on measuring instrument
Fig. 17
34. Battery - generator tester
Fig. 18
Spring clamps (Wago or Weidmüller)
35. Cranked screwdriver (Fig. 19) to open spring
clamps (Fig. 20).
Fig. 19
Fig. 20
Deutsch contacts
37. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).
Fig. 21
38. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
AWG 12 = 4,0 mm2 cable cross-section
BOMAG part-no.: 079 900 79
Fig. 22
39. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
AWG 8 = 10,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
Fig. 23
Fig. 24
ITT contacts
41. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 25
42. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 26
43. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.
Fig. 27
Fig. 28
45. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.
Fig. 29
FCI Burndy contacts
46. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO
Fig. 30
AMP contacts
47. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).
Fig. 31
Fig. 32
49. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).
Fig. 33
50. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 14 - 10.
Fig. 34
51. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 16 - 14
and AWG 18.
Fig. 35
Fig. 36
53. Crimping jaws for Crimping tool 079 900 25
Fig. 37
54. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77
Fig. 38
Universal tools
55. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.
Fig. 39
Fig. 40
Measuring adapter
57. Current measurement adapter for Hirschmann
plugs.
Fig. 41
58. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).
Fig. 42
59. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.
Fig. 43
Bild 44
i Hinweis
The documentation "Service Training Electrics BAM (BOMAG Asphalt Manager)" contains also the documenta-
tion BEM (BOMAG Evib-meter).
The BOP (BOMAG Operation Panel) is only installed in connection with BAM machines, BEM-machines are
equipped with display module. The display module is used for the output of fault codes and display values, as
well as for the input of code numbers.
Service Training
Electrics
BAM
Table of contents
1 Document alteration list.....................................................................................................................3
2 Proof of software change MESX .......................................................................................................4
3 Proof of software change BOP..........................................................................................................5
4 Known faults......................................................................................................................................6
5 How to proceed when replacing components?.................................................................................7
5.1 How to proceed when replacing an ESX control? .....................................................................7
5.2 Which components can be replaced without a subsequent adjustment procedure? ................7
5.3 List of machine types .................................................................................................................8
6 Possible adjustments on machines without BOP .............................................................................9
6.1 Description of the Display Module .............................................................................................9
6.2 Input of code numbers ...............................................................................................................9
6.3 Changing the machine type (only via display module) ............................................................10
6.4 Changing the bit rate (only with display module).....................................................................11
7 Adjustment/display possibilities on machines with BOP.................................................................12
7.1 Adjusting the machine type (BOP)...........................................................................................12
7.2 Changing the units system (metric/imperial) ...........................................................................14
7.3 Accessing the diagnostics menu .............................................................................................16
7.3.1 Extended diagnose for articulated machines ......................................................................... 18
7.3.2 Extended diagnose pivot steered machines........................................................................... 19
7.4 Changing the printout language...............................................................................................20
7.5 Setting the machine serial number ..........................................................................................22
7.6 Teaching distance pulses ........................................................................................................24
7.7 Changing the display mode (metric/imperial) ..........................................................................26
7.8 Simulation mode ......................................................................................................................28
8 Block diagram BOMAG Evib meter (BEM) .....................................................................................33
9 Block Diagram BOMAG Asphalt Manager ......................................................................................34
10 Description of the Signals on the ESX-Control............................................................................35
11 Fault codes of the ESX control ....................................................................................................41
11.1 Overview...............................................................................................................................41
11.2 Description of fault reactions ................................................................................................42
11.3 Detailed description of fault codes and their possible causes ............................................43
12 Input codes for ESX control (only via BEM display module) .......................................................48
12.1 Travel system .......................................................................................................................48
12.2 Vibration ...............................................................................................................................49
12.3 Light......................................................................................................................................49
12.4 Acceleration transducer........................................................................................................50
12.5 Diesel engine........................................................................................................................50
12.6 Setting the machine type......................................................................................................51
13 Terminology in connection with ESX...........................................................................................52
3.00 30.03.2005 x Software version changed, because MESX version is also Löw
3.x (analog single drum rollers)
x imperial display for pivot steered machines corrected
x Designation "ESX" replaced by "MESX" and "OPUS" by
"BOP"
x Flags for all EU-languages, Japan and China stored in
BOP
3.01 21:07:2005 x Designation ESX replaced by MESX and OPUS by BOP Löw
x Show "Changing settings" when changing the display
mode (metric/imperial)
x Show warning message on machines with circular exciter
4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kBit
reading "ct0" => see "Setting the bit rate"
The following chapter describes the necessary adjustments to the control when replacing individual
components in the measuring system.
You should therefore set the machine type first! see "7.1 Setting
the machine type (BOP) Adjusting the machine type (BOP)").
x Set the machine serial number (only on machines with BOP), see: 7.5
x Set the printer language (only machines with printer), see: 7.4
Machine type First serial number Last serial number Code Available from
version
141 AD-4 101 920 00 1001 XXX XXX XX XXXX 7700 3.06
141 AD-4 AM 101 920 20 1001 XXX XXX XX XXXX 7703 3.03
144 AD-4 XXX XXX XX XXXX XXX XXX XX XXXX 7710 not available at present
144 AD-4 AM XXX XXX XX XXXX XXX XXX XX XXXX 7713 not available at present
151 AD-4 101 920 01 1001 XXX XXX XX XXXX 7720 3.06
151 AC-4 101 920 10 1001 XXX XXX XX XXXX 7722 3.05
151 AD-4 AM 101 920 21 1001 XXX XXX XX XXXX 7723 3.03
151 AC-4 AM 101 920 41 1001 XXX XXX XX XXXX 7724 3.06
154 AD-4 XXX XXX XX XXXX XXX XXX XX XXXX 7730 not available at present
154 AD-4 AM 101 920 51 1001 XXX XXX XX XXXX 7733 2.00
161 AD-4 101 920 02 1001 XXX XXX XX XXXX 7740 3.05
161 AC-4 XXX XXX XX XXXX XXX XXX XX XXXX 7741 not available at present
161 AD-4 AM XXX XXX XX XXXX XXX XXX XX XXXX 7743 not available at present
161 ADH-4 XXX XXX XX XXXX XXX XXX XX XXXX 7745 not available at present
170 AD-2 XXX XXX XX XXXX XXX XXX XX XXXX 7750 not available at present
170 AD-2 AM 101 870 13 1001 XXX XXX XX XXXX 7753 3.04
174 AD-2 XXX XXX XX XXXX XXX XXX XX XXXX 7760 not available at present
174 AD-2 AM 101 870 53 1001 XXX XXX XX XXXX 7763 2.00
174 AC-2 AM XXX XXX XX XXXX XXX XXX XX XXXX 7764 not available at present
180 AD-2 XXX XXX XX XXXX XXX XXX XX XXXX 7770 not available at present
180 AD-2 AM XXX XXX XX XXXX XXX XXX XX XXXX 7773 not available at present
184 AD-2 XXX XXX XX XXXX XXX XXX XX XXXX 7780 not available at present
184 AD-2 AM 101 870 52 1001 XXX XXX XX XXXX 7783 3.04
190 AD-4 XXX XXX XX XXXX XXX XXX XX XXXX 7791 not available at present
190 AD-4 AM 101 920 26 1001 XXX XXX XX XXXX 7793 2.00
202 AD-4 XXX XXX XX XXXX XXX XXX XX XXXX 7800 not available at present
202 AD-4 AM XXX XXX XX XXXX XXX XXX XX XXXX 7803 not available at present
203 AD-4 XXX XXX XX XXXX XXX XXX XX XXXX 7810 not available at present
203 AD-4 AM 101 920 25 1001 XXX XXX XX XXXX 7813 2.00
Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP the settings are made via the BOP!
(see item "7 Adjustment/display possibilities on machines with BOP")
The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.
Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible. Higher
values lead to the display "- - - - ", negative values are indicated by the "minus dot" lighting up (see
illustration).
Vorzeichen
057 667 72
15/54
1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
)The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.
Note: Parameter adjustments can only be performed when the engine is not running!
x Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type".
The display module now permanently shows the entered code. (e.g. 7 5 3 3 )
x Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control initiates a restart, the display module shows the new
machine type for approx. 3 seconds.
After this the newly adjusted machine type will be displayed for approx. 3 seconds.
Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!
New controls are delivered with the default machine type setting 7 5 0 0 .
x Hold both keys (F1 and F2) of the multi-function display depressed and switch on the ignition.
) The currently set bit rate is displayed, e.g. 0 1 0 0 .
x The bit rate can now be changed in fixed steps by pressing the right hand key (F2). Hold the key
depressed until the display reads 0 1 2 5 .
x By pressing the left hand key (F1) the bit rate is accepted and the display changes back to the
normal display mode.
Note: Parameter adjustments can only be performed when the engine is not running!
x Press key "?" to open the screen page "MENU". The following screen is displayed1:
x Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:
1
Note: This document shows the menu screen for articulated machines as an example. Operation of pivot steered machines is
identical, only the roller symbols are different.
x The desired machine type can be selected by pressing the keys "F11" and "F12". (see "List of
machine types" under item "7.1 Adjusting the machine type (BOP)").
x After selecting the desired machine type press key "F14", until the symbol (F14) lights green for
confirmation (approx. 4s).
When releasing the key the start screen will automatically be displayed and the control will initiate a
restart.
BOP and BAM are now adjusted to the new machine type.
x Press key "?" to open the screen page "MENU". The following screen is displayed:
x Press key "F4" to open the screen page "Change units". The following screen is displayed:
x You can now switch between imperial and metric units system by pressing key "F5" ("Imperial = 1"
or "Imperial = 0").
x After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
When releasing the key "F14" the start screen will automatically be displayed and the control will
initiate a restart.
BOP and printer have been changed over to the new units system.
x Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:
If an actual error is present the corresponding error code will be displayed in the field "Actual Errors".
x By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see
below).
MD+ Status BAM input MD+ (detection engine running) (LED on = 12V)
NOT Neutral: Status BAM input "travel lever NOT in neutral" (LED on = 12V)
+01234 Distance pulses detected by the control (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
Backward: Direction signal detected by the BAM on basis of the travel pump control
MD+ Status BAM input MD+ (detection engine running) (LED on = 12V)
Forward: Direction signal detected by the BAM on basis of the travel pump control
+01234 Distance pulses detected by the control (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
x Press key "F6" to open the screen page "Printout language". The following screen is displayed:
x The desired printout language can be selected by pressing the keys "F11" and "F12".
x After selecting the desired language press key "F14" to save the setting. The symbol (F14) lights
green for a moment as a sign of confirmation.
x Press key "F7" to open the screen page "Serial number". The following screen is displayed:
x The desired printout language can be selected by pressing the keys "F11" and "F12".
x After the adjustment press key"F14" to save the setting. The symbol (F14) lights green for a
moment as a sign of confirmation.
Note: An adaptation of the distance pulses is only possible within a range of +/- 10% of the
preset value.
x Press key "?" to open the screen page "MENU". The following screen is displayed:
x Press key "F8" to open the screen page "Distance pulses". The following screen is displayed:
x Pressing the key "F5" starts the teach mode. The following symbol appears:
x Drive a distance of 10 m length in forward and press the key "F6" at the end. The following symbol
appears:
x After the end of the measuring travel press key "F14" to save the adjustment. The following
symbol appears:
Note: If the following symbol is displayed after the end of the travel distance the measured
distance pulses are not in the range of +/- 10% of the preset value. Saving is in this
case not possible! The measurement must be repeated!
x Press key "F4" to open the screen page "Display mode". The following screen is displayed:
x The imperial display (mph, °F, etc.) can now be activated or deactivated by pressing key "F5"
("Imperial = 1" or "Imperial = 0").
x After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
ATTENTION: In simulation mode the exciter swivels even with the machine at standstill!
Before switching on vibration the machine must therefore be placed on a
suitable base (rubber mat, car tires, etc.), as otherwise the base may be
damaged!
x Press key "?" to open the screen page "MENU". The following screen is displayed:
x Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:
x Press key "A" to open the screen page "extended diagnose". The following screen is displayed:
x Press key "A" again to open the screen page "simulation m ode". The following screen is
displayed:
x The simulated travel direction can be selected with keys "F5", "F6", "F7". The detected travel
direction is displayed in the roller symbol underneath.
x The assignment of keys "F9" to "F14" is identical with their assignment in standard operation.
The voltage of the "exciter position" potentiometer is displayed in addition to the detected Evib value
and the vibration frequency. This view does not show the asphalt temperature.
Exiting this page via "ESC" aborts the simulation mode. The adjusted manual and automatic stages as
well as the operating mode remain active.
008 910 92
8 Block diagram BOMAG Evib meter (BEM)
BEM, BOMAG Evib-meter
BOMAG
Status: 30.05.2006 Block diagram Page 33 of 55
Author: T. Löw / TE
9.1
207
208
9.1
CAN Bus I
Drucker
BOP RS 232
BOMAG
!
Beschleunigung
VV / VL 15g
Signale
Lageregelung Lageregelung
Ventil 2 vorn Ventil 1 vorn
Hebel
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Erreger
Position vorn Vibrations-
Schalter
008 910 92
Service Training BAM Description of signals
008 910 92
10 Description of the Signals on the ESX-Control
Notes:
1. Wherever the value of 12 V is mentioned in the following text it refers to the current battery
voltage under due consideration of voltage drops in the lines.
X0:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X0:2
X0:3 Output Evib display (only BEM) PWM signal (100Hz): ) approx. 0..6 V
PWM (max. 2.5 A)
X0:4 Interface RS 232 RxD, used for printer control. Measurement not possible!
X0:5 Interface RS 232 TxD, used for printer control. Measurement not possible!
X0:6
BOMAG
X0:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
X0:9 Input exciter position front Position of front exciter (measured against AGND)
Analogue input / voltage input 0..8.5 V Bottom stop ) approx. 2,2 V
Neutral position ) approx. 4,25 V
Top stop ) approx. 6,6 V
209
210
9.1
BOMAG
Digital input active high Button not depressed ) 2V
X0:18 Input button PRINT (option) Button depressed: ) 12 V
Digital input active high Button not depressed ) 2V
X0:19 Input button CLEAR (option) Button depressed: ) 12 V
Digital input active high Button not depressed ) 2V
X0:20
X0:21
X0:22
X0:23 Output voltage supply for sensors Nominal voltage = 8,5 V
This output supplies steering joystick, travel speed range switch, etc. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch This voltage must be measured against AGND.
to override condition (emergency operation).
X0:24
008 910 92
Service Training BAM Description of signals
008 910 92
ESX terminal Signal description Nominal values (voltage / current)
X0:25
X0:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X0:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.
BEM, BOMAG Evib-meter
BOMAG
Analogue input / voltage input 0..8.5 V
X0:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)
X0:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X0:34
X0:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on
machine type.
Digital input active high
211
212
9.1
BOMAG
X0:40
X0:41
X0:42
X0:43
X0:44
X0:45
008 910 92
Service Training BAM Description of signals
008 910 92
ESX terminal Signal description Nominal values (voltage / current)
X0:49
X0:50
X0:51
X0:52
BEM, BOMAG Evib-meter
BOMAG
Status: 30.05.2006 Description of signals Page 39 of 55
Author: T. Löw / TE
9.1
213
214
9.1
X0:61
BOMAG
X0:62
X0:63
X0:64
008 910 92
BEM, BOMAG Evib-meter 9.1
11.1 Overview
BOMAG
The machine is no longer able to drive, e.g. because parts of the travel system are defective
) the diesel engine is shut down.
Fault code is displayed.
Signal light in BOP (option) lights in 1 second intervals.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
Fault code is displayed.
008 910 92
Service Training BAM Description of fault codes of the ESX control
008 910 92
11.3 Detailed description of fault codes and their possible causes
1 The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse has tripped or wire breakage in voltage supply current path
) Potentiometer defective
450 Input exciter potentiometer front ) Current path connected to +12 V / +8,5 V X0:09 2
2 The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective
BOMAG
Status: 30.05.2006 Description of fault codes of the ESX control Page 43 of 55
Author: T. Löw / TE
9.1
217
218
9.1
452 Output proportional solenoid front ) Current path has short circuit to voltage supply X0:47 2
BOMAG
6 Valve for exciter down ) Current path has impermissible connection to another current
Output current too low. path
) Current path is interrupted
452 Output proportional solenoid front ) Current path has short circuit to ground X0:47 2
7 Valve for exciter down ) Current path has impermissible connection to another current
Output current too high. path
008 910 92
Service Training BAM Description of fault codes of the ESX control
008 910 92
Fault Fault description Possible cause Termina Input Fault
code l on code for reaction
ESX diagnose
453 Position controller positive limit reached ) Supply and ground terminal on exciter potentiometer mixed up X0:09 2
1 The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X0:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
BEM, BOMAG Evib-meter
453 Position controller negative limit reached ) Supply and ground terminal on exciter potentiometer mixed up X0:09 2
2 The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X0:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low
460 Input acceleration transducer 1 ) Current path has no connection to +12 V / +8,5 V X0:29, 2
1 The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X0:31
BOMAG
460 Input acceleration transducer 1 ) Current path connected to +12 V / +8,5 V X0:29, 2
2 The voltage applied to the input is above the ) Current path not connected to ground or
specified range (see signal description). ) Transducer defective X0:31
460 Input acceleration transducer 2 ) Current path has no connection to +12 V / +8,5 V X0:30, 2
6 The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X0:07
460 Input acceleration transducer 2 ) Current path connected to +12 V / +8,5 V X0:30, 2
7 The voltage applied to the input is above the ) Current path not connected to ground or
specified range (see signal description). ) Transducer defective X0:07
219
220
9.1
463 Input asphalt temperature sensor ) Current path connected to +12 V / +8,5 V X0:06 2
1 The voltage applied to the input is above the ) Current path not connected to ground
specified range (see signal description). ) Transducer defective
BOMAG
Status: 30.05.2006 Description of fault codes of the ESX control Page 46 of 55
Author: T. Löw / TE
BEM, BOMAG Evib-meter
008 910 92
Service Training BAM Description of fault codes of the ESX control
008 910 92
Fault Fault description Possible cause Termina Input Fault
code l on code for reaction
ESX diagnose
800 Error message "Incorrect BOP Software version" - - 2
0 The software version of the BOP is too old, i.e.
various functions cannot be displayed.
This fault cannot be repaired on the machine.
BEM, BOMAG Evib-meter
920
BOMAG
Fault message "Severe internal fault in control" - - - 5
0 - The control has automatically switched off. This
999 fault cannot be rectified on the machine. The
9 control must be immediately replaced.
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X0:26 - -
control. ) Short circuit between CAN bus lines X0:27
) One or both CAN bus line(s) has (have) connection to 12V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)
221
222
9.1
12 Input codes for ESX control (only via BEM display module)
BOMAG
1003 Travel speed Display value = max. speed in km/h
Shows the actual speed.
008 910 92
Service Training BAM Description of fault codes of the ESX control
008 910 92
12.2 Vibration
12.3 Light
BOMAG
Status: 30.05.2006 Description of fault codes of the ESX control Page 49 of 55
Author: T. Löw / TE
9.1
223
224
9.1
BOMAG
Status: 30.05.2006 Description of fault codes of the ESX control Page 50 of 55
Author: T. Löw / TE
BEM, BOMAG Evib-meter
008 910 92
Service Training BAM Description of fault codes of the ESX control
008 910 92
12.6 Setting the machine type
definiert. )!
7011 Confirms entered machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert. )!
7500..75 Preselect machine type see adjustment instructions (page Fehler! Textmarke nicht
99 definiert. )!
BOMAG
Status: 30.05.2006 Description of fault codes of the ESX control Page 51 of 55
Author: T. Löw / TE
9.1
225
9.1 BEM, BOMAG Evib-meter
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
x torn (not necessarily visible from outside)
x chafed
x chafed mostly in connection with a short circuit to ground
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital, many states are permitted within a certain range. E.g. room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 : to 300
:; valve 0% to 100% opened (proportional valve)
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Ohm’s law:
U R
I
U = Voltage
R = Resistance U
I = Current
I
R
U
R
I
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position
forward and reverse will cause an fault message, because this condition is normally not
possible.
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
Description UPM03
920 225 03
1 Version history....................................................................................................3
Januar 2008
Version history
Version history
0 Version history
Description of hardware
1 Description of hardware
Input PIN11 HIGH-active LED lights when applying operating voltage (+UB)!
Input PIN12 HIGH- active LED lights when applying operating voltage (+UB)!
Input PIN13 LOW- active LED lights when applying ground potential (0V)!
Input PIN14 HIGH- active LED lights when applying operating voltage (+UB)!
Input PIN15 HIGH- active LED lights when applying operating voltage (+UB)!
* The pick-up winding is currently not used (but function is implemented), because
it is not required for the installed engine!
However; the function is also part of this description.
Description of hardware
Figure 1: Module
Description of hardware
Description of function
2 Description of function
The output signals of the module are now switched in dependence on the inputs.
Output PIN 7 Indication driver standing always has 12 Volt applied (LED lights) when the
LED on PIN 11 Input seat contact sensor is off or no 12 Volt is applied.
Output PIN 5 Brake valve and PIN 6 Signal brake applied also work inverse to one another
(the brake is applied when the brake valve is not energized).
Attention:
Input PIN 12 (travel lever) and input PIN 15 (brake detent) must always have opposed
signals. If this is not true, the brake control light (output PIN 5) in the round instrument
will flash.
If no 12 V voltage is applied to PIN 14 (D+) when the module is switched on (LED on PIN 14
does not light), but ground is applied to PIN 13 (oil pressure) (LED on PIN 13 lights), it is
assumed that the engine is stopped and the brake will be applied, irrespective of PIN 15
(brake switch), to make sure that the machine is reliably stopped on an incline.
Figure 2 illustrates the sequence of a switch-on process. PIN 11 (Input seat contact switch)
in this case has no influence, because the engine is stopped.
When PIN15 (Brake switch) is opened (PIN 15 has ground contact, the LED on PIN 15 does
not light), the holding winding of the shut-down solenoid is switched off (0V on output PIN 8
Holding winding, LED on PIN 8 lights). This has the effect of preventing an engine start when
Description of function
the brake is open (however, the starter motor would be able to turn, if this was not prevented
by an external circuitry).
All this happens, irrespective of the fact whether the driver is sitting or not!
If the travel lever is in neutral position (LED on PIN 12 is off), the engine can be started.
Description of function
The brake valve is now switched in dependence on input PIN 15 (Brake switch). If the brake
switch is closed (LED on PIN 15 lights), the brake valve will be closed (LED on PIN 5 is off),
the brake is applied and the signal lamp Brake lights up (LED on PIN 6 lights). If the switch is
open (LED off), the brake valve will be opened (LED on PIN 5 lights) and the signal lamp is
off (LED on PIN 6 off).
If no D+ is detected, the brake will be applied, irrespective of input PIN 15!
Description of function
If the travel lever is actuated while the engine is running (D+ on PIN 14, LED lights), while
the driver is not sitting down (LED on PIN 11 is off), PIN 8 Holding winding will be
energized (LED on) and the engine will be shut down immediately.
Figure 4: Influence of the travel lever when the engine is running (driver standing)
If the driver is sitting while the travel lever is actuated, no shut-down will occur and the
machine will travel.
Description of function
If the engine stops before the driver has sat down (D+ switches off, LED on PIN 14 goes
out), the brake will be closed (LED on PIN 5 is off, LED on PIN 6 lights). This condition
remains, even if the driver sits down.
Description of function
_________________________________________________________________________
_________________________________________________________________________
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Description UPM03
Vibration Interlock Module / A71
920 225 02
Januar 2008
Table of Contents
1 Version history....................................................................................................3
2 Description of hardware .....................................................................................4
2.1 Input pin assignment .............................................................................................................4
2.2 Output pin assignment ..........................................................................................................4
2.3 Emergency operation.............................................................................................................5
3 Description of function.......................................................................................7
3.1 Switch-on process .................................................................................................................7
3.2 Switching the vibration on ....................................................................................................7
3.3 Switching on the chip spreader ............................................................................................9
4 Software version history ..................................................................................11
Version history
1 Version history
Description of hardware
2 Description of hardware
Description of hardware
Figure 1: Module
The complete module (including the specific software) is available under
BOMAG part-number 920 225 02.
Description of hardware
Description of function
3 Description of function
Dependence of the vibration on the switching position of the vibration selector switch:
Potential PIN 11 Potential PIN 14 Vibration rear PIN 7 Vibration front PIN 4
12V / LED on open / LED off ON LED OFF LED
OFF ON
open / LED off 12V / LED on OFF LED ON LED
ON OFF
open / LED off open / LED off ON LED ON LED
OFF OFF
Description of function
Switching these inputs over will only cause changes to the outputs, if input PIN 12 "Vibration
switch" has been switched off (LED on PIN 12 off)!
When switching from "Vibration both drums" to "one drum" the outputs PIN 4 and PIN 7 will
be switched with an 0.7 second delay.
Description of function
Einschalten Splittstreuer
Betriebsphase
1 2 3 4 5 6 7 8 9 10 11 12
PIN: 15 Auswahl ein LED an
Splittstreuer ein
Einschalter
Auswahl aus LED aus
Description of function
When the chip spreader is switched off, the system will wait for another 2 seconds, before
the vibration can be switched on again. This means that, after switching off the chip
spreader, a period of 4 seconds will pass before the vibration will start again.
_________________________________________________________________________
Version management: BOMAG Vibration interlock for BW 161/202
Module: BM UPM 3
Controller: PIC16F84
__________________________________________________________________________
Description UPM1
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Description of function
With the programmable module BM UPM the software
realizes a speedometer function. To ensure that the
tachometer function is not only realized for one spe-
cial roller, there is a possibility to adapt the module to
any machine with the help of a self-teaching mode.
● Whenever the module is switched on the system
runs a self-test by passing through the entire dis-
play range in both directions. The display self-test
takes approx. 15 seconds.
● After this the module changes to measuring mode.
The frequency of the travel pulses of the roller is de-
tected and converted to a proportional output volt-
age that triggers the display.
● The output signal for the display is a PWM-signal.
Caution
!
i Note
If the module is in teach mode the LED on output
"OUT +" will flash with the frequency of the path puls-
es arriving at input (IN).
●
Disconnect the cable bridge from "Teach" to "15/
54“.
●
Switch the ignition off and on again (Reset).
Service Training
Tandem Rollers
BW 141 - 151 AD/AC-4
BW 154 AD/AC-4
Service Training
Table of contents
Foreword A1
Documentation A2
General A3
Service Training
Vibration G1
Vibration pump G3
High pressure relief valves G6
Control G7
Vibration motor G8
Vibration shut-off valve G9
Drum BW 141 AD-4 G 11
Drum BW 154 AD-4 G 12
Test and adjustment points, vibration system G 14
Trouble shooting in vibration system G 18
Steering system H1
Steering pump H3
Priority valve H4
Steering valve H5
Articulated joint H8
Test and adjustment points H 11
Trouble shooting steering system H 14
Blower drive K1
AC-variant M1
Wiring diagram
Hydraulic diagram
Service Training
Foreword
Reliable construction equipment is of greatest advantage for all parties involved:
• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
• in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
• for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
• the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
• the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
Service Training
Documentation
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
Service Training
General
The tandem rollers of series BW 141 - 154 AD/AC-4 are high performance machines for the extremely
difficult use in asphalt compaction and earth work.
The machines of this series are powered by engine oil cooled Deutz diesel engines of series BF4M
2011.
Engine driven pumps transfer the engine output power via hydrostatic circuits for travel and vibration
systems to the drums. These hydrostatic drives ensure lowest possible power losses and a high
efficiency. The steering and crab-walk functions as well as the additional edge cutter option are supplied
by gear pumps driven by the auxiliary engine output.
The machines are equipped with a 2 cylinder operated articulated steering and a crab-walk function with
a separate hydraulic cylinder to offset the front frame laterally relative to the rear frame.
For the first time a machine of this product range is equipped with axial piston drum drive motors with
reduction gears The discs of the parking brakes are integrated in the reduction gears. When starting the
engine and opening the brake valve the brakes are relieved by charge pressure. When closing the brake
valve or when shutting the engine down the brakes are automatically applied by spring pressure. These
parking brakes should not be used as service brake, because the deceleration effect is extremely high
and the braking process may damage the brake discs.
The drums are equipped with an exciter shaft and two vibrator units each. The exciter shafts are driven
by hydraulic motors via Bowex couplings. Vibration of the drum is caused by the centrifugal forces
generated by the exciter shaft mounted eccentric weights.
Since the machines are designed for operation with two different frequencies and amplitudes, the sense
of rotation of the exciter shaft can be reversed. Changing the sense of rotation also changes the position
of the change-over weights inside the eccentric weights on the exciter shafts.
This also changes the centrifugal force and the amplitude. The rotary speed of the exciter shaft is also
different to both directions of rotation. This means, that the vibration frequency will also change.
In combination with the hydraulic vibration drive the change-over weights are arranged in such a way,
that the high amplitude works with low frequency and vice-versa.
The combination of high amplitude and low frequency is particularly suitable for compaction work in
earthwork with high lift heights and for preliminary compaction. For soil compaction the combination of
low amplitude and high frequency should be used for the finishing passes.
The individual machine functions like travel system, vibration and steering are described in more detail
in the corresponding chapters. Optional equipment, such as BAM, BOMAG Asphalt Manager
(Variomatic) and chip spreader etc. is not included in this training manual.
008 910 92
Fig. 1
gears.
Service Training
5
T2: Leak oil to tank
T1: Connection to vibration pump
2
Y30
BOMAG
5
6
1 Travel pump 20) Rear travel motor
4 Pressure override 23) Front travel gear Leak oil with flushing oil
6) Flushing valve
circuit. It mainly consists of travel pump with integrated safety elements and travel motors with travel
Service Training
-E1-
11.1
319
11.1 Service Training
Service Training
The installation of a hydraulic pump with variable displacement into a closed hydraulic circuit is a perfect
solution for a hydrostatic travel system, because with this design the travel direction can be reversed
without any problems.
The travel pump is flanged to the flywheel side of the diesel engine. It is directly driven by the engine
with constant speed.
The tandem gear pump driven by the auxiliary output of the engine is responsible for steering, crab walk
with additional functions and charge system. The tandem gear pump also serves as charge pump,
because the oil flow from steering valve and crab walk valve is flowing to the charge ports on travel and
vibration pumps.
The oil is cleaned by pressure filters, which are hydraulically arranged directly after the tandem gear
pumps.
Besides its function of supplying the closed circuit with cool and filtered oil as replacement for leakage
and flushing losses, the oil from the charge circuit is also needed for the following machine functions:
• to control the variable displacement pumps for travel and vibration systems,
All safety and control elements needed for the operation in a closed hydraulic circuit are integrated in
the travel pump. These are:
• High pressure relief valves (440 bar) with integrated boost check valves
• Servo control
The travel motors are plug-in motors mounted to travel gears and hydraulically connected in parallel
mode.
Both travel motors are fitted with an additional flushing valve for the closed hydraulic circuit.
Service Training
travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch
Rexroth-Hydromatik, type A4 VG 56 HW.
to the
T1: Connection to vibration pump travel motors
T2: Leak oil to tank
Charge pressure
440
2
1 5
M
440 400
4
5 26 6
Charge pressure
to the
to vibration
travel motors
pump
1 Pump drive
2 Control piston
3 4/3-way servo valve
4 Charge pressure relief valve
5 High pressure relief valves
6 Pressure override
The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit.
These are:
Service Training
• Servo control
• Pressure override
Travel pump and vibration pump are connected to a tandem pump unit.
The travel pump unit is directly driven by the flywheel side of the engine via an elastic coupling. The
pump speed is therefore identical with the engine speed.
8
5
7
2 4
1
3
1 Drive shaft
2 Swashing cradle with swashing lever
3 Cylinder block
4 Working pistons
5 Control piston
6 Control unit with feedback lever
7 Slipper pad
8 Valve plate
Service Training
Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction
(direction of oil flow).
A manually operated 4/3-way valve directs the pilot oil flow (from the charge circuit) to the corresponding
control piston side in the servo control. The 4/3-way valve is controlled by the travel lever and the travel
cable.
In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way
valve pilot oil (from the charge circuit) is directed to one of the control piston sides and moves the control
piston to the corresponding direction.
The swashing lever between the control piston and the swash plate transfers the control piston
movement to the swash plate. The needle bearing mounted swash plate swivels to the chosen direction.
This causes the axial movement of the pistons inside the cylinder block. The axial movement draws oil
into the pump and presses it to the travel motors.
All working pistons are drilled through their entire length. Pressure fluid flows through these bores into
the areas between the slipper pads and the surface of the swash plate. This forms a hydraulically
balanced field, on which the slipper pads can slide without any metal to metal contact between swash
plate and slipper pads. The feedback lever on the control piston detects when the swash plate has
reached a position that corresponds with the displacement of the travel lever. This feedback lever
controls a pilot oil portioning valve which interrupts the pilot oil flow to the control chambers when the
swashing angle corresponds with the position of the travel lever. Swashing angle and displacement of
the working pistons (oil flow rate) remain constant, until a new control command requires a different
swashing angle.
When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the travel motors will change. The spherical valve plate centres the
cylinder block, which is mounted on the splines of the drive shaft. This avoids the appearance of
undesired transverse forces.
• valve plate
• swash plate
is held together and preloaded by Belleville springs. This immediately eliminates any appearing wear,
increases the efficiency of the pump and prolongs the lifetime considerably.
When controlling the travel pump pressure will build up in the line between pump outlet and motor inlet.
This pressure depends on the load acting on the travel motors. This pressure keeps the boost check
valve inside the high pressure relief valve for this particular side of the closed hydraulic circuit closed.
Cool and filtered oil can now only enter into the closed circuit on the opposite side (low pressure side).
The high pressure relief valve limits possibly occurring extreme pressure peaks to the adjusted value.
If one of these valves responds, hydraulic oil will flow out of the high pressure side and enter the low
pressure side through the corresponding boost check valve.
Service Training
Since the cross-sections of these valves are very small and the hydraulic oil enters the low pressure
side already inside the pump, the system would very quickly overheat if the pressure in the system
would be permanently relieved via the high pressure relief valves. For this reason the pump is fitted with
an additional pressure override valve. The pressure override valve interrupts the pilot oil flow to the
control piston, thereby maintaining the pressure level at the adjusted value of the pressure override
valve. If the pressure drops again, the pressure override valve will open and the pump can swash back
to the previously chosen position. This installation prevents overheating of the hydraulic system and
overloading of the diesel engine.
Control
The servo control of the pump is an integral part of the pump housing and consists mainly of:
• the swashing lever with the swashing cradle (see Fig. 3).
When actuating the travel lever the 4/3-way valve moves out of neutral position to the desired direction
and guides the pilot oil flow through the pilot oil portioning valve to the corresponding control piston side.
Service Training
The control piston moves to the corresponding direction and operates the swash plate via the swashing
lever accordingly.
The feedback lever, which is mounted with its ball head in the pump control shaft, follows the control
piston and interrupts the pilot oil flow when the control piston has reached a position corresponding with
the displacement of the travel lever. The pump can now deliver oil to the travel motors.
The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump
housing.
The supply bores to both control chamber sides are fitted with nozzles (swashing time nozzles). These
nozzles restrict the pilot oil flow and enable a very sensitive control of the pump.
to – from motor
4/3-way valve
travel pump
Control piston
to – from motor
Service Training
The feedback lever controls the pilot oil portioning valve so that the swashing angle remains unchanged,
until the introduction of a new control command.
to – from motor
4/3-way valve
travel pump
Control piston
to – from motor
When the 4/3-way valve is in neutral position, the pressure values in both control chambers are identical
(case pressure = max. 3 bar).
Service Training
Charge pressure relief valve
The charge pressure relief valve belongs to the group of safety elements in a closed hydraulic circuit.
This valve limits the pressure in the charge circuit to the adjusted value.
The charge pressure relief valve is installed in the travel pump and internally connected with the
vibration pump.
pilot oil
fixed spring
The charge circuit is needed for the compensation of leak oil and flushing quantities in the closed
hydraulic circuit. Charge oil is also required to control the pumps and to release the parking brake.
Since feeding of cool and filtered oil is only possible on the low pressure side of the closed circuit, the
pressure in the low pressure side is identical with charge pressure. If the travel pump is in neutral
position, both boost check valves can open and let in oil from the charge circuit. In this case the pressure
in both sides of the closed circuit is identical with charge pressure.
Service Training
High pressure relief valves, (with bypass for towing)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit.
These valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.
1 Pressure override
2 High pressure relief valves, (fixed adjustment) with bypass for towing
3 Charge pressure relief valve (fixed)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit. These
valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.
Service Training
.
1
4
2
1 Travel pump
2 Control piston (actuated)
3 4/3-way valve (actuated)
4 High pressure relief valves, fixed
The high pressure relief valves in both sides of the hydraulic circuit protect the hydraulic system, the
diesel engine and all other machine components against overloads.
The boost check valves are integrated in the high pressure relief valves. These valves open to the low
pressure side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit,
in order to compensate leaks and flushing quantities.
Service Training
Pressure override
Since the cross-sections of the high pressure relief valves are very small, longer responding of these
valves would cause very quick overloading of the hydraulic circuit and would subsequently lead to
severe damage in pump or other components. In order to avoid this, the travel pump is equipped with
another safety device, the pressure override.
2
5
1 3
4
1 Charge pump
2 Pressure override
3 Travel pump
4 Control piston
5 3/4-way valve
6 Shuttle valve
The pressure override is hydraulically arranged in the pilot oil flow to the pump control before the 4/3-
way valve and consists mainly off:
Service Training
Since the cross-sections of the high pressure relief valves are very small, longer responding of these
valves would cause very quick overloading of the hydraulic circuit and would subsequently lead to
severe damage in pump or other components. In order to avoid this, the travel pump is equipped with
another safety device, the pressure override.
Service Training
A shuttle valve ensures that the spool of the pressure override is always subjected to the highest
pressure in the closed circuit. As long as the pressure in the closed circuit is lower than the adjustment
value of the pressure override, the pilot oil connection via the 4/3-way valve to the corresponding control
chamber is released. The pump can now be actuated up to maximum displacement.
If the pressure reaches the setting of the pressure override, the spool inside the valve will move and cut
off the pilot oil flow to the control piston. The pump cannot be actuated any further. The system pressure
is maintained at the setting of the pressure override, until the resistance causing this high pressure in
the system is overcome or the pump is returned to neutral position by the operator.
Should the pressure in the closed circuit drop below the setting of the pressure override, the valve spool
will be forced back by spring force, whereby the passage between charge circuit and pump control is
opened again. Now pilot oil can flow to the corresponding control piston side again and the pump can
be actuated.
The spring force of the pressure override and its reaction value can be adjusted via the adjustment
screw.
Due to its design and the hydraulic arrangement of the pressure override, the high pressure relief valves
will not respond. This type of pressure limitation does not relieve any oil from the closed hydraulic circuit
via the very tight cross-sections of the high pressure relief valves. This avoids overheating of the
hydraulic oil.
As a measure to ensure correct function the pressure setting should always be 10% lower than the
setting of the high pressure relief valves.
Service Training
Travel motors BW 141/151
The two travel motors are plug-in fixed displacement bent axle motors of series A2FE 32 ccm from
Bosch-Rexroth, which drive a travel gear 705 C2H from Bonfigioli.
2 3
1
Leakage with
flushing quantity
from/to the
from/to the travel pump
travel pump
22 Travel motor
23 Travel gear
1 Travel motor drive
2 Brake housing in travel gear
3 Flushing valve with flushing pressure limitation valve
Service Training
2 6
8
1
3
1 Drive 5 Piston
2 Drive shaft 6 Tapered roller bearing
3 Valve plate 7 Radial seal
4 Center journal 8) Flushing valve
Service Training
Flushing valve on motor deckel
10
8
Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
The flanged mounted flushing valve flushes out approx. 6-8 litres from the low pressure side into the
motor housing. The flushing pressure relief valve limits the flushing pressure to 16 bar, so that it does
not fall below the charge pressure of 16 bar.
Service Training
Drum drive reduction gear BW 141/151
2 3 7
4
1
11
5 6 10
8
Service Training
Test and adjustment points travel pump
3
7
6
4
8 15
4 3
5
2
6
Service Training
Travel motor with travel gear
1
5 4
2
4
2
3
1
2
3
Service Training
Brake valve with hand pump for emergency brake release
5 1
2
4 3
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
Service Training
POSSIBLE CAUSES
Brake valve (electrically/mechanically/hydraulically) 1
Brake in drum drive travel gear (mechanically/hydraulically) 2 2 3
Speed range selector switch position/defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override / travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Travel cable adjustment 1 2
Travel pump mechanical neutral position 3 3
Travel pump(s) defective 3 3 2
Control valve travel motor(s) (electrically/mechanically/hydraulically) 1 2
Flushing valve for travel motor(s) stuck 3
Travel motor(s) defective 3 3
Drum drive travel gear defective 3
Hydraulic oil cooler dirty (internally/externally) 1
Thermostat (hydraulics) dirty/jammed/defective 2
Coupling diesel engine- pumpe 2
Diesel engine 1
Service Training
Travel system BW 154 AD
On the machines described in this training manual the travel system consists of a closed hydraulic
circuit. It mainly consists of travel pump with integrated safety elements, travel motors with travel gears
and a flow divider.
Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch
Rexroth-Hydromatik, type A4 VG 56 HW.
T1: Connection to vibration pump from/to the
T2: Leak oil to tank travel motors
Charge pressure Via flow
divider
3
3
440
22
1 5
5
M 1
440 400
4
5 26 66
4
7
5
from/to the
travel motors
Service Training
The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit.
These are:
• Servo control
• Pressure override
Travel pump and vibration pump are connected to a tandem pump unit.
The travel pump is fitted with a flushing valve for the closed circuit
All safety and control elements needed for the operation in a closed hydraulic circuit are integrated in
the travel pump. These are:
• High pressure relief valves (440 bar) with integrated boost check valves
• Servo control
The travel motors are bent axle motors plugged into a travel gear with an upstream or downstream flow
divider.
Service Training
Charge pressure relief valve
The charge pressure relief valve belongs to the group of safety elements in a closed hydraulic circuit.
This valve limits the pressure in the charge circuit to the adjusted value.
The charge pressure relief valve is installed in the travel pump and internally connected with the
vibration pump.
pilot oil
fixed spring
The charge circuit is needed for the compensation of leak oil and flushing quantities in the closed
hydraulic circuit. Charge oil is also required to control the pumps and to release the parking brake.
Since feeding of cool and filtered oil is only possible on the low pressure side of the closed circuit, the
pressure in the low pressure side is identical with charge pressure. If the travel pump is in neutral
position, both boost check valves can open and let in oil from the charge circuit. In this case the pressure
in both sides of the closed circuit is identical with charge pressure.
Service Training
High pressure relief valves, (with bypass for towing)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit.
These valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.
1 Pressure override
2 High pressure relief valves, (fixed adjustment) with bypass for towing
3 Charge pressure relief valve (fixed)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit. These
valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.
Service Training
.
to flow divider
from there to the travel moto
1
4
2
1 Travel pump
2 Control piston (actuated)
3 4/3-way valve (actuated)
4 High pressure relief valves, fixed
The high pressure relief valves in both sides of the hydraulic circuit protect the hydraulic system, the
diesel engine and all other machine components against overloads.
The boost check valves are integrated in the high pressure relief valves. These valves open to the low
pressure side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit,
in order to compensate leaks and flushing quantities.
Service Training
Travel motor BW 154
The two travel motors are plug-in fixed displacement bent axle motors of series
A2FE 32 ccm from Bosch-Rexroth, which drive a travel gear GFT 07 from Bosch Rexroth.
Service Training
Travel gear BW 154
Service Training
Service Training
BW 154 AD-4 - F 10 -
Service Training
Flow divider BW 154
from or to
the travel pump
High pressure port B
BW 154 AD-4 - F 11 -
Service Training
On machines of series BW 154 AD/AC with split drums all drum halves or drum halves and wheels or
Wheel halves and wheels are driven by own travel motors. These machines are therefore equipped with
4 travel motors.
In order to assure that all motors are always supplied with the required oil quantity, a four-fold flow
divider is installed between travel pump and travel motors.
Flow dividers are used where several consumers have to be hydraulically arranged in parallel mode and
wherever the use of the consumers requires a differential lock, as it is necessary on rollers of type BW
154.
The hydraulic diagram (Fig. 1) shows the flow divider (16) with the integrated secondary pressure relief
and boost check valves.
Here four travel gears (23) for drum or wheel drive (AC) are hydraulically linked in parallel mode. In order
to avoid that a motor of any drum half will start to spin, the installation of a ”differential lock” is necessary.
To be able to understand the function of a 4-fold flow divider MH4FA one should first examine the
function of a 2-fold flow divider based on the constant orifice principle:
BW 154 AD-4 - F 12 -
Service Training
The control piston of the flow divider is fitted with measuring orifices. Since the diameter of the orifice
bore remains of identical size and does not change during operation, these orifices are called constant
orifices.
During operation of the hydraulic system a pressure differential (p) is created at these constant orifices.
If the flow rate at the two consumer ports (1 and 2) is of identical size, the pressure difference p1 =
pressure difference p2 and the control piston is centred in middle position. If the pressure differential p
between inflowing and outflowing oil is bigger on one side, the piston will be forced in this direction.
During this process the cross section of the discharge orifice for this outlet is decreased, the discharged
oil flow is throttled. This restriction of flow volume to the corresponding consumer is maintained, until an
equilibrium of the pressure differentials returns the control piston to middle position and the discharge
nozzles have identical cross sections again.
In this case the division ratio is determined by the opening cross sections of the discharge orifices.
The division accuracy depends on the accuracy of the measuring orifices, the spring rate and the friction
of the piston in the housing. With low pressure differentials the division accuracy is quite low, i.e. at low
flow volumes the flow divider works quite inaccurate. If the volume flow increases and with it also the
pressure differential at the constant measuring orifices, the division accuracy will also enhance. Higher
pressure differentials at the orifices result in a higher energy conversion. Hydraulic energy is converted
to heat energy. The influence of the spring has thereby not yet taken into account.
If uniformly adjustable measuring orifices, the cross sections of which would change in dependence on
the arriving oil flow, were used instead of constant measuring orifices, both the level of energy
conversion (loss) as well as the division fault could be maintained at an almost constant level. Another
negative factor for the division accuracy is the effect of the regulating spring. Stronger springs require
higher forces to move the control piston, i.e. the flow divider will only control at higher pressure
differentials p.
For the 2-fold flow divider described above it would also be possible to use two control pistons with only
one control edge each, instead of the control piston with two control edges.
BW 154 AD-4 - F 13 -
Service Training
Each consumer port would then have its own measuring orifice and control piston. When changing the
flow direction, the mobile sleeve with the control edge on the control piston enables an automatic
change to summarizing mode, i.e. in the flow divider the oil flow returning from the consumers are joined
and returned to the pump.
Form this description it is clear that this principle is not only suitable for two-fold flow dividers, but also
for a multiple division of the flow volume from the pump.
BW 154 AD-4 - F 14 -
Service Training
If the flow rates are identical on all consumer ports, all control edges are open. If the pressure drops in
one of the consumer lines (e.g. ”C”), this is a sign that a higher flow volume flows to this consumer. The
related control edge on the control piston moves towards closing, thereby trying to compensate this
difference. At the same time this pressure drop in consumer line ”C” causes a relatively bigger opening
to consumer ”B” and from there to consumer ”A”, until a condition of equilibrium is reached on all 4
control pistons or in all consumer lines.
BW 154 AD-4 - F 15 -
Service Training
Design and function of MH4FA
The flow divider consists mainly of housing (1), single edge control piston (2), sleeve (3), pressure spring
(10) and piston (11).
Port P1
not available
Fig. 6
In housing (1) sleeve (3) is retained by pin (5). Sleeve (3) contains worked in measuring orifices
(windows), according to the division and summarizing ratio. These measuring orifices have the function
to compare the arriving and out flowing flow volumes in the consumer channels
A, B, C and D.
The flow volume arriving from the pump flows from port ”P” via bush (13) into chamber (15) and moves
the piston (11) against the preloaded pressure spring . This alters the cross section of the measuring
orifices (windows) in dependence on the magnitude of the flow volume and the pressure fluid flows
through bore (12) into the consumer channels A, B, C and D. The necessary corrective movements to
reestablish the state of equilibrium in all consumer lines are performed by the single edge control pistons
(2), as described above. For the automatic change-over from dividing to summarizing function and vice-
versa the single edge control pistons (2) are fitted with additional rings (4).
BW 154 AD-4 - F 16 -
Service Training
Since the single edge control pistons (2) only start to regulate after a certain pressure differential is
reached, the wheels or drum halves will not start to spin, the machine is maintained in a manoeuvrable
condition.
The flow divider used in the machine types BW 154 works like a differential lock. Due to this type of
operation a lack of oil in the consumer lines may occur when driving around curves. This would
obviously cause cavitation, or, in case of sudden reversing operations, pressure peaks in the system.
In order to avoid this and resulting damage each consumer port is fitted with a secondary pressure relief
and boost check valve.
The flow divider is connected with the charge circuit of the machine via two “Y”-ports. This charge
pressure is permanently applied to the boost check valves. In case of a lack of oil in one of the consumer
lines the corresponding boost check valve will open and feed in the required oil quantity.This protects
the system against cavitation.
If pressure peaks occur e.g. when changing the travel direction all of a sudden, the corresponding
secondary pressure relief valves will respond and protect the system against overloads.
Note:
Port P1 is not available on machines of series BW 154. In other applications this port is needed to enable
and disable the differential lock via an external 2/3 way valve.
BW 154 AD-4 - F 17 -
Service Training
Trouble shooting flow divider
If a malfunction in the travel system is detected during operation of the machine, the function of the flow
divider can be tested by jacking the complete machine up (all drums must be able to rotate freely).
If the drums rotate with strongly different speeds at full engine speed and maximum travel speed (slight
speed differences can be caused by resistances in bearings and between the drum halves), the flow
divider must be replaced.
BW 154 AD-4 - F 18 -
Service Training
Test and adjustment points
Travel pump
10 9
5
4
3
6
1
2
7
8
BW 154 AD-4 - F 19 -
Service Training
Travel motor with travel gear
7
6
1 4
3 4
2 1
2
3
5
5
2
BW 154 AD-4 - F 20 -
Service Training
Flow divider
BW 154 AD-4 - F 21 -
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
BW 154 AD-4 - F 22 -
Service Training
POSSIBLE CAUSES
Brake valve (electrically/mechanically/hydraulically) 1
Brake in drum drive gear (mechanically/hydraulically) 2 2 3
Speed range selector switch position/defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Travel cable adjustment 1 2
Travel pump mechanical neutral position 3 3
Travel pump(s) defective 3 3 2
Control valve travel motor(s) (electrically/mechanically/hydraulically) 1 2
Flushing valve for travel motor(s) stuck 3
Travel motor(s) defective 3 3
Drum drive gear defective 3
Hydraulic oil cooler dirty (internally/externally) 1
Thermostat (hydraulics) dirty/jammed/defective 2
BW 154 AD-4 - F 23 -
Service Training
Vibration
The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.
• vibration pump,
• vibration motors
Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the
diesel engine.
When operating a 4/3 way solenoid valve, pilot oil is guided to one of the control piston sides. This
actuates the pump from neutral position to one of the two possible maximum displacement positions. If
the vibration shut-off valve is not activated the pump now pumps oil to the vibration motors, which are
connected in series mode.
When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the vibration motors will change.
Since the displacements are different to both pumping directions, the speed of the vibration motors to
the two directions of rotation is also different.
The vibration motor output shafts are joined with the exciter shafts in the drums via Bowex coupling. The
rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically
suspended drums.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights.
Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.
The displacement of the pump is different to both flow directions. This results is different exciter shaft
speeds in dependence on the sense of rotation of the vibration motors.
The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled
with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.
Charge pressure port from leak oil port front travel motor
T1: to tank
Fig. 1
T2: travel pump connection
19
1 4 7
5 6
BOMAG
4 18
8
Charge oil
from travel pump
to tank
1 006 Vibration pump 9 Pressure relief valve from leak oil port
2 Control piston 18 Rear vibration motor rear travel motor
3 4/3-way control solenoid valve 19 Front vibration motor Cross-flushing
4 High pressure relief valves
5 Pressure override Y54 Solenoid valve, front vibration
6 Shuttle valve Y55 Solenoid valve, rear vibration
7 Flushing valve Y56 Solenoid valve, low amplitude
8 007 Vibration shut-off valve Y57 Solenoid valve, high amplitude
Service Training
-G2-
Service Training
008 910 92
Service Training 11.1
Service Training
Vibration pump
The vibration pump is a swash plate operated axial piston pump with variable displacement of type A10
VG 45 EZ from Hydromatik. The pump is fitted with all control and safety elements needed for operation
in a closed hydraulic circuit. These are:
• servo control
• Pressure override
T2: Connection to travel pump
T1: to tank
3
to / from
Vibration
shut-off
valve
1 4
2
4 5
from/to
Vibration
shut-off
valve
Charge oil from
Travel pump
1 Pump drive
2 Control piston
3 Solenoid valve
4 High pressure relief valves (405 bar)
5 Pressure override (380 bar)
Service Training
3 4 5
2
9 8 7 6
1 Drive shaft
2 Control piston
3 Pilot pressure port (X1/X2)
4 Servo control
5 Pressure override
6 Cylinder block
7 Working pistons
8 Slipper pad
9 Swash plate
The complete drive consisting of valve plate, cylinder block and swash plate is held together by Belleville
springs. This results in a high efficiency over the entire lifetime of the pump.
The spherical valve plate centres the cylinder block which is driven by the drive shaft via a splined
connection. This avoids the appearance of undesired transverse forces.
Service Training
Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction
(direction of oil flow). A 4/3-way valve guides this pilot oil to the corresponding control piston side in the
servo control. Due to the use of a remote control (electrically operated via solenoids) the pump can only
be actuated from neutral to one of the two possible maximum displacement positions.
In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way
valve pilot oil (from the charge circuit) is directed to one of the control piston sides and moves the control
piston to the corresponding direction. The pump swashes to the adjusted maximum displacement.
When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the exciter shaft will change.
This results in different speeds of the vibration motor to both travel directions.
This means:
The position of the change-over valves depends on the sense of rotation of the exciter shaft. The
different positions of the change-over weight in relation to the basic weight results in the following
vibration effects:
The resistance affecting the rotation of the exciter shaft causes pressure to build up between pump and
motor. This pressure closes the boost check valve in the high pressure side of the closed circuit.
Feeding of cooled and filtered hydraulic oil can therefore only take place in the low pressure side.
Once the pressure reaches the adjusted value of the pressure override valve the pilot oil flow to the 4/
3 way solenoid valve is interrupted. The pressure cannot increase any further.
Sudden pressure peaks are eliminated by high pressure relief valves. In this case hydraulic oil flows
from the high pressure side through the boost check valve directly into the opposite side, the low
pressure side.
Service Training
High pressure relief valves
8 3*
6 5
When switching the vibration off the vibration motors for a short while have the function of a pump. They
pump the oil back to the vibration pump. This effect is caused by the rotating exciter shafts with the
attached eccentric weights.
Since the vibration pump is already in neutral position, the oil cannot pass through the pump. In this case
the pressure override valve has no function. Under this condition the high pressure relief valves work as
brake valves.
The functions of pressure override valve and high pressure relief valves in the vibration circuit are
identical with the functions of these valves in the travel circuit. The description of these components
does therefore not need to be repeated.
Service Training
Control
The control is part of the pump and consists mainly of the 4/3-way solenoid valve, the control piston and
the swash plate with swashing lever.
If one of the two magnets is energized by actuating the frequency selector switch and the vibration
control switch, the 4/3 way solenoid valve is switched to open position. Pilot oil flows now to the
corresponding control piston side. The control piston slides to the corresponding direction and moves
the swash plate via the swashing lever. The pump delivers oil.
6
2
The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump
housing.
When the 4/3-way valve is in neutral position, the pressure values in both control chambers are identical
(case pressure = max. 3 bar).
Service Training
Vibration motors
The vibration motors are fixed displacement axial piston motors of bent axle design, type A4 FM 22, from
Hydromatik. These motors are designed for two directions of rotation and can therefore subjected to
pressure from both sides.
The pressure oil provided by the pump flows through the kidney shaped control slots in the valve plate
into the cylinder block with the working pistons. The pressure oil causes a stroking movement of the
working pistons. Due to the swash plate design this axial movement of the pistons is converted to a
radial movement of the motor drive. The output shaft transfers this rotary movement via an elastic
Bowex coupling to the exciter shaft with the two eccentric weights.
2 4 5
3 6
1 7 8
When switching the vibration on the vibration motors must first accelerate the resting exciter shaft up to
nominal speed. This resistance causes a hydraulic starting pressure, which is limited to 380 bar by the
pressure override valve.
Once the exciter shaft has reached its final speed, the pressure will drop to an operating pressure of
approx. 60 - 160 bar. This operating pressure depends on the state of compaction of the soil.
Service Training
Vibration shut-off valve
Charge pressure Leak oil from front travel mo
With this vibration shut-off valve the vibration motors can be switched on or off individually.
The vibration shut-off valve is a solenoid operated pilot controlled valve. It controls start, stop of vibration
and flow direction of the flow volume.
Service Training
Flushing valve
The housing of the vibration shut-off valve contains a flushing valve. The flushing valve is connected
with both sides of the closed circuit.
When the vibration is switched on the high pressure side of the closed circuit moves the flushing piston
and opens a discharge channel for oil from the low pressure side.
Oil flows now from the low pressure side back to the tank. This oil is immediately replaced by fresh,
cooled and filtered oil from the charge circuit.
The flushing quantity is limited by the orifice or nozzle with a bore of (d=2mm).
If the flow direction of the oil changes (when changing the vibration frequency), the flushing valve shifts
to the other side and opens the discharge channel for the opposite side of the closed circuit (now low
pressure side).
If the vibration is not operated the flushing spool is centred in neutral position by two pressure springs.
The flushing valve has the function to maintain the temperature in the hydraulic system at a permissible
level.
Service Training
Drum BW 141 AD-4
10
13
12
10
4 52 12
53 13
8 7
7
8
9
6 2
3 64
11
11
1
9 9
1
Service Training
Drum BW 154 AD-4
13 13
12 12
13
5 10 10
8 14 12
3 4 5 15 7
2
8
7
11 6 11
3 6 4 9
2
11
1
9 9
1
Service Training
Exciter weights
1 Basic weight
2 Change-over weight
3 Oil paddle
Service Training
Test and adjustment points
Vibration pump
5 4
1
6
3
2
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Vibration pump 6
2 Pressure test port, charge pressure 6 26 bar
3 Pressure test port, vibration 6 max. 380 bar
pressure high amplitude
4 Pressure test port, vibration 6 max. 380 bar
pressure low amplitude
5 Solenoid for high amplitude Y57 Page 008 6
6 Solenoid for low amplitude Y56 Page 008 6
Service Training
Vibration pump
4 3 5
2
1
Service Training
Vibration shut-off valve
1
2
1
5
2
3
3
5 4 4
Service Training
Vibration motor front/rear
1 3 4
2
2
4
2
3
2
1
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
Service Training
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1 1
Push button vibration (on/off) 1
Electrics defect / wiring 2 2 2
Vibration shut off valve magnets defective /
1 1
dirty / jammed
Pump control (electrically / hydraulically) 1 1
Pressure override/ high pressure limitation vibration pump
2
dirty/out of adjustment/defective
Charge pump(s) / charge pressure relief valves
2
dirty/defective
Flushing valve in vibration shut-off valve dirty/jaqmmed/defective 2 2 2
Vibration pump frequency setting 2
Vibration pump defective 2 2 2
Coupling between engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor(s) defective 2 1
Diesel engine 1
Service Training
Steering
The machines described in this manual are equipped with a hydraulically operated articulated steering.
12
to charging
to blower motor
Suction lines
Service Training
The steering system consists mainly of:
As the steering pump also supplies the hydraulic oil for the charge circuit for travel and vibration drives
as well as the crab walk facility besides the steering, the system is equipped with a priority valve. The
priority valve ensures that the steering will always be prioritized under any condition. The priority valve
is triggered by the steering valve through the LS-line. This valve restricts the oil flow to charge circuit
and crab-walk whenever oil is needed for the steering. However, this does not mean that in such a case
there would be a lack of oil for the charge circuit, because the return flow from the steering is directly
fed into the charge circuit.
The steering pump supplies the hydraulic oil from the hydraulic oil tank through the pressure filter to the
priority valve. If the steering is not operated, the complete oil flow will flow through the crab walk valve
to the charge ports for the travel and vibration circuits.
When operating the steering the steering valve will generate a load signal „LS“, informing the priority
valve that more oil should be directed to the steering.
When turning the steering wheel the distributor valve guides the oil flow to the corresponding steering
cylinder sides.
A rating pump inside the steering unit measures the exact oil quantity corresponding with the turning
angle of the steering wheel and delivers the oil to the steering cylinders.
The steering valve contains also a pressure relief valve. This valve limits the steering pressure to 170
bar. Since the oil is available for the charge circuit after it as left the steering unit, the charge pressure
of 26 bar must be added to this value. The maximum steering pressure is therefore approx. 196 bar.
Suddenly occurring pressure peaks, which may be caused by e.g. external influences like driving
against a curb stone, are compensated by two shock valves (setting 235 bar), which are integrated in
the steering valve.
Note
This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min) will
always flow via the LS-line.
Service Training
Steering pump
The steering/charge pump is a tandem gear pump with fixed displacement. Pump section 1, which is
directly mounted to the engine (11 ccm), supplies the steering and the crab-walk valve, the second
pump unit (8 ccm) serves the fan motor. After serving the above mentioned functions both pump flows
are united for the charge oil supply.
The tandem pump is driven by the auxiliary drive of the diesel engine and draws the hydraulic oil directly
out of the oil tank. The oil then flows through a pressure filter to the priority valve, the steering valve or
the crab walk valve or the blower motor, and from there to the charge circuit.
9 9 6 1 7
3
8
2
4 5
The drive pinion of the steering pump is driven by the auxiliary drive of the engine. Drive gear and driven
gear are positioned by a bearing plate in such a way, that the teeth of both gears mesh with minimum
clearance when rotating.
The displacement chambers are formed between the tooth flanks, the inside wall of the housing and the
faces of the bearing plates. The chambers transport the hydraulic oil from the suction side to the
pressure side. This generates a vacuum in the suction line, which draws the hydraulic oil out of the tank.
These tooth chambers transport the hydraulic oil along the inside wall of the housing from the suction
side to the pressure side, from where it is pressed to the consumers. To ensure a safe function of the
pump the tooth chambers must be so tightly sealed that the hydraulic fluid can be transported from the
suction side to the pressure side without any losses.
Outer gear pumps are fitted with gap seals. This results in pressure level dependent fluid losses from
the pressure side to the suction side. An axial pressure field presses the bearing plate on the cover side
against the front face of the gears, making sure that only a very little quantity of oil will leak from the
pressure side to the suction side when the pressure increases during operation.
The pressure field is always under system pressure.
Service Training
Priority valve
Since the pressure oil from the steering pump is also needed for the working hydraulics, i.e. the crab
walk valve, the machine is fitted with a priority valve. This valve ensures that the steering will always be
prioritized under any condition. The priority valve guides the oil to the following consumers:
• to the crab-walk valve and from there to the charge circuit (port EF)
Priority valve
Distribution of the oil is determined by the switching position of the valve spool.
This position depends on the following values:
• the requirements caused by the steering load (LS-signal) arriving from the steering valve
The load signal (LS) from the steering valve controls the position of the valve spool in such a way, that
the oil flow is at any time determined by the steering speed.
Note
This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min) will
always flow via the LS-line.
Service Training
Steering valve
1
2
9
3
8
6
Steering unit
1 Neutral setting springs 6 Ring gear
2 Housing 7 Gear
3 Inner spool 8 Check valve
4 Outer spool 9 Pressure relief valve
5 Universal shaft
Service Training
When turning the steering wheel the oil flow from the pump is guided through the distributor valve to the
rating pump and from there to the respective sides of the steering cylinders.
The rating pump determines the exact oil quantity in dependence on the turning angle of the steering
wheel.
The high pressure relief valve in the steering unit limits the pressure in the steering system to 170 bar
+ charge pressure.
The steering unit is equipped with so-called shock valves for both pressure sides to the steering cylinder.
These valves are adjusted to 235 bar. They compensate extreme pressure peaks, which can be
introduced from outside, e.g. when driving over obstacles. The system is thereby protected against
overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. These anti-cavitation valves
protect the system against cavitation which could be caused by the reaction of the shock valves.
A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump
if forces are introduced from outside. In such a case the steering cylinders would act as pumps and
press the oil back to the pump.
Note
This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min) will
always flow via the LS-line.
Service Training
The machines are equipped with two steering wheels. However, the machines are fitted with only one
steering valve, which is arranged between the steering wheels. Two circulating chains connect both
steering wheels with the steering valve.
Service Training
Articulated joint
The articulated joint is the connection between front and rear frames.
The rear console is tightly bolted to the rear frame via a live ring.
The front console is fastened with screws to the rear cross-member of the front frame. The front console
is additionally fitted with the welded on bearings eyelets for the steering cylinders.
When turning the steering wheel the steering will extend or retract. The piston rods swivel the front
console around the vertical bolts. The machine articulates and steers.
All bearing points on the articulated joint are maintenance free, lubrication is not required.
Service Training
Service Training
Articulated joint
Service Training
Test and adjustment points
3 1
2 4
2
Service Training
Steering valve
3 2
9
5
6
4 3
4 2 1
5
Service Training
Priority valve
4 3
2 1
Service Training
Trouble shooting:
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
Service Training
POSSIBLE CAUSES
Steering valve 2 2 1
Steering/charge pump 11 ccm 1 1 2
Blower/charge pump 8 ccm 2
Priority valve 3 3 3 2
Steering cylinder 3 3 3
Articulated joint 3 3 2
Crab walk cylinder 3
Crab walk valve 2
electr. control/solenoid valve for crab walk 1
Service Training
Working hydraulics - crab walk and optional equipment
12 13
y20
y18
to
y19 y21 charging
to the
blower motor
Suction lines
Service Training
Crab-walk valve
The crab walk facility enables lateral offsetting of the front frame to the rear frame. The max. offset value
is approx. 170 mm.
This offset between front and rear frame is of great help when pressing edges and cornering along curb
stones.
The crab-walk control valve consists of the actual electro-magnetically operated valve, the 160 bar
(pressure differential) pressure relief valve and the two unlockable non-return valves (pressure retaining
valves).
12
2
y18
3
1
from
priority valve y19
port EF to charging
If the crab-walk is not operated, the complete oil flow is directed through the open channel in the closed
valve to outlet T and from there to the charge circuit.
If the control valve is actuated out of neutral to one of the two active positions, the open oil flow passage
is closed and the oil flows through the valve to the corresponding side of the crab-walk cylinder. The
unlockable non-return valves lock the oil in the cylinder chambers, until a new control command opens
these valves and allows the oil to flow out.
Service Training
Test and adjustment points
Service Training
Proximity switch
The proximity switch indicates the position of the crab walk, i.e. middle position front frame to rear frame.
Service Training
Crab-walk valve
1
3 2
1
5
6
Service Training
Crab-walk cylinder
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience:
Service Training
TROUBLE SHOOTING
POSSIBLE CAUSES
Steering valve 2 2 1
Steering/charge pump 11 ccm 1 1 2
Blower/charge pump 8 ccm 2
Priority valve 3 3 3 2
Steering valve 3 3 3
Articulated joint 3 3 2
Crab walk cylinder 3
Crab walk valve 2
electr. control/crab walk solenoid valve 1
TROUBLE SHOOTING
Service Training
Blower drive
On the new articulated tandem rollers of series 4 the external blower is hydraulically driven
Check valve or
anti-cavitation valve
to the
priority
valve,
Steering
to charging
Suction lines
The hydraulic blower motor is driven by the second pump (8ccm) of the tandem gear pump on the
auxiliary drive of the engine.
Service Training
Blower motor
The blower motor is an 8ccm gear motor with a pressure relief valve flange mounted on the motor inlet
side P.
The blower speed is identical with the diesel engine speed (when the pressure relief valve is not active),
because the displacements of pump (8 ccm) and motor (8 ccm) are identical.
Service Training
Test and adjustment points
3 1
2
2
Service Training
Blower motor
1
2
1
P
4 3
Service Training
Return flow block with thermostat valve
4
2
3
1
1
1 1
1
1
Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
TROUBLE SHOOTING
BW 141-4 FAMILY
Blower speed not correct
No blower speed
SYMPTOMS
POSSIBLE CAUSES
Blower / charge pump 8 ccm 1 2
PRV 2 1
3
Blower motor
TROUBLE SHOOTING
BW 141 - 154 AD/AC -4 -G6-
Service Training
Water sprinkling system
The new articulated tandem rollers of series 4 are equipped with two independently working water
pumps. Both pumps can be operated as desired.
These water pumps are direct controlled diaphragm pumps, solenoid valves are therefore not required.
The water filter is located behind the water tank cover or water pump suction port, at the lowest position
of the water tank.
The water sprinkler system is controlled by means of the travel lever monitoring and water sprinkler
module A03
2
1
3
4
5
Service Training
Circuit diagram, water sprinkler system
Service Training
AC-Variants: BW 141 - 154 AC-4
On the machines described in this training manual the travel system consists of a closed hydraulic
circuit. It mainly consists of travel pump with integrated safety elements and travel motors with travel
gears. The AC wheel set is equipped with radial piston travel motors.
23
from brake valve
5
22
4
420
25
3
440
4Pressure override
6) Flushing valve
2Servo control
1Travel pump
2
Service Training
Travel motors of the AC wheel set
The two travel motors in the AC wheel set are radial piston motors
Leakage with
flushing quantity
Leakage
from/to the
from/to the travel pump
travel pump
Hydraulic diagram
Service Training
Travel motor Poclain MS 08
These travel motors consist of three housing parts, the flat distributor, the cylinder block with the working
pistons and the output shaft.
2 3
4
1
43090070
8 7 6 5
Service Training
The housing consists of:
• oil distributor.
Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race. This transforms the axial movement of the pistons to a radial
movement of the cylinder block. The cylinder block transfers this rotation via a splined connection to the
output shaft. The output shaft runs in two tapered roller bearings. It transfers the rotary movement via
the drive disc and the rubber elements to the drum. The function of the radial piston motor is described
hereunder. The piston positions described in this explanation can be seen in the related illustration. The
movement of a piston along the cam race must be examined in several phases during a full rotation:
5
2
3
Service Training
Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the
roller along the cam and causes a rotation of the cylinder block.
Piston position 2:
At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.
Piston position 3:
Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.
Piston position 4:
Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to
the pump.
Piston position 5:
The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre
position. This point is the start of a new working cycle.
Reversing the oil flow reverses also the rotation of the motor.
The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.
Service Training
Test and adjustment points
Service Training
Travel system
5
6
1 2
3 4
2
Service Training
AC sprinkler system
Emulsion tank
Service Training
Emulsion pump
1
2
3
4
The AC sprinkler system is controlled via the sprinkler system module A04
Fig. 1 Engine compartment, left hand side toothed timing belt, compared with the predecessor
Tandem rollers series BW141/154 AD/AC-4 are pow- 1011 F.
ered by a Deutz diesel engine series BF4M 2011.
The engines are characterized by the following posi-
tive features:
In contrast to the 1011/2011 engines already used by
BOMAG this engine is fitted with an external oil cool-
ing system, i.e. a separate oil cooler with hydraulically
driven fan, instead of the established integrated oil
cooler/fan system.
The engine is characterized by the following positive
features:
●
short and compact design
●
low noise level
●
low vibration operation
●
low fuel consumption
●
low exhaust emissions
● excellent access to all service locations.
● due to the automatic tensioning device and an im-
proved enclosure for the belt drive, extended main-
tenance interval (5000 operating hours) for the
Fig. 1 Lubrication oil circuit 17 Oil return flow through crankcase into oil sump
1 Oil sump 18 Lubrication oil flow to exhaust turbo charger
2 Oil suction pipe 19 Exhaust turbo charger
3 Oil pump 20 Return flow from exhaust turbo charger to oil
4 Main oil channel sump
5 Oil cooled cylinders
6 Cylinder head cooling groove
7 Oil gallery for rocker arm lubrication
8 Rocker arm
9 Oil manifold to thermostat
10 Feed to external engine oil cooler
11 Return flow from external engine oil cooler
12 Thermostat housing with slide-type thermostat
13 Oil gallery to oil filter
14 Oil filter
15 Oil gallery to camshaft, conrod and crankshaft
bearings
16 Spray nozzle for piston cooling
Heating
The heat generated in the cooling oil circuit is dissipat-
ed through a heat exchanger and used to heat the
driver's cab. For this purpose the cooling oil flow from
the engine is routed through a heat exchanger. At
cooling oil temperatures above 93° C the cooling oil
flow through the engine oil cooler is enabled by ther-
mostat 2 (Fig. 3) and (Fig. 4).
Fig. 4
Pressure relief valves and thermostat are located be-
hind the plugs.
Tightening torque 2 (Fig. 4) 75 Nm
Fig. 3 Cooling oil circuit with heat exchanger heating Tightening torque (3, 5, 6 and 7) 111 Nm
1 Oil pump with pressure relief valve
2 Thermostat
3 Pressure relief valve 3.0 bar (without heating con-
nection, pressure spring with green colour mark)
4 Heat exchanger
5 Pressure relief valve 1.0 bar (with heating connec-
tion, pressure spring with yellow colour mark)
6 Pressure relief valve 0.3 bar (with heating connec-
tion, pressure spring with blue colour mark)
7 Pressure relief valve 1.7 bar (with heating connec-
tion, pressure spring with red colour mark)
8 Engine oil cooler
Fig. 5
i Note
Observe the assembly direction of the pressure relief
valves (Fig. 5).
Fit the plugs with new copper sealing rings.
Fig. 1
1 Oil pressure switch
General:
After starting the oil pressure switch (B06) reports
when a safe operating pressure has been reached
and causes the warning light (H09) in the monitoring
board (A15) to light, if the engine oil pressure drops
below approx. 0.8 bar.
In case of too low engine oil pressure with the engine
running, the module (A68, terminal 8) will send a time
delayed (10 sec.) signal to relay K22 (terminal 85).
The relay interrupts the electric power supply to the
solenoid valve (Y13) and the diesel engine is shut
down.
Fig. 1
1 Generator (G02)
i Note
The generator is maintenance free. Function tests and
repair work must only be performed in authorized
workshops.
Fig. 2
! Caution
Tightening torque D+ maximum 2.7 to 3.8 Nm.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
Before removing the generator you must discon-
nect 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 run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When connecting e.g. the battery cable to the ter-
minal 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 el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
Fig. 2
●
Take out the roller-type plunger for the injection
pump (use outer circlip pliers) (Fig. 2).
Assembly
i Note
For installation of the injection pump the roller-type
plunger must be placed on the basic circle of the cam-
shaft drive cam.
Both the installation measurement "X" and the depth
"A" must also be measured.
Fig. 3
●
Move governor rod and throttle control lever to mid-
dle position and hold.
● Turn the governor rod adjustment bolt into the
crankcase until it bottoms (Fig. 3) and (Fig. 4).
i Note
Special tool 079 947 03.
Fig. 1
1 Roller-type plunger
2 Compensation gasket
3 Camshaft
Fig. 4
●
Release the throttle control lever.
Fig. 2
● Unscrew the plug from the crankcase (Fig. 2).
Fig. 5
●
Crank the engine by the crankshaft pulley, until the
plunger stroke of the corresponding cylinder
reached BDC (Fig. 5).
Fig. 6 Fig. 8
●
Assemble the roller-type plunger (Fig. 6).
Caution
!
i Note
The nominal measurement "X" on the injection pump
can be enquired from the BOMAG Service Depart-
ment or the Deutz Customer Service by submitting the
data on the engine type plate. (There are various ver-
sions and adjustment measurements).
●
Calculate the difference between installation meas-
urement "X" and depth "A".
Example:
"X"= 60.00 mm
"A"=59.35 mm
Fig. 7
● Measure the depth "A" from crankcase contact sur- Difference = 0.65 mm
face to spring cup rest on the plunger. (Fig. 7)
Fig. 9
● Choose the compensation gasket from the table ac-
cording to the identification (Fig. 9).
Fig. 12
● Remove the locking pin 1 (Fig. 12) from the injection
pump.
Fig. 10
i Note
Since the compensation gasket is not marked with
part-no. and thickness of gasket, the thickness of the
gasket can be checked with the special tool 103 020 Fig. 13
(Fig. 10). ● Insert the locking wire (Fig. 13).
i Note
Special tool 100 880.
!Caution
Before assembling the injection pump make sure
that the locking wire has engaged in the control le-
ver.
Fig. 11
● Attach the selected gasket (Fig. 11).
i Note
Mind the installation position.
Fig. 14 Fig. 17
●
Assemble the injection pump. Press the injection ●
Remove the governor rod adjustment bolt (Fig. 17).
pump centrally in until it bottoms.
●
Tighten the nuts (Fig. 14).
Tightening torque: 21 Nm
Fig. 18
● Fit the plug with a new copper sealing ring (Fig. 18).
Tightening torque: 18 Nm
Fig. 15
●
Pull the locking wire back out (Fig. 15).
Fig. 19
● Connect the fuel line with new copper sealing rings..
Fig. 16 ● Tighten the banjo fittings (Fig. 19).
● Close the bore with the locking pin (Fig. 16).
Tightening torque: 29 ± 2 Nm
Fig. 22
Fig. 20
●
Connect the rubber hose to the overflow line and
fasten with a hose clamp (Fig. 22).
● Install and tighten the injection lines (Fig. 20).
i Note
i Note
Use clamping pliers 8011.
Use a claw spanner 8018.
Fig. 23
●
Connect the rubber hose to the fuel line and fasten
Fig. 21 with a hose clamp (Fig. 23).
● Connect the rubber hose to the fuel line and fasten
with a hose clamp (Fig. 21).
i Note
●
Pull the protective hose over the rubber hose. Use clamping pliers 8011.
● Run the engine and check for leaks.
i Note
Use clamping pliers 8011.
i Note
Injection valves may wear mechanically over the
course of time. Spray pattern and injection pressure
should be tested on an injection valve test bench ("hy-
drostesting"). The nozzles must be disassembled for
this purpose. In case of excessive deposits on the
nozzles these may be cleaned in an ultrasonic bath
with gasoline. The injection pressure can be corrected
by means of shims.
!Caution
Ensure strict cleanliness when working on the in- Fig. 1
jection system. Use only clean testing oil acc. to ● Slide the seal ring with some grease over the injec-
ISO 4113 or clean diesel fuel to test the injection tion valve (Fig. 1).
valves.
Removal
Fig. 2
●
Insert the injection valves (Fig. 2).
Fig. 1
i Note
●
Disassemble the injection lines. The leak fuel connection must face towards the ex-
haust side.
i Note
Use claw-type spanner 8018 for the injection lines.
Close connections on injection pumps and injection
valves.
● Remove the clamping claws (Fig. 1).
● Disassemble the injection valves.
Fig. 3
● Attach the clamping claws (Fig. 3).
!Caution
Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
Fig. 4
●
Tighten the screws (Fig. 4).
Tightening torque: 21 Nm
● Install and tighten the injection lines.
i Note
Use a claw spanner 8018.
Fig. 5
● Mount the injection valve to the nozzle tester (Fig.
5).
Fig. 1
Danger
!
Fig. 3
!Caution
Nozzle needle and nozzle body have been fitted
by lapping and must never be mixed up by mis-
take or replaced individually. Do not touch the
nozzle needle with your fingers. With the nozzle
body in vertical position, the nozzle needle must
smoothly slide on its seat just by its own weight
(Fig. 3).
Fig. 1
● Unscrew the spigot nut and remove all parts (Fig. i Note
1). If the needle slides down jerkily, wash out the nozzle
body with diesel fuel again, replace if necessary.
Clean the new injection nozzle also in clean diesel fu-
el.
Fig. 2
Sequence of disassembly (Fig. 2):
1 Spigot nut
2 Injection nozzle
Fig. 4
3 Intermediate piece
● Check the seat areas of the intermediate piece for
4 Pressure bolt
signs of wear. Make sure that the centring pins are
5 Pressure spring present (Fig. 4).
6 Shim
● Clean all parts with clean diesel fuel and blow off
with compressed air.
Fig. 5 Fig. 8
●
Assemble the shim (Fig. 5). ●
Insert the centring pins of the intermediate piece
into the bores of the nozzle holder (Fig. 8).
i Note
A thicker shim increases the opening pressure. i Note
The chamfer points towards the pressure bolt.
Fig. 6
Fig. 9
●
Assemble the pressure spring. ● Attach the centring bores of the injection nozzle to
the centring pins of the intermediate piece (Fig. 9).
i Note
The nozzle needle must not drop out of the nozzle
body.
Fig. 7
● Install the pressure bolt with the centring collar to-
wards the pressure spring (Fig. 7).
Fig. 10
●
Turn on the spigot nut . Fig. 1
● Dry nozzle and nozzle holder - blow dry with com-
pressed air.
● Press the hand klever of the tester slowly down, to
a point about 20 bar before the previously indicated
opening pressure (Fig. 1).
Fig. 11
● Tighten the spigot nut.
Tightening torque: 45 ± 5 Nm
Fig. 2
i Note
The nozzle is leak tight, if no drop drips off within a pe-
riod of 10 seconds.
! Caution
If a drop drips off (Fig. 2), the injection valve must
be dismantled and the leak must be eliminated by
thorough cleaning. If this does not lead to a suc-
cess, replace the injection nozzle.
Rework is not permitted!
Fig. 1
●
Switch off the pressure gauge on the tester.
i Note
The rattle test enables audible testing of the nozzle
needle movement inside the nozzle body. In compar-
ison with used injection valves, new ones have a dif-
ferent rattling behaviour. It becomes worse as the
wear in the needle seat area progresses.
!Caution
A used injection valve must audibly rattle and
spray off well atomized fuel when operating the le-
ver quickly. The spray pattern may be noticeably
different from the one produced by a new injection
valve.
If an injection nozzle does not rattle despite of
cleaning, it nees to be replaced by a new one!
General ● Open the drain valve and drain off approx. 0.5 l of
The quality of the fuel filter and the compliance with fuel. The fuel above the filter element presses
the specified service intervals are decisive for the life- through the filter element and frees the underside
time of the fuel injection system. The heart of the fuel from dirt.
filter is made of hydrophobic special paper, which is ● Close the drain valve again.
spirally wound in form of a bag in order to offer the
largest possible filtering area under the prevailing spa- Perform
tial conditions and thus to achieve a high lifetime in
combination with a high dirt retaining capacity. A power drop or poor starting of the engine is mainly
caused by leaks in the fuel system. If you suspect a fil-
The fuel pre-filter / water separator mainly consists of:
ter problem, you should check whether bleeding
●
the dirt / water collecting bowl screw and drain valve are tightly closed and the filter
element is flush with the sight glass. Check the filter
● and the filter element
connections for leaks and the lines for clogging or po-
rous points.
Function
The fuel lift pump draws the fuel through this filter.
Any water contained in the fuel deposits on the dirt
side of the filter paper and separates from the fuel in
form of large drops on the clean side of the filter (coa-
lescence effect).
Water is heavier than diesel fuel, it settles as a differ-
ent colour fluid on the bottom.
Once the water level reaches the height of the warn-
ing connections (sensor B124), the warning lamp
(H70) in the monitoring board (A15) will come on.
Fig. 3
Compression:
FL/M 25 - 30 bar
BFL/M 22 - 27 bar
Fig. 1
●
Install the adapter with special seal (Fig. 1). i Note
●
Attach the clamping claw. The measured compression (Fig. 3) depends on the
starter speed during the measuring process and the
●
Tighten the screw. altitude of the engine location. Limit values can there-
fore not be specified exactly. It is recommended to
use the compression measurement to compare the
cylinders of an engine among each other. Should a
deviation of more than 15% be measured, the affected
cylinders should be dismantled to examine the cause.
● Disconnect the compression tester.
● Install the injection valves.
Fig. 2
● Connect the compression tester (Fig. 2).
●
Crank the engine with the starter.
i Note
In order to avoid soot emissions on turbo charged en-
gines when suddenly changing from low to full load,
the governor is equipped with a charge pressure de-
pendent full load stop. This device will only allow a fuel
Fig. 2
With the boost fuel suppression switch S182 (Fig. 2)
the boost fuel quantity can be switched over to sum-
mer or winter operation.
Fig. 1
1 Engine shut-down solenoid
General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the module (A68) in case of too low oil pres-
sure (terminal 8).
Fig. 1
1 Differential pressure switch
!Caution General
Combustion air lines between filter and engine The air filter retains the dust contained in the intake air
("clean air lines") must be absolutely leak tight and keeps it away from the engine in order to avoid
and withstand mechanical loads caused by en- engine wear.
gine vibrations and pressure pulsation. On paved roads the dust content in the air is 1 mg/m3
on average, on sealed roads or construction sites the
dust content can rise up to 40 mg/m3.
Dry air filters with integrated dust separator are char-
acterized by a good filtering effect (irrespective of en-
gine speed and inclination) and thus enable long
lasting and low wear engine operation.
The air filter has the additional function of damping the
air intake noise. This damping is achieved by the de-
sign of the air filter in from of a reflection silencer
Crankcase ventilation
During the combustion process in a diesel engine cer-
tain waste gas quantities escape through the ring
gaps on pistons and piston rings into the crankcase.
The crankcase ventilation serves the discharge of
these waste gases.
The engines are by standard and currently only
equipped with open crankcase ventilation. A crank-
case ventilation valve with oil separator separates
most of the oil from the waste gas and returns it into
the engine. The waste gas itself escapes into the at-
mosphere.
Fig. 4
● Switch on the ignition.
● Turn the rotary switch (Fig. 4) to position "MAX".
Fig. 3 Fuses
12.21Engine monitoring
10 sec. 2 min.
a H49, control light en- red, flashing X X Switch off vibration, run
gine overheating engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
b H09, engine oil pres- red, flashing X X Check the engine oil lev-
sure control light el, if necessary repair the
engine.
c H15, engine air filter yellow, lights If necessary clean or re-
control light place engine air filter
d H08, charge control yellow, lights Check V-belt, if neces-
light sary repair the generator
i H70, control light, yellow, lights Check, clean the water
water in diesel filter separator
k H52, pre-heating yellow, lights
control light yellow, flashes see chapter "Check heat-
in case of fault ing flange control"
j Coolant provision not used
10 sec. 2 min.
i H49, control light en- red, flashing X X Switch off vibration, run
gine overheating engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
e H09, engine oil pres- red, flashing X X Check the engine oil lev-
sure control light el, if necessary repair the
engine.
h H15, engine air filter yellow, lights If necessary clean or re-
control light place engine air filter
g H08, charge control yellow, lights Check V-belt, if neces-
light sary repair the generator
b H70, control light, wa- yellow, lights Check, clean the water
ter in diesel filter separator
c H52, pre-heating con- yellow, lights
trol light yellow, flash- see chapter "Check heat-
es in case of ing flange control"
fault
f Coolant provision not used
12.22Engine
The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Injection valve defective Have examined by a specialist
Engine oil level too low Top up engine oil to the upper dipstick
mark
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective
! Danger
Danger of scalding!
Danger of scalding when draining off hot engine
oil!
i Note
Drain the oil only when the engine is warm.
!Caution Fig. 9
Before longer work periods you should always top ● Unscrew the drain plug (Fig. 9), catch running out
the oil up to the "MAX"-mark. oil.
● Screw the plugs back in.
Danger
!
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the filter cartridge.
Caution
!
Fig. 11
●
After a short test run check the oil level on the dip- Fig. 12
stick (Fig. 11). The oil level should reach the MAX- ● Loosen and unscrew the fuel filter cartridge (Fig.
mark, top up oil if necessary. 12) using an appropriate filter wrench.
● Wipe the sealing face clean.
● Cover the rubber seal of the new filter cartridge
slightly with clean oil.
● Spin the new fuel filter cartridge on and tighten it
hand tight.
● Perform a short test run and inspect the engine for
leaks and check the oil level, top up oil if necessary.
i Note i Note
Dirty operating conditions, particularly lubrication oil The service intervals for the water separator depend
and fuel deposits on the cooling fins reduce the cool- on the water content in the fuel and can therefore not
ing effect. You should therefore immediately seal any be determined precisely. After taking the engine into
oil or fuel leaks near cooling fan, cylinder or oil cooler operation you should therefore check the filter bowl in-
and subsequently clean the cooling fins. itially every day for signs of water.
Danger
! Environment
Danger of injury! Catch running out fuel and dispose of environ-
mentally.
Perform cleaning work only with engine stopped
and cooled down!
Fig. 14
Fig. 13
● Slacken the drain plug (Fig. 14) for a few turns and
catch running out fuel / water.
● Remove dried on dirt from the cooling fins with a
suitable brush. ● Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.
●
Blow coolers (Fig. 13) out with compressed air. Re-
move all dirt that has been blown into the engine ● Open the fuel shut-off valve .
compartment.
●
In case of oily dirt spray the cooler with a cold
cleansing agent and let it soak in for about 10 min-
utes.
Environment
Catch running off fluid and dispose of environ-
mentally.
● Clean off with water or steam jet.
● Repeat the process if necessary.
Danger
!
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.
Fig. 17
●
Unscrew the water separator from the filter car-
tridge.
Fig. 15
● Close the fuel shut-off valve (Fig. 15).
Fig. 18
● Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 18).
●
Screw the water separator on by hand (2), until the
seal contacts.
●
Tighten the water separator for another half turn (3).
●
Fill the filter cartridge with clean diesel fuel (4).
●
Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
Fig. 16
● Tighten the filter element for another half turn (6).
●
Unscrew the fuel filter cartridge (Fig. 16) using an ●
Check the filter cartridge for leaks after a short test
appropriate filter wrench. run.
● Clean the sealing face on the filter carrier from any
dirt.
12.29Change the fuel filter cartridge 12.30Check, adjust the valve clear-
ance
! Danger
When working on the fuel system do not use open Before checking the valve clearance let the engine
fire, do not smoke and do not spill any fuel. cool down for at least 30 minutes. The engine oil
temperature must be less than 80 °C.
Catch running out fuel, do not let it seep into the
ground. Valve clearance
Do not inhale any fuel fumes. Intake valve = 0,3 mm
Exhaust valve = 0,5 mm
● Open the engine hood completely and support it
safely.
Fig. 19
●
Unscrew the fuel filter cartridge (Fig. 19) using an
appropriate filter wrench.
●
Clean the sealing face on the filter carrier from any Fig. 20
dirt. ●
Remove the valve cover (Fig. 20).
●
Cover the rubber seal on the new filter cartridge
slightly with oil and fill in clean fuel.
●
Turn the new fuel filter cartridge on by hand, until
the seal contacts.
● Tighten the fuel filter cartridge for another half turn.
●
After the test drive check the filter cartridge for
leaks.
i Note
Bleeding of the fuel system is not necessary.
Fig. 21
● Unscrew the fastening screw from the plug of the
shut-down solenoid (Fig. 21) and pull off the plug.
Fig. 22
● Crank the engine with the starter until both valves
Fig. 24
on cylinder 1 (Fig. 22) are “overlapping”.
● Loosen the counter 2 (Fig. 24) and regulate the set-
screw (1), until the feeler gauge can be inserted and
i Note
pulled out with little resistance after retightening the
Overlapping means that the exhaust valve is not yet counter nut.
completely closed and the intake valve starts to open.
The valves marked black (Fig. 22) can be checked Caution
!
and adjusted.
After a short test run check the engine for leaks.
Fig. 23
● Crank the engine with the starter until both valves
on cylinder 4 (Fig. 23) are “overlapping” (360° rota-
tion of the crankshaft).
The valves marked black (Fig. 23) can be checked
and adjusted.
● Assemble the cylinder head cover with a new gas-
ket.
! Caution
Perform cleaning, maintenance and repair work
only with the engine shut down. Do not start the
engine after removing the filter element.
Do not use gasoline or hot fluids to clean the filter
element.
After cleaning the filter element must be inspected
for damage using a torch.
Fig. 25 Old design
Air filter elements with damaged paper bellows or
seal lips must be replaced in any case.
The main filter element must be replaced after 3
times cleaning, but at the latest after one year, ir-
respective of the operating hours.
Each cleaning interval must be marked with a
cross on the cover of the filter element.
Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit. Use a new
filter element.
Incorrectly handled filter elements may become
ineffective because of damage (e.g.: cracks) and
cause engine damage.
Fig. 26 New version
Maintenance of the dry air filter is due when control
light c (Fig. 25) h (Fig. 26) in the left hand instrument
cluster lights permanently when the engine is running,
but at the latest after one year.
i Note
Once the air filter service indicator lights up, work may
be continued until the end of the day.
● Open the left hand maintenance door.
Fig. 27
●
Fold three clips up and take the filter hood (Fig. 27)
off.
●
Clean filter hood and dust discharge valve.
Fig. 28 Fig. 30
● Carefully loosen the main filter element. ● Clean the sealing face on the outlet tube (Fig. 30).
The main filter element is located directly on the air in- Dust on the outer diameter of the outlet tube can im-
take tube, thereby providing a seal on the inside of the pair effective sealing.
filter cover. Carefully remove the main filter element, ● Check the old main filter element.
in order to reduce the released amount of dust. To re-
lease the seal pull the main filter element carefully up, The old main filter element can be of help to discover
down and sideways or turn it (Fig. 28) . foreign particles on the sealing face, which could lead
to leaks. A line of dust on the clean air side of the filter
may be a sign for such a leak. Eliminate this problem
before installing a new main filter element.
● If the main filter element is damaged, the safety el-
ement must be replaced as well.
! Caution
The safety element must not be cleaned. It must
be replaced after three times cleaning of the main
filter element, but at least once every year.
Do not run the engine without an intact safety and
main filter element.
Fig. 29
●
Clean or replace the main filter element.
Caution
! i Note
Avoid contact between main filter element and We generally recommend to change the filter. A new
housing. filter element is far less expensive than a possible en-
gine damage.
● Pull the main filter element (Fig. 29) carefully out of
the housing. ● Examine the main filter element thoroughly for dam-
age.
Before installing the new main filter element check it
for possible damage from transport, cleaning or incor-
rect handling. Especially on the inside of the open end
(sealing area). Do not install damaged filter elements.
● If necessary use safety elements.
! Caution
Do not continue to use a damaged main filter ele-
ment. If in doubt use a new main filter element.
Fig. 31
● Insert the main filter element (Fig. 31).
The radial sealing area is located at the inside of the
open filter edge. This critical sealing area must be un-
der slight tension after the filter has been installed. In
order to achieve a tight seal apply pressure to the out-
er edge of the filter and not to the moveable centre.
● Reinstall the filter hood with the dust discharge
valve.
Caution
!
Danger
!
Eye injury!
Wear protective clothing (goggles, gloves).
Fig. 32
i Note
For cleaning purposes fit a tube to the compressed air
gun (Fig. 32), the end of which should be bent for ap-
prox. 90°.
The length should reach down to the bottom of the el-
ement.
Kompressionsdruckprüfer 8005
057 250 67
Compression tester
Compressiomètre
Compresímetro
Düsenprüfgerät 8008
Nozzle tester
Klemmenzange 8011
Clip pliers
Klauenschlüssel 8018
Claw key
Clé à griffes
Llave de garra
8024 Ventilschaftdichtungszange
8036 Stecknuss SW 32
Socket a/flats 32
Clé à douille de 32
Llave de vaso de 32
9088 Schlauchklemmenzange
9090 Federklemmenzange
Pince à ressorts
057 250 83
057 250 90
©
Extracteur de tube
079 947 28
©
6067 Motormontagebock
Aufspannhalter 6067/115
Support d’ablocage
Soporte de fijación
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.
Fig. 1
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 re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.
Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F 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 pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.
Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
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, 13.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
Compressor
Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
! Caution
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).
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.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
i Note
Topping up compressor oil / refrigeration oil is possi-
ble 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 refrigeration system dur-
ing the evacuation process.
Fig. 2
! Danger
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
Fig. 1 Fig. 1
The evaporator is mounted inside the HKL-module in The feeler of a defroster thermostat to switch off the
the cabin. It consists of a heat exchanger (inside air - magnetic clutch in case of icing up or to switch the
refrigerant), with refrigerant flowing to a pipe system clutch back on after defrosting, is mounted on the
with cooling flanges. evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
As with the condenser, correct operation of all fans
should be checked during maintenance.
and cleanliness of the fins must be assured.
Switching point on: + 1°C (+/- 1°C)
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator, Switching point off: + 5.5°C (+/- 1°C)
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. i Note
A condensation water filter is mounted in the air flow It is very important that the feeler is mounted down-
after the evaporator. This filter has the function to col- stream of the evaporator, but before the pressure sen-
lect the water that has condensed from the air in the sor, in countercurrent direction, with full length and
evaporator block and to discharge this water into the insulated against the outside temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
!Caution
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 / re-
frigeration oil PAG SP-20 (H14-003-404).
● Run the compressor for 10 minutes at engine idle
speed.
● In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi- Fig. 2
tioning system. ● Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.
i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
● Insert the oil dipstick.
● Pull out the dipstick and count the notches covered
by oil.
● Drain off oil or fill up as specified in the table.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
Fastening angle (de- Oil dipstick in incre-
● Measure the fastening angle (Fig. 1) of the com- gree) ments
pressor (oil plug at top) 0 5-7
●
Remove the oil filler plug. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
●
Screw the oil filler plug back in.
! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
● Refill the air conditioning system.
Fig. 1
i Note
Nominal value approx. 3.5 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.
●
Check the electric control panel. If discolorations on
● Inspect the entire circumference of the V-belt (Fig.
conductors are found, these should be replaced 4) visually for damage and cracks. Replace dam-
and possibly also the corresponding relays. aged or cracked V-belts.
●
Switch on the cooling system and check the refrig-
● Check with thumb pressure whether the V-belt can
erant level. be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
●
Filter/dryer and filter/dryer/fluid container combina- essary.
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
Tighten the V-belt.
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
● Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
●
Measuring the pressure in the refrigerant circuit
Fig. 5
● Slightly slacken fastening screws 1, 2 and 3 (Fig. 5).
● Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
● Retighten all fastening screws.
!Caution
Under very dusty conditions clean every day in or-
der to maintain the cooling power of the air condi-
tioning system.
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
Fig. 6 age or explosion of the system.
● Slightly slacken the fastening screws 1, 2 and 3
(Fig. 6). Cleaning the condenser
● Press the compressor against the direction of arrow
completely against the engine.
● Take the old V-belt off.
● Fit the new V-belt to the V-belt pulleys.
● Tension the V-belt as previously described.
● Fasten the fan again.
! Caution
Check the V-belt tension after a running time of 30
minutes.
Fig. 7
● Unscrew the condenser fastening screws and fold
the condenser forward.
●
Clean the condenser fins on front and back with
compressed air or cold water (Fig. 7).
!Caution
During cleaning work do not damage the cooling
fins and realign bent fins.
1 Optional equipment
Fig. 8 Fig. 10
● Switch the air conditioning (Fig. 8) on. ● Check whether the white float (Fig. 10) inside the in-
spection glass of the drier/collector unit floats right
at the top.
i Note
The refrigerant level is correct.
Fig. 9
● Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 9) in the blue section.
●
Open the air outlet nozzles.
●
Check, whether the out flowing air is noticeably
cooler. Fig. 11
●
If the white float (Fig. 11) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
i Note
the service department.
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on. i Note
● Open the right hand service door. The refrigerant level is not correct.
● Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.
Fig. 13
● Check the drier/collector unit (Fig. 13) for mechani-
cal damage or rust.
Fig. 12
● Check the moisture indication pearl (Fig. 12) inside
the inspection glass of the drier/collector unit.
blue = drying agent o.k.
purple = moisture level of drying agent too high.
● Inform the service department. Replace drier/col-
lector unit, check air conditioning system.
Caution
!
!Caution
According to the regulation for pressure reser-
voirs 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 this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.
! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.
! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
13.15Filling instructions
! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
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 filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.
i Note
White frost on the suction line is no measure for as-
sessing the filling.
19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
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.
13 Then connect the hose to the refrigerant bottle.
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.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
● Expert knowledge
● technical equipment
Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
●
Service station
Filling the system with refrigerant causes an excess
●
Pressure gauge pressure of Pe = 3 bar.
●
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
●
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
●
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
●
Container for old oil
●
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
●
Hoses
● Scales
● Suction station
● Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.
Pressure gauge
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 pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
Pressure gauge with saturation temperature scale 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 lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
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 over-
heating. Overheating also improves the oil recircula-
tion.
Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause
Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"
13.18Trouble shooting procedure ● Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
● The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
● Ambient temperature above 15 °C.
about the system design, the installed components ● The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:
Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
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.
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.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.
i Note
The dangerous part of common rules is that they ap-
ply 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.
Test prerequisites
● Cooler and condenser are clean, clean if neces-
sary.
● The ribbed belt for compressor and generator is
correctly tightened.
● All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
● The engine has operating temperature.
Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
● C, condenser measuring points tainer the inspection glass is most suitable to check
● E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
● O, evaporator measuring points
The hot gas temperature can be used to check wheth-
● V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
● a) Which measuring equipment is required ?
can be used to derive the overheating of the evapora- ● b) Where to measure with which size ?
tor. Overheating is a clear indicator for the evaporator ● c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is ●
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- ● e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „Δto2h“ ?
Pressure and temperature at the condenser outlet can ●
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used
Solution:
●
a) Pressure gauge, thermometer, steam table
●
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
● c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
● d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
● e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
● f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Other faults
Noise in system
Monitoring devices
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
Fig. 1
2. Suction lifter
commercial
Fig. 2
Commercial
Fig. 1
4. Window glass bonding agent
Fig. 2
5. Activator
Fig. 3
Fig. 4
! Danger
Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).
Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.
Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).
Fig. 3
i Note
Do not overtighten the thread.
Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).
i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.
Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.
Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 7
Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).
i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.
Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).
Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).
Fig. 11
Fig. 12
20. Treat the inside joint (Fig. 13)
Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.
i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 14
Fig. 1
Fig. 2
Fig. 3
! Danger
Fire hazard!
Follow the safety regulations and general re-
pair instructions!
1. Clean engine and engine compartment.
! Caution
Keep hydraulic hoses, fuel hoses and wiring
looms away from welding points, or tie them
up.
i Note
(Fig. 1) shows engine compartment left
(Fig. 2) shows engine compartment right.
If necessary pull the plugs of the solenoid valves
for brake and vibration.
Fig. 1
2. Cover combustible parts.
Fig. 2
3. Remove paint at fasten the earth strap (Fig. 3).
Fig. 3
i Note
The length of the crack may be different on inside
and outside.
Fig. 4
5. Grind the crack out completely ad weld it.
6. Grind the welding points (Fig. 5) metallic blank.
! Caution
The bore must not be closed by welding, it
should protect against a possible continua-
tion of the crack.
Fig. 5
7. Grind the gusset (Fig. 6) approx. 45°.
i Note
(Fig. 6) shows gusset on left hand side of frame.
Grind the gusset on the right hand side of the
frame from the opposite side.
Fig. 6
8. Attach the gusset (Fig. 7).
Fig. 7
Fig. 8
The gusset must be continuously welded in
this area 1 (Fig. 9) (therefore the 45° chamfer).
9. Weld the gusset to the frame.
i Note
Lay the welding seam all the way around.
(Fig. 10) shows the finished welding seam on the
left hand side of the frame.
(Fig. 11) shows the finished welding seam on the
right hand side of the frame.
Fig. 9
! Caution
After welding this area (Fig. 10) must be
ground, it must be free of notches. Here the
frame crack developed.
Fig. 10
10. Clean, prime and paint the welding seams.
i Note
Round off the gussets and the welding seams to
avoid any chafing points for wiring looms and
hoses.
11. Reroute hydraulic lines and wiring looms correct-
ly.
Fig. 11
Fig. 1
2. Unplug the wiring loom (Fig. 2).
Fig. 2
3. Unscrew all fastening screws and lift off the driv-
er's seat (Fig. 3).
Fig. 3
Fig. 4
5. Unscrew the hexagon screws on both sides (Fig.
5).
Fig. 5
Fig. 6
i Note
Note on assembly:
Assemble the holding angle so that the travel
control cable is flush with the hexagon nut (Fig.
7).
Fig. 7
7. Carefully fold the seat carrier forward (Fig. 8).
Fig. 8
8. Detach the travel control cable from the bottom of
the seat carrier (Fig. 9).
Fig. 9
9. Unhook the travel control cable from the counter-
bracket (Fig. 10).
i Note
Notes on assembly:
Engage the parking brake (travel lever "0"-posi-
tion), then adjust the travel control cable on the
counter-bracket so, that the screw on the travel
pump lever (Fig. 11) can be installed without ten-
sion.
The travel pump control lever is automatically in
neutral position.
Fig. 10 Adjust the travel cable accurately on the clevis.
Fig. 11
11. Remove hexagon nuts and washers 1 (Fig. 12).
Fig. 12
i Note
Tightening torque 150 Nm (Fig. 13).
Fig. 13
Machine with ROPS
12. Attach lifting gear to ROPS and operator's stand
(Fig. 14).
Fig. 14
Fig. 15
14. Slightly lift cab with operator's stand (Fig. 14) or
ROPS with operator's stand (Fig. 15).
! Caution
Only lift as much as required to remove the
travel control cable.
Mind wiring looms and hoses (Fig. 16) and
(Fig. 17).
Fig. 16
!Danger
Danger of accident!
Do not stand or step under loads being lifted.
Secure the operator's stand with square tim-
ber beams.
Fig. 17
15. Cut the cable straps under the operator's stand
(Fig. 18).
16. Remove the travel control cable.
i Note
Reassemble in reverse order.
Fig. 18
Fig. 1
2. Guide bolts M16 x 270
Fig. 2
3. Guide bolts M12 x 270
Fig. 3
4. Screw bolt for vibrator unit lifting device
Fig. 4
Fig. 5
Fig. 2
i Note
The procedures for the removal of front and rear
drums are identical. The following instructions de-
scribe the removal of the front drum, however, the
work steps apply also for the removal of the rear
drum.
1. Jack the appropriate side of the machine up (Fig.
1), until the rubber buffers on the drive disc are re-
lieved.
! Danger
Danger of accident!
Block front and rear drums with wedges
against rolling!
Do not work in the articulation area of the roll-
er while the engine is running.
Fig. 1
2. Disconnect the main battery switch (Fig. 2).
! Caution
Do not start the engine during repair work!
Fig. 2
3. Unscrew the guard 1 (Fig. 3) and remove the
hose clamps (2).
Fig. 3
Fig. 4
i Note
(Fig. 5) shows the machine without AM.
(Fig. 6) shows the machine with AM.
6. Mark the hydraulic hoses and disconnect these
from vibration motor and travel motor (Fig. 5) or
(Fig. 6).
Environment
Catch running out hydraulic oil and dispose
of environmentally.
7. Close hydraulic connections and hydraulic hoses
Fig. 5 with dummy plugs
8. Pull the hydraulic hoses up and out of the support
leg and lay them down in the frame.
Fig. 6
i Note
(Fig. 7) shows the machine without AM.
(Fig. 8) shows the machine with AM.
9. Mark the hydraulic hoses and disconnect these
from the travel motor (Fig. 7) or (Fig. 8).
Environment
Catch running out hydraulic oil and dispose
of environmentally.
10. Pull the hydraulic hoses up and out of the support
leg and lay them down in the frame.
Fig. 7
11. Mark the hydraulic hoses and disconnect these
from the swivel motor (Fig. 8), only on AM ma-
chines.
12. Close hydraulic connections and hydraulic hoses
with dummy plugs
13. Pull the hydraulic hoses up and out of the support
leg and lay them down in the frame.
Fig. 8
14. Remove the head lights 1 (Fig. 9).
Fig. 9
15. Pull plug 1 (Fig. 10) off the head lights.
16. Pull the wiring harness through bore (2) out of the
cross member.
Fig. 10
Fig. 11
18. Attach the lifting tackle (Fig. 12) to the support
leg.
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
19. Unscrew the fastening screws (1).
20. Unscrew the fastening screws (2) for the cross
member.
Fig. 12
21. Separate the support leg with fastening angles
(Fig. 13) from the frame and lay it to the side.
Fig. 13
22. Attach the lifting tackle to the cross-member 1
(Fig. 14).
Fig. 14
! Danger
Danger of squashing!
Do not stand or step under loads being lifted.
Fig. 15
24. Lift off cross member 1 (Fig. 16).
Fig. 16
25. Fasten the lifting gear to the support leg and un-
screw fastening screws 1 (Fig. 17).
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
Fig. 17
26. Separate the support leg with fastening angles
(Fig. 18) from the frame and lay it to the side.
Fig. 18
! Danger
Danger of squashing!
Fig. 19
28. Secure the drum (Fig. 20) against unintended
rolling.
Fig. 20
i Note
Tighten the rubber buffers with 300 Nm.
Fig. 21
30. Place the drum (Fig. 22) parallel in the frame.
!Danger
Danger of squashing!
Fig. 22
31. Attach the lifting tackle to the support leg (Fig. 23)
and mount it to the rubber buffers of the drum.
!Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
Fig. 23
32. Attach the lifting tackle to the support leg (Fig. 24)
and mount it to the rubber buffers of the drum.
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
Fig. 24
i Note
The slots (4) in holding angle (1) are to be used
to adjust the pretension of the rubber buffers.
34. Pull support leg (2) fully out and retighten again
with the fastening screws.
35. Screw nuts and washers on the rubber buffers (3)
and tighten with 300 Nm.
Fig. 25 36. Adjust the support leg on the opposite side in the
same way.
! Caution
Pretension of rubber buffers!
Fasten the support legs (Fig. 26) under
preload to the frame.
The preload of the rubber buffers is achieved
by the gap (X) between support leg and frame
or cross-member when tightening.
Fig. 26
37. Retighten fastening screws 1 (Fig. 27).
Fig. 27
38. Retighten fastening screws 1 (Fig. 28).
Fig. 28
! Caution
The distance must be the same on both sides,
compensate if necessary.
41. Lower the machine to the ground.
Fig. 29
i Note
(Fig. 30) shows the machine without AM.
(Fig. 31) shows the machine with AM.
42. Feed the hydraulic lines (Fig. 30) or (Fig. 31) from
above through the support legs and connect as
required.
Fig. 30
Fig. 31
i Note
(Fig. 32) shows the machine without AM.
(Fig. 33) shows the machine with AM.
43. Feed the hydraulic lines (Fig. 32) or (Fig. 33) from
above through the support legs and connect as
required.
Fig. 32
Fig. 33
44. Insert cross member 1 (Fig. 34) into the frame.
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
Fig. 34
45. Turn screws 2 (Fig. 35) into the cross member
from both sides and tighten correctly.
46. Install head light (1) and connect the wiring har-
ness.
! Caution
Ensure correct routing of the wiring harness-
es. Avoid chafing.
Fig. 35
47. Install guard 1 (Fig. 36) and hose clamp (3) for the
hydraulic hoses.
48. Reconnect the water hose (2).
Fig. 36
Fig. 37
50. Check the hydraulic oil level (Fig. 38), top up if
necessary.
! Caution
Bleed the hydraulic system before starting
operation.
51. Perform a test drive, check function of travel sys-
tem, vibration and water sprinkling system.
52. Check all connections and fittings for leak tight-
ness.
Fig. 38
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
53. Move the drum, until the drain plug (Fig. 1) is in
bottom position.
54. Clean and unscrew drain and filler plugs.
55. Drain off and catch old oil.
Environment
Dispose of old oil environmentally.
Fig. 1
56. Unscrew both fastening nuts (Fig. 2).
57. Remove the vibration motor.
Fig. 2
58. Loosen clamping screws 2 (Fig. 3) and pull off
coupling hub (1).
Fig. 3
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
Fig. 4
61. Force the bearing cover off with two forcing
screws (Fig. 5).
Fig. 5
62. Lift the bearing cover off and lay it to the side (Fig.
6).
Fig. 6
63. Remove the intermediate shaft with the elastic
coupling element (Fig. 7).
Fig. 7
Fig. 8
65. Screw in two guide bolts (Fig. 9) and unscrew all
screws.
66. Force the flange off the drum using two forcing
screws (arrow).
Fig. 9
67. Attach the lifting tackle to the bearing flange and
lift it off the drum (Fig. 10).
!Danger
Danger of squashing!
Do not stand or work under suspended loads!
Fig. 10
68. Pull the travel bearing off with a puller (Fig. 11).
Fig. 11
Fig. 12
Fig. 13
71. Lift off the travel motor (Fig. 14).
Fig. 14
72. Attach the lifting tackle to the drive disc (Fig. 15).
!Danger
Danger of squashing!
Do not stand or work under suspended loads!
73. Unscrew the hexagon screws.
74. Lift the drive disc off and lay it to the side .
Fig. 15
75. Cover the travel gear opening (Fig. 16).
Fig. 16
Fig. 17
78. Attach the lifting tackle to the travel gear (Fig. 18)
and lift it off.
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
79. Turn the guide bolts back out.
Fig. 18
80. Unscrew the pipe elbow (Fig. 19).
81. Unscrew the magnetic plug.
Fig. 19
82. Unscrew the fastening screws (Fig. 20).
Fig. 20
83. Attach the lifting tackle to the exciter unit (Fig. 21).
84. Press the exciter unit out of the drum with three
forcing screws and lift it out.
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
Hold the exciter unit in horizontal position.
Take care that the exciter unit does not slip
out of the flange.
Fig. 21
85. Take the bearing flange off the exciter unit (Fig.
22).
Fig. 22
86. Remove circlip 1 (Fig. 23) and pull the cylinder
roller bearing (1) with a puller out of the travel
gear flange.
Fig. 23
Fig. 24
88. Remove the bearing housing with three forcing
screws (Fig. 25).
Fig. 25
89. Take off the bearing flange (Fig. 26).
Fig. 26
Fig. 27
91. Drive out the cylinder roller bearings with a suita-
ble mandrel (Fig. 28).
Fig. 28
i Note
Depending on the version of machine a differen-
tiation is made between:
Exciter unit with short shaft 1(Fig. 1).
Exciter unit with long shaft (2).
! Caution
In case of a repair the complete unit needs to
Fig. 1 be changed.
When dismantling several units, parts like
flanged covers, weights and housing must
not be mixed up by mistake
Each exciter unit is an individually manufac-
tured unit!!
Strict cleanliness is mandatory when per-
forming repair work.
Dismantling
1. Unscrew the fastening screws (Fig. 2) and take
off the oil paddle.
i Note
The illustration shows a small oil paddle, depend-
ing on the machine version these paddles are of
different sizes.
Fig. 2
2. Unclip the circlip (Fig. 3).
3. Extract the inner bearing race with a puller.
Fig. 3
i Note
Depending on the exciter unit design a differenti-
ation is made between:
Claw-type coupling without centring point (Fig. 4).
Claw-type coupling with centring point.
Shaft coupling (Fig. 5).
5. Unclip the circlip.
6. Extract the inner bearing race with a puller.
Fig. 4
Disassembling the shaft coupling
7. Loosen the clamping screws. (Fig. 5).
! Caution
Loosen the clamping screws evenly one after
the other. Each screw may only be loosened
for half a turn with each revolution. Back out
all clamping screws for 3 to 4 turns.
Non-observance of this sequence can ad-
versely affect the function of the coupling.
8. Take off the shaft coupling.
Fig. 5 9. Unclip the circlip.
10. Extract the inner bearing race with a puller.
11. Unscrew the fastening screws (Fig. 6) and take
off the flange.
i Note
Observe the roll pin.
Fig. 6
12. Take off the O-ring (Fig. 7).
Fig. 7
Environment
Catch old oil and dispose of environmentally.
Fig. 8
Assembly
1. Screw the transport eyelet into the change-over
weight (Fig. 9).
Fig. 9
2. Insert the change-over weight into the exciter
housing (Fig. 10).
Fig. 10
3. Rotate the change-over weight and check
smooth running (Fig. 11).
Fig. 11
4. Fill the exciter housing with approx. 1.2 litres of oil
Silicon 1000 cST (Fig. 12).
Fig. 12
Fig. 13
6. Attach the flange . Install the roll pin with LOC-
TITE 243 (Fig. 14).
Fig. 14
7. Wet the fastening screws with LOCTITE 542 and
tighten as specified (Fig. 15).
Fig. 15
Assembling the inner bearing race
8. Heat both inner bearing races up to approx. 80 °
and slide them on against the stop (Fig. 16).
! Danger
Danger of burning!
Wear protective gloves.
Fig. 16
Fig. 17
Assemble the claw-type coupling.
i Note
Depending on the exciter unit design a differenti-
ation is made between:
Claw-type coupling without centring point (Fig.
18).
Claw-type coupling with centring point (Fig. 19).
Shaft coupling (Fig. 20).
Fig. 18
10. Install the fastening screws with LOCTITE 2701
and tighten them (Fig. 19).
Fig. 19
Assembling the shaft coupling
11. Clean hub bore and shaft and apply a thin coat of
thin flowing oil (Fig. 20).
i Note
Suitable oil is e.g. Castrol 4 in 1 or Klüber Quitsch
EX).
12. Clean tapered areas of clamping ring hub and
clamping ring and apply a thin coat of thin flowing
oil.
Fig. 20
i Note
Intermediate tightening steps with 3 Nm and 5
Nm.
Fig. 21
! Caution
Repeat this process, until the tightening
torque is correct on all clamping screws. In
the intermediate stages this process must
also be repeated, until the respective tighten-
ing torque has been reached for all screws.
Assembling the oil paddle
18. Assemble the fastening screws (Fig. 22) with
Loctite 243.
Fig. 22
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
! Caution
Ensure strict cleanliness.
Fig. 1
20. Press the seal ring into the groove (Fig. 2).
Fig. 2
21. Mount the V-ring on the flange (Fig. 3).
Fig. 3
Fig. 4
23. Clean the bearing housing (Fig. 5).
Fig. 5
24. Press the grooved ball bearing in until it bottoms
(Fig. 6).
! Caution
Open bearing side up.
Fig. 6
25. Slide the bearing housing with grooved ball bear-
ing over the flange (Fig. 7).
Fig. 7
! Caution
Apply the pressing force via the grooved ball
bearing.
Fig. 8
27. Fill the grooved ball bearing with grease (Fig. 9).
Fig. 9
28. Fill the second grooved ball bearing with grease
(Fig. 10).
Fig. 10
29. Mount the ring on the flange (Fig. 11).
Fig. 11
! Caution
Open bearing side down.
Fig. 12
31. Press the second grooved ball bearing in until it
bottoms (Fig. 13).
Fig. 13
32. Install the new O-ring and apply a thin coat of oil
(Fig. 14).
Fig. 14
Fig. 15
34. Cool the vibration bearing down to -25 ° Celsius
and slide it into the flange (Fig. 16).
! Danger
Wear gloves.
Fig. 16
35. Press the bearing down to full contact (Fig. 17).
Fig. 17
Fig. 18
Fig. 19
38. Cool the vibration bearing down to -25 ° Celsius
and slide it into the flange (Fig. 20).
! Danger
Wear gloves.
Fig. 20
39. Press the bearing down to full contact (Fig. 21).
Fig. 21
Fig. 22
41. Assemble a new O-ring and apply a thin coat of
oil (Fig. 23).
42. Oil the cylinder roller bearing.
Fig. 23
43. Oil the bearing shell (Fig. 24).
Fig. 24
44. Slide the bearing flange onto the exciter unit (Fig.
25).
Fig. 25
Fig. 26
47. Assemble screw fitting, pipe elbow and magnetic
plug (Fig. 27).
Fig. 27
Fig. 28
50. Slide the bearing flange over the guide bolts (Fig.
29).
Fig. 29
51. Install the screws with LOCTITE 243 (Fig. 30).
52. Remove the guide bolts.
Fig. 30
53. Tighten the screws crosswise (Fig. 31).
Fig. 31
i Note
Install the dowel pin with LOCTITE 243 .
Fig. 32
56. Oil the bearing shell (Fig. 33).
Fig. 33
57. Attach the lifting tackle to the exciter unit (Fig. 34).
!Danger
Danger of squashing!
Do not stand or work under suspended loads!
Hold the exciter unit in horizontal position.
Take care that the exciter unit does not slip
out of the flange.
i Note
Observe the centring by the dowel pin.
Fig. 34
58. Install the fastening screws with LOCTITE 542
(Fig. 35).
Fig. 35
Fig. 36
Checking the end float
60. Turn the eye bolt into the bore in the exciter shaft
(Fig. 37).
61. Push the exciter shaft into the bearing housing
against the end stop.
62. Unscrew the screw.
Fig. 37
63. Measure the distance from the exciter shaft to the
front face of the bearing housing (Fig. 38).
Fig. 38
64. Turn the eye bolt into the bore in the exciter shaft
(Fig. 39).
65. Pull the exciter shaft out against the stop.
66. Unscrew the screw.
Fig. 39
i Note
Subtract the second measurement from the first
measurement to calculate the end float.
Nominal value:
min. + 0,5 mm
Fig. 40
68. Assemble the screw fitting and the magnetic plug
with seal ring. (Fig. 41).
Fig. 41
69. Assemble the pipe elbow with magnetic plug and
sealing ring (Fig. 42).
Fig. 42
70. Spray the inner tube in the drum with a corrosion
protection wax (Fig. 43).
Fig. 43
Fig. 44
72. Attach the lifting tackle to the travel gear and slide
it over the guide bolts (Fig. 45).
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
Fig. 45
73. Turn in the fastening screws with washers (Fig.
46).
74. Unscrew the guide bolts.
75. Tighten the screws crosswise.
Fig. 46
Mounting the bearing flange (travel motor
side)
76. Turn in two guide bolts (Fig. 47).
Fig. 47
!Danger
Danger of squashing!
Do not stand or work under suspended loads!
i Note
Check the rubber buffers, replace if necessary.
Fig. 48
78. Turn the guide bolts back out (Fig. 49).
79. Screw in all fastening screws and tighten them
crosswise.
80. Take off the travel gear cover (arrow).
Fig. 49
Installing the travel motor
81. Attach a new O-ring to the travel motor flange and
apply a thin coat of oil (Fig. 50).
Fig. 50
82. Install the travel motor (Fig. 51).
Fig. 51
Fig. 52
Assembling the bearing flange (vibration mo-
tor side)
84. Check the dowel pin, replace if necessary (Fig.
53).
i Note
Install the dowel pin with LOCTITE 243 .
Fig. 53
85. Screw in two guide bolts to assist the installation
of the travel bearing flange (Fig. 54).
86. Attach the lifting tackle to the travel bearing
flange and slide it over the guide bolts.
!Danger
Danger of squashing!
Do not stand or work under suspended loads!
Fig. 54
87. Assemble the screws with LOCTITE 542 and re-
move the bearing bolts (Fig. 55).
88. Tighten the screws crosswise.
Fig. 55
Fig. 56
90. Attach the bearing race and tighten the screws
crosswise (Fig. 57).
Fig. 57
Installing the intermediate shaft
91. Install the intermediate shaft with the elastic cou-
pling element (Fig. 58).
i Note
Check the elastic coupling element, replace if
necessary.
Fig. 58
Installing the bearing cover
92. Turn in two guide bolts (Fig. 59).
Fig. 59
Fig. 60
94. Attach the lifting tackle to the bearing cover and
slide it over the guide bolts (Fig. 61).
! Danger
Danger of squashing!
Do not stand or work under suspended loads!
i Note
Check the rubber buffers, replace if necessary.
Fig. 61
95. Turn in the fastening screws with washers (Fig.
62).
96. Remove the guide bolts.
Fig. 62
97. Tighten the fastening screws crosswise (Fig. 63).
Fig. 63
Fig. 64
102. Attach a new O-ring to the vibration motor flange
and apply a thin coat of oil (Fig. 65).
Fig. 65
103. Rotate the coupling hub to match the coupling el-
ements (Fig. 66).
Fig. 66
104. Install the vibration motor (Fig. 67).
105. Tighten the fastening nuts.
Fig. 67
Fig. 68
107. Change the oil in the drum drive gear. (Fig. 69).
Fig. 69
! Caution
Do not start the engine during repair work on
the articulated joint!
! Danger
Do not work in the articulation area of the roll-
er while the engine is running.
Fig. 1
109. Open the maintenance cover (Fig. 2) to gain ac-
cess to the water pump.
Fig. 2
110. Drain the water tank
111. Loosen hose connections 3 and 4 (Fig. 3) and
drain off all water.
112. Disconnect plugs (1 and 2) from water sprinkling
pumps, pressure switch and float switch.
Fig. 3
Fig. 4
114. Remove the left and right hand sraps 1 (Fig. 5).
115. Remove protective frame (2).
Fig. 5
Fig. 6
! Caution
Catch hydraulic oil and dispose of environ-
mentally!
Fig. 7
119. Mark connecting lines 1 and 2 (Fig. 8) for crab
walk cylinders and disconnect. Close the hydrau-
lic connections with plugs.
! Caution
Catch hydraulic oil and dispose of environ-
mentally!
Fig. 8
120. Mark connecting lines 1 and 2 (Fig. 9) for steering
cylinders and disconnect. Close the hydraulic
connections with plugs.
! Caution
Catch hydraulic oil and dispose of environ-
mentally!
121. Remove the holding plate (3).
122. Unscrew screws (5) and disassemble holder (6)
with proximity switch.
123. Disconnect plug (4) from the proximity switch..
Fig. 9
124. Mark and disconnect all hydraulic hoses (Fig. 10).
Close the hydraulic connections with plugs.
! Caution
Catch hydraulic oil and dispose of environ-
mentally!
Fig. 10
i Note
Plug
X1:71 - 74, X1:125-126, X1:127-131, X132-133,
X1:145-148, X1:185-186.
Fig. 12
128. Remove the battery (Fig. 13).
! Caution
When removing the battery disconnect the
minus pole first and the plus pole after.
Follow the rules for handling batteries (see
technical manual "Basic Electrics").
Fig. 13
129. Attach the lifting tackle to the rear frame (Fig. 14).
130. Support the front frame safely and block the front
wheel with wedges against rolling.
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
Fig. 14
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
134. Knock out bearing bolt (3).
135. Remove the steering cylinder (4).
Fig. 15
136. Unscrew the screws 1 (Fig. 16) from the crab
walk cylinder.
137. Remove the axle holder (2).
138. Attach the lifting tackle to the crab walk cylinder.
139. Knock out bearing bolt (3).
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
140. Remove the crab walk cylinder (4).
Fig. 16
141. Unscrew nut 1 (Fig. 17).
Fig. 17
142. Pull hexagon screw 1 (Fig. 18) down and out.
Fig. 18
i Note
The cover hides Belleville springs and shims.
Fig. 19
145. Unscrew the screws with washers 1 (Fig. 20)
from the bottom cover.
146. Remove the bottom cover.
Fig. 20
147. Use a tap (M24) 1 (Fig. 21) to cut a thread into top
and bottom joint bolts (2).
Fig. 21
148. Turn a screw (M24) 1 (Fig. 22) into the joint bolt
(2) in the front frame.
! Danger
Make sure that front and rear frames are prop-
erly secured against rolling and tipping over.
Danger of accident! Do not stand or step un-
der loads being loaded.
149. Pull the bottom joint bolt out of the console.
150. Pull the top joint bolt (2) out of the console.
Fig. 22
Fig. 23
153. On the rear frame unscrew the screws (Fig. 24)
from the top and bottom covers.
154. Remove the top cover.
i Note
The top cover hides Belleville springs and shims.
155. Remove the bottom cover.
Fig. 24
156. Use a tap (M24) 1 (Fig. 25) to cut a thread into top
and bottom joint bolts on the rear frame (2).
Fig. 25
157. Turn a screw (M24) 1 (Fig. 26) into the joint bolt
(2).
158. Pull the bottom joint bolt out of the console.
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
159. Pull the top joint bolt (2) out of the console.
Fig. 26
Fig. 27
161. Lay the cross member to the side (Fig. 28).
Fig. 28
162. Check the pivot bearings (Fig. 29) on console and
cross member, replace if necessary.
Fig. 29
163. Check the pivot bearings (Fig. 30) on the front
frame, replace if necessary.
Fig. 30
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
165. Unscrew the screws (1), remove both stops (2)
and lift off the cosole with the live ring connection
(3).
Fig. 31
166. Unscrew the screws 1 (Fig. 32) and separate the
live ring connection (2) from the console (3).
Fig. 32
167. Use forcing screws 1 (Fig. 33) to press the pivot
bearings (3) off the joint bolts.
Fig. 33
! Caution
Do not use any grease.
Attach the inner bearing race in straight posi-
tion.
2. Assemble backing disc (2).
3. Press the inner bearing race (1) over the joint bolt
(3).
Fig. 1
4. Assemble live ring 2 (Fig. 2) and console (3) with
screws (1) and washers.
5. Tighten the fastening screws cross-wise.
Fig. 2
6. Attach the lifting tackle to the console with live
ring (Fig. 3) and position the assembly on the rear
frame.
Fig. 3
i Note
Mind the correct position of the grease nipples.
8. Tighten the fastening screws cross-wise.
Fig. 4
9. Change the seal ring in the upper area of the front
frame (Fig. 5).
Fig. 5
10. Change the seal ring in the lower area of the front
frame (Fig. 6).
Fig. 6
11. Clean the receiving bores for the joint bolts (Fig.
7).
Fig. 7
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
Fig. 8
13. Insert the cross member (Fig. 9) into the front
frame.
Fig. 9
14. Spray the mating surfaces with sliding lacquer
OKS 571 or cover with grease to ease assembly
(Fig. 10).
15. Insert the upper joint bolt.
16. Insert the lower joint bolt.
Fig. 10
17. Press upper and lower joint bolts in together (Fig.
11).
! Caution
Avoid skewing of the joint bolts.
Fig. 11
! Caution
Do not use any grease.
Ensure straight installation of the outer bear-
ing race.
19. Attach the outer bearing race and knock it in.
i Note
Allow the bearing to protrude for about 5-10 mm
Fig. 12 and pull it completely in later when assembling
the cover.
20. Spray the lower outer rocker bearing race with
sliding agent OKS 571 (Fig. 13).
! Caution
Do not use any grease.
Ensure straight installation of the outer bear-
ing race.
21. Attach the outer bearing race and knock it in.
i Note
Allow the bearing to protrude for about 5- 10 mm
Fig. 13 and pull it completely in later when assembling
the cover.
22. Attach the lower cover and tighten the screws
crosswise (Fig. 14).
Fig. 14
Fig. 15
24. Insert backing disc 1 (Fig. 16) and Belleville
springs (2) into the upper cover.
i Note
Lay the Belleville springs into the cover with the
curvature pointing down .
Fig. 16
25. Assemble nut 1 (Fig. 17) and washer and tighten
with 90 Nm.
! Caution
Check the measurement with an axial preload
of 40kN. Tightening torque = 90Nm.
26. Measure the gap (measurement „Y“) between
cover and frame.
i Note
Shim thickness "S" = 3.2 mm - "Y"
Fig. 17 27. Remove the cover again.
28. Insert shims 2 (Fig. 18) of appropriate thickness
and backing disc (1) into the cover.
Fig. 18
Fig. 19
30. Assemble cover 2 (Fig. 20) with Belleville springs,
shims and backing disc.
31. Turn in screws (1) and tighten crosswise.
Fig. 20
32. Insert screw 1 (Fig. 21) from underneath.
33. Assemble the washer, turn on the nut and tighten
with 120 Nm.
Fig. 21
34. If previously disassembled, press the rocker
bearing (Fig. 22) fully into the frame with a press-
ing mandrel.
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease!
Fig. 22
Fig. 23
36. Join the cross member with the rear frame (Fig.
24).
! Danger
Fig. 24
37. Spray the mating surfaces with sliding lacquer
OKS 571 or cover with grease to ease assembly
(Fig. 25).
38. Insert the upper joint bolt.
39. Insert the lower joint bolt.
Fig. 25
40. Press upper and lower joint bolts in together (Fig.
26).
! Caution
Avoid skewing of the joint bolts.
Fig. 26
! Caution
Do not use any grease.
Keep straight when assembling.
42. Knock upper (1) and lower outer races in with a
plastic hammer.
i Note
Allow the bearing to protrude for about 5-10 mm
Fig. 27 and pull it completely in later when assembling
the cover.
43. Attach the lower cover (Fig. 28) and tighten the
screws crosswise.
Fig. 28
Determining the shim thickness
44. Insert backing disc 1 (Fig. 29) and Belleville
springs (2) into the upper cover.
i Note
Lay the Belleville springs into the cover with the
curvature pointing down .
Fig. 29
45. Assemble the cover and tighten screw 1 (Fig. 30)
with 90 Nm.
! Caution
Check the measurement with an axial preload
of 40kN. Tightening torque = 90Nm.
46. Measure the gap (measurement „Y“) between
cover and frame.
i Note
Shim thickness "S" = 3.2 mm - "Y"
Fig. 30 47. Remove the cover again.
Fig. 31
49. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 32).
Fig. 32
50. Assemble the cover (Fig. 33) with Belleville
springs, shims and backing disc.
51. Turn in the screws and tighten crosswise.
Fig. 33
52. Turn in screw 1 (Fig. 34).
53. Assemble the washer, turn on the nut and tighten
with 120 Nm.
Fig. 34
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease!
55. Install and connect the crab walk cylinder.
Fig. 35
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
! Caution
Connect the plus pole first and the minus pole
after.
Follow the rules for handling batteries (see
technical manual "Basic Electrics").
60. Install the battery box.
61. Grease the articulated joint (Fig. 36).
Fig. 36
Fig. 37
63. Reconnect all wiring harness plugs (Fig. 38).
! Caution
Ensure correct routing of the wiring harness-
es. Ensure sufficient length compensation
when steering the machine. Avoid chafing.
Fig. 38
64. Install and fill the water tanks.
65. Connect and wire the water sprinkling pumps
(Fig. 39).
! Caution
Check the water sprinkling system for func-
tion and leak tightness before putting the ma-
chine back into service.
Fig. 39
66. Check the hydraulic oil level (Fig. 40).
! Caution
Check the hydraulic system for function and
leak tightness before putting the machine
back into service.
i Note
To bleed the steering cylinders run the engine
with idle speed and operate the steering several
times to left and right. Extend and retract the crab
walk cylinder several times. Then check the hy-
Fig. 40 draulic oil level once again.
Bild 41
Weist auf hohes Risiko und die Gefahr von Tod oder schwe- Indicates high risk, mortal danger and serious injuries.
ren Verletzungen hin.
! WARNUNG ! WARNING
Weist auf mittleres Risiko und die Gefahr von Verletzungen Indicates middle risk, injuries or serious material damage.
und schweren Sachschäden hin.
! VORSICHT ! CAUTION
Weist auf geringes Risiko und Sachschäden hin. Indicates low risk or material damage.
Hinweis Note
Kennzeichnet Informationen, die zum besseren Verständnis Indicates information that contributes to a better understan-
der Maschinenabläufe beitragen oder weist auf einen beson- ding of the machine processes or indicates important informa-
deren bzw. wichtigen Sachverhalt hin. tion.
Tipp Tip
Kennzeichnet Informationen, die zum effizienteren Arbeiten Indicates information that contributes to more efficient work.
beitragen.
2 Sicherheit 2 Safety
Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei- Read through this chapter carefully before you start any work
ten an der Verstellpumpe beginnen. on the variable pump.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht- The Rexroth variable pump are in the sense of the machine gui-
linie 98/37/EG Komponenten, die zum Einbau in eine Anlage deline 98/37/EG components of a larger machine or system.
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung be- The safety guidelines in this manual only cover the variable
ziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich pump. You must additionally follow the system manufacturer’s
die Sicherheitsrichtlinien des Anlagenherstellers. safety guidelines.
Informieren Sie sich an Hand der allgemeinen Betriebsanlei- Read the general manual for axial piston units to get more infor-
tung für Axialkolbenmaschinen über die bestimmungsgemäße mation on the designated use and the operator‘s obligation to
Verwendung und die Sorgfaltspflicht des Betreibers und exercise dilligence.
Bedieners.
! GEFAHR ! DANGER
! WARNUNG ! WARNING
! GEFAHR ! DANGER
! WARNUNG ! WARNING
! GEFAHR ! DANGER
! WARNUNG ! WARNING
! GEFAHR ! DANGER
! WARNUNG ! WARNING
! WARNUNG ! WARNING
1 3FYSPUI
D-89275 Elchingen
2 TYP: A4VG56DA2D2/32R-NZC02F003SP 7
3 MNR: R90XXXXXXX
7202 8
4 SN: 12345678
5 FD: 03W28 Rotation:
-1 9
6 n = XXXX min P = XXX kW
Made in Germany 10
Folgende Informationen finden Sie auf dem Typschild: The following information can be found on the type plate:
1 Hersteller 1 Manufacturer
2 Typschlüssel 2 Ordering code
3 Materialnummer der Axialkolbenmaschine 3 Material number of the axial piston unit
4 Seriennummer 4 Serial number
5 Fertigungsdatum 5 Date of manufacturing
6 Drehzahl 6 Speed
7 interne Werksbezeichnung 7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: rechts) 8 Direction of rotation (when facing the shaft; here: clockwi-
9 vorgesehener Platz für Prüfstempel se)
10 Leistung 9 Designated space for certification stamp
Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren- 10 Power
den Verstellpumpe mit dieser Anleitung übereinstimmen. Ensure that the variable pump to be repaired is of the type and
size covered by this manual.
Schwenkwiege /
Cradle
Antriebswelle /
Drive Shaft
Anschlussplatte
mit Hilfspumpe /
Port Plate with
Auxiliary Pump
Wellendichtring /
Shaft Seal Ring
Triebwerk /
Rotary Group
Draufsicht Verstellungen/
Top View with Controllers
Steuergerät
HWD Control Device DAD
Antriebswelle
Antriebswelle Drive Shaft
Drive Shaft
Verstellkolben
Control Piston
EPD HDD
Antriebswelle
Drive Shaft
Antriebswelle
Drive Shaft
Steuergerät
Control Device
Ansicht Anschlussplatte /
View Port Plate
DAD
Hinweis Note
Alle in nachfolgenden Zeichnungen dargestellten Steuergerä- All the following illustrations are only examples and do not
te sind nur stellvertretend und müssen nicht der Konfiguration have to completely correspond with the configrations of your
Ihrer Axialkolbenmaschine entsprechen. axial piston unit.
! WARNUNG ! WARNING
Beispiel/Example HW
b
a
a: Sicherungsring Circlip
b: Wellendichtring Shaft Seal
c: Triebwelle Drive Shaft
4 Fetten Sie den Wellendichtring zwischen Dicht- und Staub- 4 Grease the shaft seal between the seal and dust lip to avoid
lippe leicht ein, um Trockenlauf zu vermeiden. a dry run.
5 Pressen Sie den Wellendichtring mit Hilfe der Montagehülse 5 Using the mounting sleeve (special tool), press the shaft seal
(Sonderwerkzeug) auf Anschlag ein. until it is in stop position.
6 Führen Sie den Sicherungsring so ein, dass er in die dafür 6 Place the safety ring so that it locks into place in the respec-
vorgesehene Nut einrastet. tive slot.
7 Entfernen Sie die Abklebung an der Triebwelle. 7 Remove the mask on the drive shaft.
Dichtung an den Stellkolbendeckeln austauschen Exchanging the valve positioning piston covers
Die beiden Seiten des Stellkolbens sind mit zwei unterschiedli- Both sides of the positioning piston have their own different
chen Deckeln abgedeckt. Die nötigen Schritte zum Austausch covers. The required steps to exchange the covers are threre-
der Deckeldichtungen unterscheiden sich daher. fore different.
a
c
d
c c b
Um die Dichtung an den Stellkolbendeckeln auszutauschen: To exchange the valves of the positioning pistons:
1 Entfernen Sie die Befestigungsschrauben (f) des linken 1 Remove the fastening screw (f) of the left cover (a).
Deckels (a).
2 Verdrehen Sie den Deckel (a) und lösen Sie ihn vorsichtig 2 Twist the cover (a) and carefully loosen it by tapping it with a
mit leichten Hammerschlägen (Gummihammer). (rubber) hammer.
h g
4 Setzen Sie einen neuen O-Ring ein und schrauben Sie den 4 Install a new o-ring and screw the cover shut.
linken Deckel fest.
5 Markieren Sie die Lage des rechten Deckels (b), damit Sie 5 Mark the position of the right cover (b) so that you can set it
ihn nach dem Abdichten wieder lagerichtig aufsetzen kön- back to its original position after sealing.
nen.
Messen und notieren Sie das Maß X der Kontermutter (e) für Measure and write down the dimension X of the counter
die spätere Montage. nut (e). You need this for the subsequent assembly.
Entfernen Sie die Kontermutter (e). Halten Sie dazu die Remove the counter nut (e). To do so, grip the positioning
Stellschraube (d) fest. screw (d).
b
X
d
6 Drücken Sie den Deckel durch Eindrehen der Stellschraube 6 Press the cover off by screwing in the set screw.
ab.
7 Entfernen Sie die beiden O-Ringe (c). Kontrollieren Sie die 7 Remove the two o-rings (c). Check the slots (i) and housing
Nuten (i) und das Gehäuse (j) auf Verschleiß und Verunreini- (j) for wear and dirt.
gungen.
c
i j
8 Kleben Sie das Gewinde ab, um Beschädigungen des O- 8 Mask the screw thread to avoid damaging the o-ring, and
Rings zu vermeiden, und schieben Sie den kleinen O-Ring push the smaller o-ring up to the designated slot.
bis zur vorgesehenen Nut auf.
9 Setzen Sie den großen O-Ring ein, entfernen Sie die Abkle- 9 Insert the larger o-ring, remove the masking and screw the
bung und schrauben Sie den Deckel fest. cover back on.
10 Schrauben Sie die Kontermutter (e) per Hand ein. Blockie- 10 Screw in the counter nut (e) manually. Block the adjusting
ren Sie die Stellschraube (d) während Sie die Kontermutter- screw (d) while you tighten the counter nut.
festziehen.
Kontrollieren Sie das Maß X nach der Montage. Check the dimension X after assembly.
b
X
e d
Hinweis Note
Nach dem Einbau im Gerät bzw. Prüfstand muss die korrekte After the installation of the unit or the test rig, the correct
mechanische Nulllagen-Einstellung erfolgen, siehe „Überprü- mechnical zero stroke must be adjusted, refer to "Checking",
fungen“ auf Seite 29. page 29.
Hinweis Note
Möglicherweise sind nicht alle in den Zeichnungen gezeigten It is possible that the valves displayed in these illustrations are
Ventile an Ihrer Einheit vorhanden. not all present in your unit.
Niederdruckventil
Low-pressure valve
3 Setzen Sie die neuen O-Ringe ein, entfernen Sie die Abkle- 3 Insert the new o-ring, remove the masking from the screw
bungen an den Gewinden und schrauben Sie die Nieder- thread, and screw the low pressure valves back in.
druckventile wieder ein.
Ziehen Sie sie mit einem Drehmoment von 70 Nm fest. Tighten them with a torque of 70 Nm.
4 Schrauben Sie das Hochdruck-Ventil heraus. 4 Unscrew the high-pressure valve.
Es gibt zwei Ausführungen des Ventils: mit und ohne There are two types of this valve: with or without bypass
Bypass-Funktion. function.
5 Entfernen Sie O-Ring und Stützring. 5 Remove the o-ring and support ring.
6 Schieben Sie den neuen O-Ring und den Stützring mit dem 6 Push the new o-ring and the support ring back with an auxili-
Hilfswerkzeug (Hülse, siehe „Anhang“) auf. ary tool (sleeve, refer to "Appendix").
Der Stützring muss ersetzt werden, wenn er Verschleißspu- The support ring must be replaced when it shows wear or
ren oder Bechädigungen aufweist. damage.
Hülse
Sleeve
7 Bauen Sie das Hochdruck-Ventil ein und ziehen Sie es mit 7 Install the high-pressure valve and tighten it with a torque of
einem Drehmoment von 160 Nm fest. 160 Nm.
Dichtung der Druckabschneidung austauschen Exchanging the seals of the pressure cut-off
Um die Dichtung der Druckabschneidung auszutauschen: To exchange the seal of the pressure cut-off:
1 Notieren Sie das Einstellmaß X der Dichtmutter für die späte- 1 Write down the sealing nut's setting dimension X for the
re Montage. subsequent assembly.
2 Bauen Sie die Dichtmutter (a) und die Verschlussschraube 2 Extract the sealing nut (a) and the locking screw (b).
(b) aus.
Entfernen Sie den O-Ring (c). Remove the o-ring (c).
a
b 9
3 Setzen Sie einen neuen O-RIng (c) ein. 3 Install a new o-ring (c).
4 Setzen Sie die Verschlussschraube (b) ein und ziehen Sie 4 Install the locking screw (b) and tighten it with a torque of 35
sie mit einem Drehmoment von 35 Nm fest. Nm.
5 Bauen Sie eine neue Dichtmutter (a) ein und stellen Sie das 5 Install the new sealing nut (a) and adjust to the setting
notierte Einstellmaß X ein. measure X that you wrote down previously.
Ziehen Sie die Dichtmutter mit 25 Nm fest. Tighten it with a torque of 25 Nm.
b
b a
3 Schieben Sie den neuen O-Ring auf. 3 Slide the new o-ring on.
4 Entfernen Sie die Abklebung und schrauben Sie das Regel- 4 Remove the masking and screw the control valve back on.
ventil ein.
Ziehen Sie sie mit einem Drehmoment von 50 Nm fest. Tighten them with a torque of 50 Nm.
2 Entfernen Sie die vier Befestigungsschrauben (b). 2 Remove the four fastening screws (b).
3 Drücken Sie den Deckel wie gezeigt ab. 3 Press the cover off as illustrated.
4 Entfernen Sie die Hilfspumpe und untersuchen Sie die Teile 4 Remove the auxiliary punp and check the part for wear and
der Hilfspumpe auf Verschleiß und Verunreinigungen. dirt.
Markieren Sie vorher die Lage der Hilfspumpe, damit Sie sie Mark the position of the auxiliary pump beforehand, so that
später wieder lagerichtig einbauen können (sofern Sie die you can return it to its original position afterwards (if you
alte Hilfspumpe weiter verwenden). keep the old auxiliary pump in use).
Hinweis Note
Die Hilfspumpe kann nur komplett ausgetauscht werden. The auxiliary pump can only be exchanged as a whole.
5 Setzen Sie zwei neue O-Ringe bzw. Dichtringe (c) ein. 5 Install two new o-rings (c).
6 Setzen Sie die (neue) Hilfspumpe ein. 6 Install the (new) auxiliary pump.
Achten Sie darauf, dass die angefaste „Seite“ (d) zum De- Pay attention that the chamfered "side" (d) is assembled
ckel (a) montiert wird. facing the cover (a).
a
d
Hinweis Note
Die Hilfspumpe wird mit Haltestopfen (e) geliefert. Diese wer- The auxiliary pump is delivered with fixing plugs (e). These are
den bei der Montage auf die Anschlussplatte in die entspre- pressed into the bore of the port plate during assembly.
chenden Bohrungen eingepresst.
7 Schrauben Sie den Deckel (a) fest. Beachten Sie dabei die 7 Screw the cover (a) back on. Pay attention to the marking
vorher angebrachte Markierung. made previously.
Hinweis Note
Es gibt eine Vielzahl von Steuergeräten (siehe Abbildung). There exists a multitude of control devices (as illustrated).
Bitte beachten Sie, dass hier exemplarisch nur der Austausch Please pay attention to the fact that only the example of an
eines HW Steuergeräts gezeigt wird. HW control device is described here.
HW alt / old
DA alt / old
neu / new
HD
neu / new
EP
HW mit Nulllagenschalter alt / old
HW with zero position switch
neu / new
Polrohr
Anziehmoment 19 Nm /
Pole tube
Tightening torque 19 Nm
Anziehmoment 5+1 Nm
Steckschlüssel SW 26 /
Tightening torque 5+1 Nm
26 A/F socket spanner
2 Drücken Sie das Steuergerät (b) wie gezeigt ab. 2 Press the control device (b) off as illustrated.
3 Entfernen Sie den O-Ring (c) und die Flachdichtung (e). 3 Remove the o-ring (c) and the seal (e). Check the sealing
Kontrollieren Sie die Dichtflächen (d) auf Beschädigungen surfaces (d) for wear and dirt.
und Verunreinigungen.
Tauschen Sie das Steuergerät bei Bedarf aus. Exchange the control device if required.
Hinweis Note
Das Steuergerät kann nur komplett ausgetauscht werden. The control device can only be exchanged as a whole.
d
e
d
4 Setzen Sie einen neuen O-Ring und eine neue Flachdich- 4 Insert the new o-ring and the new seal (e).
tung (e) ein.
5 Setzen Sie das (neue) Steuergerät ein. 5 Insert the new control device.
6 Zentrieren Sie die Dichtung (e) mit zwei Befestigungsschrau- 6 Center the seal (e) with two fastening screws (a) and install
ben (a) und bauen Sie das Steuergerät ein. the control device.
Ziehen Sie alle vier Befestigungsschrauben mit halbem Screw all four fastening screws tight with half the torque.
Drehmoment an.
a
7 Setzen Sie die fünfte Schraube (f) ein und ziehen Sie sie mit 7 Insert the fifth screw (f) and tighten it with a torque of
einem Drehmoment von 10,4 Nm fest. 10.4 Nm.
Ziehen Sie die anderen vier Schrauben (a) nach Drehmo- Tighten the other four screws (a) crosswise and according
ment über Kreuz fest. to torque.
Hinweis Note
Nach der Montage des Steuergeräts muss die hydraulische After installing the control device, the hydraulic zero stroke
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), must be re-established. This does not apply to DA-control.
siehe „Überprüfungen“ auf Seite 29. Please refer to "Checking", page 29.
Führen Sie alle Überprüfungen bei Betriebstemperatur durch. Carry out checkings at operating temperature.
Hinweis Note
Wenn die überprüften Werte von den ursprünglichen Einstel- If the checked values differ from the original settings, please
lungen abweichen, setzen Sie sich bezüglich der Einstellung contact Rexroth in terms of adjusting the settings.
bitte mit dem Rexroth-Service in Verbindung.
! WARNUNG ! WARNING
! WARNUNG ! WARNING
5.1 Niederdruck (Speisedruck) überprüfen 5.1 Checking Low Pressure (Charge Pressure)
Dieser Abschnitt erklärt, wie Sie ND-Ventile überprüfen. This section describes how to check the low pressure valves.
Um den Niederdruck zu überprüfen: To check the low pressure:
1 Schließen Sie wie gezeigt ein Manometer an Anschluss G 1 Connect a manometer to connection G as displayed.
an.
2 Überprüfen Sie den Niederdruck (G). 2 Check the low pressure (G):
Hinweis Note
Die genauen Einstelldaten entnehmen Sie dem Technischen Refer to the catalog sheet RE 92 003 and your specification
Datenblatt RD 92 003 und Ihrer Spezifikation. for the detailed setting data.
Die genauen Einstelldaten entnehmen Sie Ihrer Spezifikation. Refer to your specification for the detailed setting data.
HW HD EP DA
! WARNUNG ! WARNING
mind. / at least
Nennweite 6 / Nominal Width 6
MA
Messbereich/
Metering range
0 ... 600 bar
MB
5.4 Hydraulische Nulllage überprüfen 5.4 Checking the Hydraulic Zero Stroke
Dieser Abschnitt erklärt, wie Sie die hydraulische Nulllage bei This section describes how to check the hydraulic zero stroke
HW-, HD- und EP-Steuergeräten überprüfen. for HW-, HD-, and EP-controllers.
! WARNUNG ! WARNING
HW HD EP
Messbereich/
Metering range
X1 0 ... 60 bar
X2
Hinweis Note
Verdrehen Sie die Exzenterjustierung (a) am Steuergerät nicht Never turn the eccentric calibration (a) of the controller over
über ±90°. ±90 degrees.
Bosch Rexroth AG
Hydraulics
Produktsegment
Axialkolbenmaschinen
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
© This document, as well as the data, © Alle Rechte bei Bosch Rexroth AG,
specifications and other information auch für den Fall von Schutzrechtsan-
set forth in it, are the exclusive proper- meldungen. Jede Verfügungsbefugnis,
ty of Bosch Rexroth AG. It may not be wie Kopier- und Weitergaberecht,
reproduced or given to third parties bei uns.
without its consent.
Die angegebenen Daten dienen
The data specified above only serve to allein der Produktbeschreibung.
describe the product. No statements Eine Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
information given does not release werden. Die Angaben entbinden
the user from the obligation of own den Verwender nicht von eigenen
judgment and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are
zu beachten, dass unsere Produkte
subject to a natural process of wear
einem natürlichen Verschleiß- und
and aging.
Alterungsprozess unterliegen.
Subject to change. Änderungen vorbehalten.
Printed in Germany
RDE 92 003-11-R/12.05
RDE 92 750-01-R/03.03
Verstellpumpe A10VG 28/63 ersetzt/replaces 10.02
Hinweis / Inhalt
Notice / Contents
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.
INHALT CONTENTS
Seite/
Page
A10VG A10VG
mit Druckabschneidung
with pressure cut-off
HW
ohne Druckabschneidung
without pressure cut-off
HDD EPD
Schnittbild
Sectional view
DA
Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!
Äußerer Dichtsatz.
Triebwerk komplett.
Stellkolben
Positioning piston
2 3
1. Anschlußplatte Standard,
1
2. Anschlußplatte mit Druckabschneidung
3. Anschlußplatte DA mit Druckabschneidung
Ansteuergerät HW
Control unit HW
alt / old
Control unit HD
alt / old
neu / new
Ansteuergerät EP
Control unit EP
alt / old
neu / new
4/3 Wegeventil DA
Control unit DA
1
2
1. HD - Ventil
2. HD - Ventil mit Bypass
3. ND - Ventil
Druckabschneidung
Pressure cut-off
3
2
Triebwelle abkleben.
Sicherungsring ausbauen.
Hilfspumpe abdichten
Sealing of the boost pump
Achtung!
* "Angefaste Seite" zum Deckel montieren.
Note!
* Mount the "chamfered side" towards the cover.
Befestigungsschrauben ausbauen.
Deckel abdrücken.
Pry-off cover.
Einbaulage kennzeichnen.
Mark position.
Hilfspumpe abdichten
Sealing of the boost pump
O-Ring ausbauen.
Remove O-ring.
Hilfspumpe abdrücken.
2
1. Verschleißplatte
2. Fixierstift
1. Wear plate
2. Locating pin
1
3 1. Kantsil-Ring
1
2. Entlastungsnut
2 3. Fixierstift
1. Kantsil-ring
2. Unloading channel
3. Locating pin
Verschleißplatte einsetzen.
Drehrichtung beachten!
Hilfspumpe abdichten
Sealing of the boost pump
Verschleißplatte einsetzen.
Drehrichtung "Rechts" bei Blick auf die Triebwelle.
Achtung! Fixierstift
Verschleißplatte einsetzen.
Drehrichtung "Links" bei Blick auf die Triebwelle.
Achtung! Fixierstift
Linkslauf - anti-clockwise
Rechtslauf - clockwise
Hilfspumpe montieren.
Stellkolbendeckel abdichten
Sealing of the control piston cover
Achtung!
Korrekte mechanische 0-Lageneinstellung
überprüfen!
Attention!
Check that the mechanical "0"-position is
correct!
Ventile abdichten
Sealing of the valves
PSP-Ventil
PSP -valve
*
Ventilkegel mit Druckfeder ausbauen.
Stützring
* mit Bypassfunktion
O-Ring
Druckabschneidung abdichten
Sealing of the pressure cut-off valve
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.
Attention!
After assembly check "valve setting".
Regelventil abdichten
Sealing of the control valve
Regelventil ausbauen.
Steuergerät demontieren
Removing of the control unit
HW
alt / old
DA alt / old
neu / new
HD
neu / new
EP alt / old
neu / new
HW mit Nullagenschalter
HW with zero position switch
* Befestigungsschrauben demontieren.
*
* Remove fixing screws.
Ansteuergerät abdrücken.
Kontrolle
Dichtfläche (1), Flachdichtung (2), O-Ringe (3).
Check
Sealing surface (1), gasket (2), O-rings (3).
Ansteuergeräte
Control units
Ansteuergerät HW
NG / Size 28
HW control unit
NG / Size 45
4/3 Wegeventil DA
DA control unit
Anziehmoment 5+1 Nm
Steckschlüssel SW 26
Tightening torque 5+1 Nm
26 A/F socket spanner
Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm
Ansteuergeräte
Control units
Ansteuergerät HD - EP alt
HD - EP control unit old
HD alt / old
EP alt / old
HD alt / old
EP alt / old
Neues Ansteuergerät HD - EP
New HD - EP control unit old
202,0 mm
131,0 mm
214,4 mm
77,4 mm
Ansteuergeräte
Control units
Ansteuergerät HD neu
HD - control unit new
Ansteuergerät EP neu
EP - control unit new
Ansteuergeräte
Control units
* Markierung Montageposition HD *
* Marking the assembly position HD
*
*
*
Wird von EP- auf HD-Ausführung umgebaut - Is converted from EP into the HD version -
Deckelposition beachten siehe Markierung take note of the cover position, see marker
Ansteuergeräte
Control units
Entlüftungsschraube * max. 2 Umdrehungen herausdrehen. The new proportional solenoids must be bled during
Bleed screw *. Unscrew by commissioning. If the air is not removed from the
a max. of 2 turns armature chamber oscillations at the control can occur.
* For bleeding purposes there is, on the end of the sole-
* noid, in the brass component a small set screw M4,
2A/F. This can be unscrewed by a maximum of 2 turns
and then after completion of the bleeding tightened to
a maximum of 2 Nm.
For the version with hand override and spring return
the plastic nut with rubber coating has to be removed
for bleeding. After bleeding it has to be replaced and
tightened with 5+1 Nm.
Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm
* *
Markierung
Klemmschraube 6,1 Nm Anziehmoment 5+1 Nm
Montageposition EP
Clamping screw 6,1 Nm Steckschlüssel SW 26
Assembly position
marker EP Tightening torque 5+1 Nm
26 A/F socket spanner
Hydraulische Nullage
Exzenterstift
Hydraulic
zero point
Eccentric pin
Beim Lösen der Klemmschraube
Exzenterstift - Hydraulische Nullage festhalten.
Pumpe demontieren
Pump disassembly
HD alt/old
EP alt/old
HD neu/new
EP neu/new
Druckabschneidung
Pressure cut-off
DA alt/old
DA neu/new
Excenterschraube
Eccentric screw
Pumpe demontieren
Pump disassembly
DA-Ausführung:
Lage der Verdrillschraube markieren (1).
Verdrillschraube auf Demontageposition stellen (2).
DA-design:
Mark the position of the eccentric screw (1).
Set the eccentric screw to disassembly position
(2).
Steuerplatte abdrücken.
Lage notieren.
Kontrolle!
2 4 O-Ring mit Nut (1)
3 O-Ring mit Nut (2)
Fixierstift - Steuerplatte (3) Bei DA - kein Stift
1 T - Ablauf verschlossen (4)
Check
O-ring and groove (1)
O-Ring and groove (2)
Locating pin - control plate (3) type DA has no pin
T drain plugged (4) open for type DA
Pumpe demontieren
Pump disassembly
DA-Ausführung
Zylinder nach unten drücken (1).
Verdrillschraube herausdrehen (2).
Triebwerk ausheben (3).
DA- version
Press the cylinder downwards (1).
Remove the eccentric screw (2).
Lift out the rotary group (3).
"Ausbauen"
1. Zylinder
2. Schwenkwiege
3. Gelenkstift
"Remove"
1. Cylinder
2. Swash plate
3. Joint pin
Triebwerk ausbauen
Removal of the rotary group
Lagerschalen ausbauen.
Sicherungsring demontieren.
Feder und Druckstifte ausbauen.
Remove circlip.
Remove spring and pressure pins.
Steuergerät abbauen.
Stellkolben zerlegen.
Steuergerät abbauen.
Stellkolben zerlegen
(Gehäuse Turcon-Glyd-Ring Abdichtung).
Überprüfungshinweise
Inspection notes
Kontrolle!
1. Verzahnung, ausgeschlagen, Passungsrost.
2. Lauffläche.
3. Einlaufrillen vom Wellendichtring.
Check!
1. Splines, wear steps, corrosion.
2. Running surfaces.
3. Grooves made by the shaft seal.
Kontrolle!
Stellkolben (1) riefenfrei.
Check!
Control piston (1) is not scored.
Überprüfungshinweise
Inspection notes
Kontrolle!
Gleitfläche riefenfrei.
Check!
Sliding surface free of grooves.
Kontrolle!
Verbindung Gleitstein/Schwenkzapfen spielfrei.
Check!
That the connection of slide ring/swivel pin is free
of play.
Kontrolle!
Rückzugeinrichtung riefenfrei (1), keine Einlaufs-
puren (2)
im Gleitschuhbereich.
Check!
That the retaining plate is free of grooves (1) and
that there is no wear (2) in the slipper pad area.
Kontrolle!
Lauffläche (1) keine Kratzer, keine Metallein-
lagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).
Check!
Check to see that there are no scratches or metal
deposits
on the sliding surface (1), and that there is no axial
play (2),
(pistons must only be replaced as a set).
Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
Überprüfungshinweise
Inspection notes
Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen,
keine Einlagerungen,
Steuerplatte nicht riefig (nur satzweise
austauschen).
Check!
Cylinder sliding surface free of grooves, no wear,
no embedded foreign particles. That there are no
scratches on the control plate. (Only replace them
as a set).
Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.
Check!
Mounting surface - control plate undamaged
Hinweis:
Bohrung bei DA-Regelung offen. (gültig nur bei
A10VG 45).
Information:
Hole for DA-control is open, without DA control valve
it is plugged.
Kontrolle!
Lagerbahnen (1)
Check!
Bearing surfaces (1)
Press the seal ring into the kidney shape using the
assembly tool. The deformation of the Turcon seal
has to be done with care so as not to damage the
sealing edges.
Pumpe montieren
Assembly of the pump
Lagerschalenpaar einsetzen.
Pumpe montieren
Assembly of the pump
Gelenkstift montieren.
Pumpe montieren
Assembly of the pump
Haltevorrichtung montieren.
Mit Gewindestift Schwenkwiege festhalten.
Keine Gewaltanwendung.
Teil/Part 3 Teil/Part 4
∅ ∅
6, 7, 8, 9
∅ ∅
3, 4, 5
∅ ∅
Teil/Part 5
∅
2
∅
1
Triebwerk einbauen
Installation of the rotary group
Neue Montageposition!
Triebwelle mit Lager und Wellendichtring einbau-
en.
Triebwerk einbauen HW / HD / EP
Installation of the rotary group HW / HD / EP
Vorrichtung ausbauen.
Zylinder mit Kolben und Rückzugeinrichtung
einbauen.
Montagehilfe:
Mit O-Ring Kolben festhalten.
Assembly aid:
Hold the pistons by using an O-ring.
Triebwerk einbauen HW / HD / EP
Installation of the rotary group HW / HD / EP
Steuerplatte Rechtslauf
* Fixierstift
* Control plate, clockwise rotation
* Locating pin
Steuerplatte Linkslauf
* * Fixierstift
Lagerichtig aufsetzen.
Hinweis:
HW, HD, EP Steuerplatte mit Fett auf
Anschlußplatte.
Triebwerk einbauen DA
Installation of the rotary group DA
Lagerichtig aufsetzen.
Bei DA Steuerplatte auf Zylinderfläche legen.
Pumpe montieren
Assembly of the pump
Hilfspumpe montieren.
Pumpe montieren
Assembly of the pump
Die Werte gelten für Schaftschrauben mit metri- The values stated are valid for bolts with metric
schem ISO-Gewinde nach DIN 13 Teil 13, sowie ISO threads to DIN 13 part 13, as well as head
Kopfauflagemaßen nach DIN 912 Zylinder- areas to DIN 912 socked head cap screws, DIN
schrauben, DIN 931 Sechskantschrauben mit 931 hexagon bolt or DIN 933 hexagon bolts with
Schaft bzw. DIN 933 Sechskantschrauben mit threads up to the head.
Gewinde bis Kopf.
2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).
G
EOLASTIC-
Dichtung / Seal
5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)
G
O-Ring / O-ring seal
Dichtung / Thread
Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm
M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180
Gewinde / Anziehdremomente Nm /
Thread Tightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12
Sicherheitsbestimmungen
Safety regulations
● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.
● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.
Sicherheitsbestimmungen
Safety regulations
Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.
Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!
Achtung! Attention!
Sicherheitsbestimmungen beachten! Observe safety regulations!
Hinweis: Note:
Nachjustierung nur bei Betriebstemperatur. Readjusting only at operating temperature.
Achtung! Attention!
* Speisedruckeinstellung! * Boost pressure setting!
Nenndruck pH - 20 bar Nominal pressure pH - 20 bar
Höchstdruck pH - 40 bar Peak pressure pH - 40 bar
Bei Max.-Drehzahl. at max. speed.
Hinweis: Note:
Einstelldaten nach Werksauftrag. Setting data is in accordance to the works order.
60 bar
"G"
*
HW
alt / old
alt / old
DA
neu / new
HD
neu / new
EP alt / old
neu / new
HW mit Nullagenschalter
HW with zero position switch
Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschließen.
Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.
600 bar
Attention!
Observe safety regulations!
Connect both control chambers with a nominal size
600 bar
6 hose. Avoidance of residual signals from hydraulic
zero position.
Connect pressure gauges to MA and MB. Adjust
the zero position so that with at blocked drive both
pressure gauges indicate the same pressure valve.
Note:
Ascertain the zero position dead band.
HD neu/new Achtung!
Sicherheitsbestimmungen
HW beachten!
*
* HD alt/old Attention!
Observe safety regulations!
*
*
*
HW mit Nullagenschalter
HW with zero position switch EP alt/old
EP neu/new
60 bar
60 bar
Achtung!
Sicherheitsbestimmungen beachten!
Druckabschneidung:
Einstellschraube auf Maß (*) zurückdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD-Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.
Attention!
Observe safety regulations.
HD- Ventile
HP- valves
HP valve without bypass-function
1. HP valves are always adjusted 10% higher than the
pressure cut-off.
2. Readjusting only at operating temperature.
Connect pressure gauge (600 bar) to MA and MB.
Pressure cut-off:
To block the pressure cut-off when testing the high
pressure valves, the adjustment screw (item 1), with the
lock-nut (item 2) loosened, has to be screwed in
with a max. torque of 2 Nm in the depressurised condition
until the end stop is reached.
HP valves: Operate the valves with small pump flow over the
valves.
Check setting value. (only for a short time "temperature“).
Change setting value - see service information.
Pressure cut-off:
Turn back setting screw to measurement (*).
Check pressure value and readjust if necessary.
Attention! Observe the 10% pressure difference
between the HP valves and the pressure cut-off!
Note: Setting data is in accordance with the works order.
1
1
Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydro- Vehicle with a pure hydrostatic transmission or with a hydrostatic
statischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung drive with gear box without free wheel position.
(Freilauf).
Hydrostatic transmission / Bypass condition
Hydrostatischer Antrieb / Bypaß-Schaltung
In this case the travel drive is switched on to the free wheel
In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. position. For this purpose the high pressure valves of the variable
Zu diesem Zweck haben die in der Verstellpumpe integrierten displacement pump have a so-called bypass function.
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. By turning the relevant screw (item 1) the valve is so released
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird that free oil circulation is made possible.
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich Bypass: Screw in item1 until it is level with the nut.
ist.
Bypass: Pos.1 einschrauben bis eben mit Mutter. Towing speed
Mutter wieder anziehen. The max. towing speed of 2 km/h should not be exceeded.
● Higher permissible speeds are depended on the hydraulic
Schleppgeschwindigkeit motor speed or the selected gear.
Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht
überschreiten. Towing distance
● Höhere zulässige Schleppgeschwindigkeiten The towing distance should not exceed 1 km.
sind abhängig von der Hydromotordrehzahl
bzw. dem eingelegten Gang. ● With no boost avaiable the hydraulic circuit drains.
The heat generation in the hydraulic motor rotary group
Abschleppdistanz has to be taken into account.
Die Schleppentfernung sollte 1 km nicht überschreiten.
● Bei fehlender Einspeisung entleert sich der Termination of the towing operation
Hydraulik-Kreislauf. After termination of the towing operation turn back item 1.
Zu beachten ist die Wärmeentwicklung im The original set pressure value is thereby avaiable.
Hydromotor-Triebwerk. Valve function: Screw back item 1 up to stop.
Screw up the nut.
Abschleppvorgang beendet
Nach beendetem Abschleppvorgang Pos.1 zurückdrehen.
Der ursprüngliche Einstellwert der Hochdruckventile liegt somit
wieder vor.
Ventilfunktion: Pos.1 zurückschrauben bis
Anschlag. Mutter anziehen.
Einstellhinweise - Bypassventil DA
Adjustment instructions - Bypass valve DA
Achtung!
Sicherheitsbestimmungen beachten!
Blockzustand
Fahrtrichtungsschalter "0“
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Meßgeräte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*
Blockzustand
Fahrtrichtungsschalter - vorwärts
(Straßengang und Festgebremst)
*
Einstelldaten Pumpe A10V/DA überprüfen
* Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube
Regelende
Verdrillung Regelbeginn
HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube
Hinweis:
Excenterjustierung - Drehrichtung beachten
Attention!
Observe safety regulations!
Block position
Drive direction switch - "0“.
Slowly increase motor speed up to the max. motor
speed and observe measuring instruments.
Boost pressure:
Idle speed of prime mover
Psp = approx. 15 - 20 bar
max. motor speed
Psp = . . . . . . . . . bar*
Block position
* Drive direction switch - forwards
(Road gear and fully applied brake)
Note:
Eccentric adjusting - observe direction of
rotation.
Printed in Germany
RDE 92 750-01-R/02.03
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.
RDE 91 001-03-R/05.03
Konstantmotor A2FM/E ersetzt / replaces 04.00
Hinweis / Inhalt
Notice / Contents
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.
A2F A2F
A2FM Pos.B
Pos.D
Pos.A
Schnittbild
Sectional view
A2FE
Schnittbild
Sectional view
A2FE
Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!
Dichtsatz
Seal kit
Spülventil
Flushing valve
Ventil
Valve
Triebwelle abdichten
Sealing of the drive shaft
Sichtkontrolle
Wellendichtring (1), Verschlußring (2),
Triebwelle (3), Gehäuse (4), O-Ring (5).
Visual check
Shaft seal (1), cover (2), drive shaft (3),
housing (4), O-ring (5).
Triebwelle abdichten
Sealing of the drive shaft
Wellendichtring demontieren.
Sicherungsring einbauen.
Sitzkontrolle des Sicherungsringes in der Nut.
Fit circlip.
Check to ensure that the circlip is correctly located
within the groove.
Anschlußplatte abdichten
Sealing of the cover plate
Anschlußplatte abdichten
Sealing of the cover plate
Saugseite /
Druckseite / Pumpe, Drehrichtung links.
Suction side
Pressure side (Blick auf sphärische Fläche.)
Motor, bi-directional.
(Viewed on spherical surface.)
Anschlußplatte abdichten
Sealing of the cover plate
Sichtkontrolle
O-Ring (1), Einstich (2), Platte (3).
Visual check
O-ring (1), Groove (2), Plate (3).
Triebwerk ausbauen
Removal the rotary group
Gewindestift,Zylinderschraube /
Threaded pin,socket head screw
NG / Size (mm)
10; 12; 16 M3 x 35
23; 28; 32 M5 x 45
45 M5 x 50
56; 63 M5 x 55
80; 90 M5 x 60
107; 125; 131 M6 x 70
160; 180 M6 x 85
Triebwerk ausbauen
Removal the rotary group
Befestigungsschraube ausbauen.
Zylinder abheben.
Überprüfungshinweise
Inspection guidelines
Triebwelle
4 4 1. kein Passungsrost, nicht ausgeschlagen.
1 2
3 2. keine Einlaufspuren, riefenfrei.
3. Kalotten riefenfrei und keine Pittings.
4. Keine Laufspuren (Lagerdreher)
3
Drive shaft
1. No wear, or fretting
2. No traces of wear, free of scratches.
3. Cups free of wear and no pitting.
4. No traces of wear, (bearing rotation).
1
1. Axiales Kolbenspiel
Alt / Old
Kolben
Riefenfrei, keine Pittings.
Piston
Neu / New
Free of scratches, no pitting.
1 2
Mittelzapfen
1. Riefenfrei, ohne Pittings.
2. Riefenfrei.
Center pin
1. Free of scratches, no pittings.
2. Free of scratches.
Rückzugplatte
Riefenfrei, keine Ausbrüche.
Retaining plate
Free of scratches, no wear.
Überprüfungshinweise
Inspection guidelines
Zylinder/Steuerplatte
1. Bohrungen riefenfrei, nicht ausgelaufen.
2. Gleichmäßiges Tragbild, riß- und riefenfrei.
Gehäuse
Im Lagerbereich riefenfrei und keine
Einlaufspuren.
Housing
No traces of wear in the bearing area.
Triebwerk einbauen
Installing rotary group
A = A* + S
S = Nennmaß - Sicherungsring /Safety ring
A A*
Triebwerk einbauen
Installing rotary group
Neue Montagestellung.
Triebwerk einbauen
Installing rotary group
Befestigungsschraube ausbauen.
Steuerplatte lagerichtig aufsetzen.
Fertigmontage
Abstimmung Pos. D - siehe Serviceinfo
Die Werte gelten für Schaftschrauben mit metri- The values stated are valid for bolts with metric
schem ISO-Gewinde nach DIN 13 Teil 13, sowie ISO threads to DIN 13 part 13, as well as head
Kopfauflagemaßen nach DIN 912 Zylinder- areas to DIN 912 socked head cap screws, DIN
schrauben, DIN 931 Sechskantschrauben mit 931 hexagon bolt or DIN 933 hexagon bolts with
Schaft bzw. DIN 933 Sechskantschrauben mit threads up to the head.
Gewinde bis Kopf.
2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).
G
EOLASTIC-
Dichtung / Seal
Sicherheitsbestimmungen
Safety regulations
● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.
Bosch Rexroth AG
Mobile Hydraulics
Produktbereich Axialkolbenmaschinen
Werk / Plant Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
Printed in Germany
RDE 91 001-03-R/05.03
02 05 08 11 18
MS
MSE
Störungsbeseitigung
Trouble Shooting
Wartungsarbeiten
Maintenance
Reparaturen
Repairs
5767
Ersatzteile
Spare Parts
5763 5765
0549 5766 0545
5764
0550 0547
General information.
Allgemeine Information.
POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht wer- POCLAIN HYDRAULICS designs products that are integrated by its
den, die auf die Anwendung der in diesem Dokument empfohlenen Ver- customers in the machines they design.
fahren zurückgehen.
POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktion Subsequently POCLAIN HYDRAULICS disclaims liability for conse-
und die Betriebsbedingungen der Maschinen und Systeme, die mit PH- quences of improper integration of its products and of improper set-up
Produkten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS we- of adjustable devices. In the same way, POCLAIN HYDRAULICS may
der für die Folgen eines falschen Einbaus der Produkte noch für ein fal- not be liable for incomplete or improper operating and maintenance in-
sches Parametrieren einstellbarer Werte, noch für ungültige oder unvoll- structions provided to the end user by the machine manufacturer nor for
ständige Gebrauchs- und Wartungsanweisungen, die den Endverbrau- failures resulting from operations performed by any person using these
chern von den Maschinenherstellern zur Verfügung gestellt worden sind, suggested procedures.
verantwortlich. A re-certification of the machine may be required for every change in
Jegliche Änderung einstellbarer Parameter der PH Produkte kann eine set-up of adjustable devices.
Neuzulassung der Maschinen erforderlich machen.
Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HY- In order to offer the best quality service, POCLAIN HYDRAULICS rec-
DRAULICS seinen Kunden, jede Anwendung von POCLAIN HY- ommends to its customers to have applications approved by POCLAIN
DRAULICS prüfen und freigeben zu lassen. HYDRAULICS.
Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nur Opening of products voids the warranty contract.
Original-Ersatzteile von POCLAIN HYDRAULICS. Die Montage von Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
Teilen anderen Ursprungs könnte den Betrieb des Bauteils und des Sy- from different sources could reduce the performance of the product and
stems sowie die Sicherheit beeinträchtigen. pose a safety hazard..
Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sich In accordance with its policy of continuous improvement, POCLAIN
POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigung HYDRAULICS reserves the right to modify the specifications of all
alle Änderungen vorzunehmen, die als nützlich für die in diesem Doku- products described herein without prior notice.
ment beschriebenen Produkte bewertet werden.
Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Ab- This document contains sections written in German and sections
schnitte, die Übersetzung in englischer Sprache darstellen. printed in italics composing the English translation of the French sec-
Im Zweifelsfall ist die französische Version ausschlaggebend. tions. The French sections will be the reference in case of dispute.
Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungen All measures are expressed in metric units. Converted values to other
in anderen Meßsystemen (vor allem angelsächsisch) werden zur Unter- systems (notably US and UK) are given for reference only.
richtung angegeben.
Die Abbildungen haben unverbindlichen Charakter. The illustrations for information only.
Inhaltsverzeichnis Contents
INHALTSVERZEICHNIS ............................................. 3 CONTENTS................................................................. 3
MS18-2-D11-F19-2A10-K000
B D
000143896J
C 40712
001
0349
Der Motor wird nicht ver- Den Antrieb der Pumpe und ih-
sorgt re Versorgung überprüfen
Kein Druckanstieg im Hochdruck-Begrenzungsventile
MOTOR DREHT SICH Kreis kontrollieren (Regler)
NICHT Zylinderblock und Ölverteiler
Interne Lecks zu groß
ersetzen
Die Bremse bleibt angezo- Den Steuerkreis der Bremse
gen kontrollieren
Trouble shooting
DAMAGE → IRON PARTICLES → DETECTION BY FILTERS → PREVENTION……
Einbau Installation
Die zum Ausbau angegebenen Arbeitsgänge in umge- Execute the removal operations in the reverse order.
kehrter Reihenfolge ausführen.
Für weitere Informationen beziehen Sie sich bitte auf Please refer to the following documentation brochures:
folgende Dokumente:
• INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION MS F/GB (ref: 677777844K)
• INSTALLATION CIRCUITS D/GB (ref: 677777853U) • INSTALLATION CIRCUITS F/GB (ref: . 677777831V)
• Stopfen (142) aus der Schutz- • Extract and release the plug 142
kappe (141) herausziehen. (142) from the brake cover (141).
6499
6556
• Mutter so weit anziehen, bis die • And tighten the nut until the
Welle frei dreht. motor shaft turns freely.
6555
Entsprechendes
Bremsen Brakes Kraft N Force [lbf] Equivalent torque [lbf.ft] Mutter Nut
Drehmoment Nm
F02-F04 18000 [4.000] 42 [30.9] M12
F05-F07 20000 [4.500] 47 [34.6] M12
F08 34000 [7.600] 110 [81.1] M16
F11 45000 [10.000] 140 [103] M16
F12 45000 [10.000] 140 [103] M16
F19 45000 [10.000] 140 [103] M16
Nach Bremslösung, einen neuen Stopfen After brake release, mount a new plug
! (142) einbauen. ! (142).
Bei fahrbaren Maschinen den Test auf ebenem For a rolling machine, make the test on a hori-
! Grund durchführen. ! zontal ground.
Bremssteuerdruck: mini 12 bar Pilot brake pressure : minimum 12 bar [174 PSI]
Maxi 30 bar. Maximum 30 bar [435 PSI]
• Sich vergewissern, daß der Bremsversorgungs- Make sure that the brake supply pressure is zero,
druck gleich Null ist,
• Die Bremse über die höchstgelegene Schraube • Purge the brake using the screw (112) located at
(112) entlüften, the highest level,
• Den Motor mit Maximaldruck beaufschlagen, • Supply the motor up to the setting pressure.
• Die Motorwelle darf sich nicht drehen, da andern- • The motor shaft must not turn, otherwise it is nec-
falls die Bremse ausgetauscht werden muß : essary to replace the brake :
Reparaturen. Repairs.
6500
6501
• Mit Hilfe des Dorns und Ab- • Using a mandrel and an ex-
ziehers (siehe Werkzeug Seite tractor (see tools page 36)
36) (fig 6502) (fig 6502)
• Mit Hilfe des Dorns und einer • Using a mandrel and a
Schraube Klasse 12.9 (siehe screw class 12.9 (see tools 6502
Werkzeug Seite 36) page 36)
• Mit Hilfe des Dorns und einer • Using a mandrel and a press
Presse (fig 6503). Die Kraft F (fig 6503). Respect the force F
beibehalten (siehe Schaubild (see table page 9)
Seite 9)
6503
!
se das Lagerteil nicht auf
den Gewindebolzen ab- ! not place the bearing
support on the studs.
stützen.
108
6508
6513
6511
Wiedereinbau. Reassembly.
Vor dem Wiedereinbau ist unbedingt Before reassembling, it is neces-
sicherzustellen, daß alle Teile, Nuten sary to ensure that all parts, the
und Dichtungs-Auflageflächen sauber surface condition of the piston seal
sind. contact surface and the grooves are
clean.
Es dürfen keine Rost-,
! Schmutz- oder Wasser-
All traces of rust, mud,
spuren vorhanden sein
! water must be removed.
6512
6509
6513
• Mit Hilfe des Dorns und Ab- • Using a mandrel and an ex-
ziehers (siehe Werkzeug Seite tractor (see tools page 36)
36) (fig 6502) (fig 6502)
• Mit Hilfe des Dorns und einer • Using a mandrel and a press
Presse (fig 6503). Die Kraft F (fig 6503). Respect the force F
einbehalten (siehe Schaubild (see table page 9) 6502
Seite 9)
Bei Verwendung der If you use the press do
!
Presse das Lagerteil
nicht auf den Gewinde- ! not place the bearing
support on the studs.
bolzen abstützen.
6503
• Sicherungsring (109) mit Hilfe • Install the snap ring (109) using
einer Zange für Innenringe gemäß internal snap ring pliers in line with
der bei der Demontage ange- the mark made during disassembly
brachten Kennzeichnung montie- . (see tools page 36)
ren: (siehe Werkzeuge Seite 36) 6504 6505
• Abzieher und Zange (fig • Extractor and pliers (fig 6504
6504 und 6505) and 6505)
• Presse und Zange (fig 6506 • Press and pliers (fig 6506
und 6507) and 6507)
6506 6507
6515
6516
!
der Außenrand des
Schutzkappe in die Nut ! edge of the cover is en-
gaged in the groove.
eingreift ist.
6517
6518
040
6519
042
6520
6521
6524
041
6525
071
6522
071
6523
041
6525
Den Nockenring anhand von zwei Center the cam using two screws 6526
einander gegenüberliegenden (042) diametrically opposite.
Schrauben (042) zentrieren.
6521
6527
042
6520
2055
Demontage Disassembly
154.a
6529
6530
154.b
2
6531
6532
154.c
6533
154.1
6534
6535
6536
Wiedereinbau Reassembly
154.2
6536
6535
6537
6538
6539
6532
154.c
6533
6532
154.b
2 6531
154.a
6530
Durchmesser D diameter
6529
Trommeldurchmesser (mm)
Bremsen Drum diameter [in] Total Spiel (mm)
Brake Total clearance [in]
nominal maximum
250 x 60 250 [9.84] 252 [9.92] 0.55 [0.02]
270 x 60 270 [10.63] 272 [10.70] 0.80 [0.03]
325 x 80 325 [12.79] 327 [12.87] 0.80 [0.03]
350 x 60 350 [13.78] 352 [13.85] 0.80 [0.03]
6528
Demontage Disassembly
Dazu die im Kapitel « Auswechseln Do operations described in chapter
des Lagerteils » unter « Demontage » "replacement of the bearing sup-
beschriebenen Arbeiten ausführen, port" section "disassembly" page 16
Seite 16
Wiedereinbau Reassembly
Dazu die im Kapitel « Auswechseln Do operations described in chapter
des Lagerteils » unter " Wiederein- "replacement of the bearing sup-
bau " beschriebenen Arbeiten ausfüh- port" section "reassembly" page 18.
ren, Seite 18. The angular position of the cam
Allerdings muß bei Motoren mit 2 must be respected on dual dis-
Schluckvolumen mit einem placement motors with a displace-
Schluckvolumenverhältnis über ment ratio different from 2.
oder unter 2 die Winkelposition be-
rücksichtigt werden. Example : Motor MS18 with dis-
Beispiel: Motor MS18, Schluckvolu- placement 1747-1049-698.
3
men 1747-1049-698 Small displacement : 698 cm
3
Kleines Schluckvolumen: 698 cm [42.59 cu.in] letter P
Buchstabe P 3
3
Medium displacement : 1049 cm
Mittleres Schluckvolumen: 1 049 cm [64.01 cu.in] letter M.
Buchstabe M The letter P or M must be located in
Die Buchstaben P oder M müssen the axis and towards the displace-
sich in der Achse befinden und in ment change spool, with the blind
Richtung des Schiebers für das hole towards the fixing of the cam
Wechseln des Schluckvolumens on the bearing support.
zeigen, auf der der Nockenring auf
dem Lagerteil befestigt ist.
M P
M P
MS08
MSE08
A R A R
MS18
MSE18
P M
M P
A R A
MS11
MSE11
P M 2035
Demontage Disassembly
6541
Wiedereinbau Reassembly
6542
6541
• Den Verteiler (047) durch An- • Separate the valving (047) from
heben an den Ausrichtungszapfen the cover (041) by levering at the
oder am Flansch vom Verteilerdek- indexing pins or at the flange.
kel (041) abmontieren.
2031
Wiedereinbau Reassembly
1135
• Die Federn (052) in ihr zuvor • Place the springs (052) in their
mit Fett gefülltes Gehäuse einset- housings, previously filled with
zen. grease.
• Die Dichtungsauflageflächen • Lubricate the faces of the seals
des Verteilers (047) fetten. of the valving (047).
• Den Verteiler(047) in den Ver- • Press the valving (047) into the
cover (041).
teilerdeckel (041) drücken
041
047 2031
041
R 047
L
053
6758
R A
053
3 2 2 7
047
R L 041
6757
R A
053
3 2 2 8
SE02 Motor :
SE02 motor : G/L Links D/R Rechts
G/L Left D/R Right
6 9 5 9
6959
S05 Motor :
S05 motor
G/L Links D/R Rechts
G/L Left D/R Right
053
6 9 4 8
6948
Demontage Disassembly
•
• Motor auf Lagerteil stellen • Place the motor on the bearing
(Muttern sind zum Schutz der Ge- support (fitted with nuts for studs
windebolzen aufgesetzt) protection)
• Schrauben (066) herausneh- • Remove the screws (066)
066
men.
6543
6544
6545
6546
Wiedereinbau Reassembly
6547
6548
6544
6543
6550
6551
• Sensor (161) mit dem Träger • Extract the sensor (161) with its
166
(166) abziehen support (166)
161
6552
Wiedereinbau Reassembly
6552
• Sensor (041) in die Bohrung • Push the sensor into the valving
des Verteilerdeckels bis zum Kon- cover (041) until it comes in contact
takt mit dem Zylinderblock (011) with the cylinders block (011),
schieben.
2064
1 5 ° m a x i
6558
6551
6550
6553
• Sechskantschlüssel für
Hex head wrench 13 17 19 22 24
Innensechskantschraube
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
Ø A
Ø B
• Montagewerkzeug
zum Anheben der • Mandrel for reassembling the
Schutzkappe oder zum brake cover or to compress the
F
E
G
Komprimieren der Tel- spring washer.
lerfeder.
Ø C
Ø D
0759
ØA ØB ØC ØD E F G
mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F02
110 [4.3] 100 [4.0] 125 [4.9] 135 [5.3]
F03
F04 M12 50 [1.96] 10 [0.39] 20 [0.78]
F05 125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]
F07
F08
125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F09
F11
50 [1.96] 20 [0.78]
F12 M16
F18 190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46] 10 [0.39]
F19 70 [2.75] 30 [1.18]
F21
Tube to immobi-
Ø 2 5
Ø 1 6
5 5
[2 .1 6 " ]
7 0 0
[2 7 .5 5 " ]
M 1 2 x 1 2 0 M 1 6 x 1 2 0
c l. 1 0 .9
H M 1 2 H M 1 6
Z 1 2 N
A = 2 0 0 A = 2 8 0 A
• Werkzeuge zur me- Tools for me-
F 0 2 F 1 1
chanischen Bremslö- chanical brake F 0 3 F 1 2
sung. release F 0 4 F 1 8
F 0 5 F 1 9 Ø 1 6 .5
F 0 7 F 2 1 [0 .6 4 ]
F 0 8
F 0 9
6 0 x 3 0 5 0 x 5
0987
Dichtungssatz
Seal kit 0988
0990
Dichtungssatz
Seal kit
0989
France
Deutschland Japan
POCLAIN HYDRAULICS GMBH POCLAIN HYDRAULICS KK
Bergstrasse 106 5-4-6 Kugenumashinme
64319 PFUNGSTADT FUJISAWA 251
DEUTSCHLAND JAPAN
Tel.: 49 6157 9474 0 Tel: 81 466 50 4400
Fax: 49 6157 9474 74 Fax: 81 466 50 4422
e-mail: info-deutschland@poclain-hydraulics.com e-mail: info-japan@poclain-hydraulics.com
Nederland USA
POCLAIN HYDRAULICS BENELUX BV POCLAIN HYDRAULICS INC.
Penningweg 32C 7900 Durand Avenue
4879 AM ETTEN-LEUR P.O. BOX 801
NEDERLAND STURTEVANT, WI 53177
USA
Tel.: 31 76 5021152 Tel.: 1 262 554 6739
Fax: 31 76 5012279 Fax: 1 262 554 4860
e-mail: info-netherlands@poclain-hydraulics.com e-mail: info-america@poclain-hydraulics.com
S/N 101 920 001 001 ⇔ 101 920 001 086 BW 141 AD-4
S/N 101 920 011 001 ⇔ 101 920 011 086 BW 151 AD-4
S/N 101 920 001 087 ⇔ 101 920 001 ... BW 141 AD-4
S/N 101 920 011 087 ⇔ 101 920 011 ... BW 151 AD-4
S/N 101 920 101 001 ⇔ 101 920 101 ... BW 151 AC-4
S/N 101 920 001 001 ⇔ 101 920 001 047 BW 141 AD-4
S/N 101 920 201 001 ⇔ 101 920 201 003 BW 141 AD-4 AM
S/N 101 920 101 001 ⇔ 101 920 101 026 BW 151 AC-4
S/N 101 920 411 001 ⇔ 101 920 411 007 BW 151 AC-4 AM
S/N 101 920 011 001 ⇔ 101 920 011 029 BW 151 AD-4
S/N 101 920 211 001 ⇔ 101 920 211 004 BW 151 AD-4 AM
S/N 101 920 311 001 ⇔ 101 920 311 007 BW 154 AD-4
S/N 101 920 511 001 ⇔ 101 920 511 021 BW 154 AD-4 AM
S/N 101 920 111 001 ⇔ 101 920 111 007 BW 161 AC-4
S/N 101 920 021 069 ⇔ 101 920 021 184 BW 161 AD-4
S/N 101 920 041 007 ⇔ 101 920 041 016 BW 161 ADH-4
S/N 101 920 061 001 ⇔ 101 920 061 015 BW 190 AD-4
S/N 101 920 261 001 ⇔ 101 920 261 013 BW 190 AD-4 AM
S/N 101 920 031 003 ⇔ 101 920 031 047 BW 202 AD-4
S/N 101 920 051 001 ⇔ 101 920 051 005 BW 203 AD-4
S/N 101 920 251 001 ⇔ 101 920 251 004 BW 203 AD-4 AM
008 910 92
table of contents: BW 141−4 ....... BW 203−4
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 920 100 04 Stromlaufplan Circuit Diagram
002 920 100 04 Versorgung, Starten, Steckdose supply, starting unit, socket
003 920 100 04 Bremse, Sitzkontakt, Not−Aus brake, seat contact, emergency off
004 920 100 04 Überwachung, Warnsummer monitoring unit, warning buzzer
005 920 100 04 Berieselung, Kantenschneidgerät sprinkler system, edge cutter
Wiring diagram 920 100 04
006 920 100 04 Drehzahlverstellung Motor, Signalhorn motor speed, warning horn
007 920 100 04 Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) illumination, working light (StVZO)
008 920 100 04 Vibration,Fahrstufenumsch.,Rückfahrwarns., Splittstreuer vibration, warning buzzer, chip spreader, speed selection
009 920 100 04 Asphalt Manager, Evib−Meter, Temperatur Asphalt asphalt manager, Evib−meter, temperature asphalt
010 920 100 04 Drucker, BCM 05, GPS printer, BCM 05, GPS
011 920 100 04 Tachograph tachograph
012 920 100 04 Geschwindigkeitsanzeige speedometer
013 920 100 04 Heizung, Klimaanlage heating, air conditioning
014 920 100 04 Kabine cab
015 920 100 04 Kabine cab
016 920 100 04 Arbeitsscheinwerfer ROPS worklamp RORS
BOMAG
017 920 100 04 Hundegang crab walk
01.10.2004
001 001
Kneip Stromlaufplan 920 100 04
01.10.2004
21.4
917
circuit diagram 001
Nallin
918
X2:3−1
X2:1−1 X2:1−2
X2:2−1
21.4
F01
X2:5−1 F105
6:1 Sicherung F05
X2:6−1 F37 fuse
5:2 X2:2−2 Sicherung
fuse
X2:4−1 F93
9:2
X2:7−1 30
7:6 30 X2:3−2
30 X13:A K11
P0123
P01 2:19
S00
X89:B
X89:A
87 87a
X91:A Zündstartschalter
K30 10:1 ignition switch 15 54 58 19 17
50a
2 X1:10
X13:B X13:C
15 3:1 K11 6:1
X2:9−1
2 F00 Sicherung F119
fuse
Sicherung Battrie
fuse, battery X2:9−2 F119 F119
1 F119 2:13 2:12 6:1
X2:23−1
V01 X1:104
option 1 Meldeleuchte Ladekontrolle
BW161−4 ...202−4 F15 X2:23−2 indicator light, charge control
Sicherung X6:+ 2:14 30 X6:+
fuse 86 1 K05 2:11 X6:+ 4:7
125A H08 3:8
2 K62 R09 H52
X1:27 X6:14 87 87a
BOMAG
30 (5) 85 2 A13 6:2
K08 2
2:14 X1:101 X6:6
P00
87 (6) W D+ X14:A X14:B X1:206
B+ G02 Betriebsstundenzähler X1:29
2:6 operating hour meter
Generator
+ Batterie generator X6:−
3:13 X1:135 X1:103
battery
G01 B+ B− B+ 2
− 2:3
X51:C
50(5) 15(7) S(2)
K11
86 +
Batterietrennschalter 30 50 XS
S30 3 Y01 Y01 Y139 L(1)
switch battery disconnect 2 1 A13 12V
1 85 −
4 X91:B 1 M01 T(4) R(6) 2 31(3)
K31 10:17 B53
R19 − 1 (R)_t K08
1 M− 3:3
BW161−4 ...203−4 Starter BW161...203−4 BW141...154−4 BW161...203−4 X1:127 X1:53
starter 31 3:1
Heizflansch 4:2 Startmehrmenge Magnetventil Minusabgleich 2:5 Kontrollampe Glühüberwachung 2:14 Steckdose
heating−flange start boost fuel solenoid valve boost−fuel indicator light, glow plug
socket
Temperatursensor
temperature switch
Steuergerät Heizflansch
controll unit, heating−flange
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
008 910 92
X1:66 F25 5:1
X23:A 1
X11:A
Initiator Bremse
proximity switch, brake A03.3
S06 8:5
B63 BR/BN 2 4
86 X23:C X23:B
X1:6 MD+ 4:1
X1:67
K22 X6:12
BL/BU SW/BK
85
X11:C X11:B
+
H20
X1:65 X6:− − X6:−
3:15 4:15
Wiring diagram 920 100 04
Meldeleuchte Sitzkontakt
1(15/54)
8 11 indicator light drivers seat 12 14
K22 30
7
A68 H14
3:10 15 8:3
Modul Sitzkontakt
87 87a
modul seat contact (A8) 1
V48
2
6 4 13
5
X1:8 X1:202
9 (GND)
3:3
9:13
BOMAG
S01 Not−Aus−Schalter 11 21 31 X7:9
switch, emergency off S01
3:11
Not−Aus−Schalter
22 X1:205
switch, emergency off 12 22 32
X1:195
X31:1
X1:47 +
X1:136 Warnsummer H82
X1:198 warning buzzer
X6:11 −
86 1
2 V03 Y13 1 K05 Y04 1 + H01
Y04 X31:2
V02
30/40Amp
2 −
BW 141..154−4
V41 1 2
(1) 2 85
M− 2:11 X6:− X6:− 3:15
2:18 M− 4:9
BW 141..154−4 BW 161..203−4
X1:137 X1:63 X1:127 X1:118 X1:53
31 X1:137
2:20 31 4:1
Hubmagnet 2:12 3:3 Bremsventil Meldeleuchte Bremskontrolle Überwachungsmodul
shut off solenoid, engine solenoid valve, brake indicator light, brake monitoring module
01.10.2004
1 1 920 100 04
Kneip Bremse, Sitzkontakt, Not−Aus
21.4
01.10.2004
919
Nallin brake, seat contact, emergency off 003
920
3:20 15
X2:13−1
F129
X2:12−1 F04
21.4
B55
Meldeleuchte 4:8 1 br
Meldeleuchte Wegfahrsperre Hydrauliköltemperatur
R14 p
indicator light,anti−theft device indicator light, hydr.oil temp. X6:20 X7:20
Meldeleuchte Motoröl
indicator light, engine oil pressure X7:+ X7:+ X7:+ 2 gn
4:17 4:15 6:8
Meldeleuchte Motorüberhitzung
H80 H79 H21 idicator ligh, engine overheating H38
X26:2
Meldeleuchte Luftfilter
indicator light, air cleaner X1:72
X7:17 X7:15 X7:7 Differenzdruck Hy.
idicator ligh, hydr.oil filter X1:44
X1:203 2:17 X6:+
X1:54 X1:19
H73 H09 H49 H15 H23 X7:2
4:8
Q
R20
P19
B55
X6:5 X6:16 X6:17 X6:15 X6:13
Wasservorrat
R21
R22
BOMAG
X1:97
X7:− 8:14
X1:196 X6:3
X1:197 X6:4
30 X6:2 X7:6
30 B21 1
K62 K104 X1:24 X1:34
5:10
2:7 X6:− X6:− 4:16 X6:− X6:− 7:6
X1:93 X1:91 X1:92 X1:94 X1:95 X1:96 3:16 4:19
87 87a p 2 X1:125 X1:185
87 87a
X10:2 X10:1
X1:128
X27:1
X1:199
X1:200
gn/gr
R03
br/br
P _t p
2 2 2 2
B124
2 p 2
X7:10 X6:10
MD+ X27:2 M− X6:10
3:20 MD+ 5:1 3:5 M− 6:11
ws/wh
X10:3 8:8
X1:127 X1:127 X1:53
3:20 31 31 5:1
Meldeleuchte Wasser im Diesel
indicator light, water in fuel
Wasserabscheider Meldeleuchte reserve Kraftstoff
Kühlmittelvorrat Motor sensor, water seperator fuel indicator light, fuel oil
indicator light, eng. coolant res.
Geber Kraftstofftank
sender, level gauge
option
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
F37 X2:18−1
2:5 Sicherung
fuse F06
008 910 92
Sicherung
X2:7−1 fuse X2:18−2
F06
F61 F37 17:1
X1:46 4 A03 Modul Vibration
fuse
modul vibration
X1:124
X2:7−2 X2:6−2
Sicherung
Schalter Berieselungspumpe 43 23 33 7
switch, water pump 13
102 X1:69 X9R:3 X9R:5
S114 0
X18:2
8,5VOLT 8:1
44 24 34 14 S82 3 3
X18:1
GND 8:3 S83
Wiring diagram 920 100 04
+
Intervallschalter X18:3 4 4
30 30 interval switch
X1:12
30 30
X1:14
K79 K80 Emulsionsberieselung A01 1−12 X9R:4 X9R:6
emulsion sprinkler K82 K83
5:12 5:11 5:18 5:19
X1:139 X1:140
87a 87 87 87a 87 87a 87 87a
23 13
1 0 2
S19 10
Taster Kantenschneitgerät auf
push button, edge cutter, up
Taster Kantenschneitgerät ab
push button, edge cutter,down
S108
24 14
5:8
X1:119 X1:120
13 5:8 X1:109 X1:111
15/54 A04
BOMAG
Modul Berieselung
S108
30 modul, sprinkler system
X1:145 X1:146 X1:50
87 X1:51
X17:1 X16:1 X1:173
13
+ + S108 86 86
X15:1 14 1 Y20 1
M02 M18 + X1:52 K82 K83
86 86 86
X1:117 2 Y21 2
− − M03 V14 V15 85 85
K104 K80 K79
X17:2 X16:2 − 1 Y99
85 85 85
nur AC−Version
only AC−version
X15:2
2
X1:147 X1:174 X1:118 X1:53 V29 X1:110 X1:112
X1:127 X1:127
4:20 31 31 6:1
ZA Kantenschneidgerät
option edge cutter
01.10.2004
1 1 920 100 04
Kneip Berieselung, Kantenschneidgerät
21.4
01.10.2004
921
Nallin sprinkler system, edge cutter 005
922
K11 K11 7:1
2:19
21.4
2:5 F105
X2:14−1
X2:14−2
F23
10:2
K35 30 K114 30
6:12 6:5
87a 87
87a 87
X1:42 X1:30
86 86 X1:138
K139 K35 2
3
L0R 33 11 23 85 85
S120 0 S03
Meldeleuchte Motordrehzahl Taster Signalhorn
incicator light, motor speed 4
switch warning horn
BOMAG
34 12 24
Schalter Motordrehzahl 4:19 X7:+ X7:+ 8:7
switch motor speed X1:102
X1:105
X1:106
+ H60
X1:60
2:14 A13 −
X7:5
X1:134
X1:16 X1:28
2
87 87a
AUX
86 + AW +
(A7) 2 HW
K114 V47 K139 Y120 B11
85 1 6:11 − −
30 Signalhorn
warning horn
4:15 M− M− 7:8
X1:127 X1:137
5:20 31 31 7:1
Motordrehzahl
motor speed
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
008 910 92
X7:1 Schalter Beleuchtung
X1:38 X6:7
H06 X6:18 X6:19 not. incl. if switch head lights
StVZO Illumination 012
2:5 30 is assembled A15 X6:1 S15
7:20 31 31 8:1
13 F07 X7:8
Sicherung 12 24
15A Schalter Blinker
fuse switch indicator option
S26 S14 S14
X2:7−2 7:11 7:9
14 Warnblinkschalter X6:8 StVZO Beleuchtung
Schalter Arbeitsbeleuchtung X1:37 S37 S37 StVZO illumination
hazard light 7:12 7:10
X1:41
X1:40
entfällt bei
X57:8 X25:4 − 31 31
ZA Splittstreuer
only acc. to option
deliting chip spreader
X58:2 − X58:1 + − + X58:4 X58:7 + − + X58:5
E09 E11 E13 E15
− − −
−
BOMAG
X25:5
X1:35
X1:36
E02 E73 E04 X25:6
+ + + + + + +
X94:1 X5:R2
E11
E10
E13
E15
E12
E14
E09
E09 E11 E13 E15
X25:1
56b − − − − 7:10 7:11 7:12 − − 7:14 7:15 7:16 7:17 −
56b
56b E27 E28 56b E18 E19 49 49a
7:10 7:11 7:12 7:14 7:15 7:16 7:17
31 31 A02
X58:3
31 31
E11
E10
E13
E15
E12
E14
E09
rechts X57:3
right 31
links/left
links X5L:C X5L:C
rechts/right
left Bel. Temp. Asphalt 7:13 7:10
X25:2 illum. temp. asphalt
X5:LC X5:R5
X58:3 7:13 X94:2 Bel. Evib−Meter
illum. Evib−meter M− M− X4:5 X58:3
X1:148 6:20 7:18 7:2 7:11 M− M− 8:9
31 X1:53 X1:110 X1:127
6:20 31 7:9
Arbeitsscheinwerfer Blinkrelais Blinkleuchte VL Blinkleuchte VR Parkleuchte links Parkleuchte rechts Scheinwerfer links
Arbeitsscheinwerfer parking light lh. parking light rh.
working head light indicator relay indicator front,lh. indicator front,rh. head light LH
working head lights
Bel. Geschwindigkeitsanz. Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts Scheinwerfer rechts
ZA illum. speedometer indicator rear,lh indicator rear,rh. tail light,lh tail light,rh head light RH
Splittstreuer
option
Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts
chip spreader indicator rear,lh indicator rear,rh. tail light,lh tail light,rh
01.10.2004
1 1 920 100 04
Kneip Blinkbegrenzung, Arbeitsbeleuchtung (StVZO)
21.4
01.10.2004
923
Nallin illumination, working light (StVZO) 007
924
7:20 K11 K11 9:1
Meldeleuchte 2. Gang
Aufnehmer Fahrhebel F03 X2:15−1 indicator light, 2nd speed range
transducer travel lever Sicherung
Vibrationsschalter man./autom. Fahrstufenschalter
21.4
fuse X2:15−2 switch, vibration, man./autom. speed range selector Schalter vorne hinten Schalter Splittstreuer Schalter Splittmenge
5:13 8,5VOLT 8,5VOLT 12:1 switch front/rear switch, gravel scratter switch quantity,chip
X1:31 8:11 X1:31
8:9
B39 3 X1:31 X7:+ BW161...BW203−4 13 23 13
6:10
X93:2 13 23 + H13
M0A VBH S73
S36
2 −
S08 X7:14 14 13 23
1 L0R
24 13 X7:18
X93:1 X93:3 2 1 14 24 + H33 0
14 24 S74
S02
5:12 GND −
23 14
X1:143 X1:70 X1:144 X1:48 X1:49 4:19 X6:10 X1:7 X1:9 4:20 X7:− X7:− 9:14 X1:11 14 24
X1:1
9 (8,5V)
1 (15/54)
11 (GND) 8
1 (15/54)
14 16 12 14 11 15 X1:13 X1:15
Y31
A71
A03
Modul Vibration 8:10 Modul Vibrationsverriegelung
modul vibration, interlock
modul vibration A71
8:15
15
10 (GND)
13 6 3 5 12 13 5 4 7 8 6
9 (GND)
8:9 3:20 9:1 A03
10 (GND)
R 8:2
9:2
K G 11 23 8:9 A71
1 Schalter Vibration klein/groß
S35 switch, vibration low/high
V46 V45
3:20 H14 (A6) (A5) 12 24
1 2
X1:3 X1:5 V44 (4)
BOMAG
X1:64
1 2
BW161...BW203−4 8:10
A73
X1:126
Y31
9:2
X9L:2
X9R:2
Y57 X1:75 X1:186
X3:1 11:1 X1:83 X1:81
Asphalt
S12 3 S13 3 Manager X77:1 X1:89
+ V2 11:1 X1:87
X28:1 X29:1 X1:118 X1:171
H14
− V08
4 4 X1:77 X1:79 Y30 Y31 V12 V11 V18
1 1
X8:1 X9:1 1 1 Y54 1 1 1 V19 V21 1
1
X3:2
Y56 Y57 2 2 Y131
X9L:1
X9R:1
2 2 2 2 2 Y55 2 2 2 2
V49 V43 X28:2 X29:2
(4) Y66 Y67
1 X8:2 1 X9:2 X77:2
X1:118 X1:63 X1:127 X1:78 7:20 M− M−13:6
X1:84 X1:82 X1:172 X1:88 X1:90
X1:137 X1:80
7:10 31 31 9:1
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
8:6 A03.3
008 910 92
A73
8:13 fuse
5:17 MD+
X20:9 X2:4−2
X2:53 X2:54 X20:25
X2:27−2
F10 RXD
7:17 V27 31 10:2
K11 X2:17−1 X1:59 X2:24−1 X2:25−1 X2:26−1 X20:23
8:20 CAN3+ 10:2 S01 TXD 10:2
V22 3:11 V25 V26
F101 CAN3− 10:2
Sicherung 32
X2:27−1
X20:13 R31 X20:14 B15.2 11:1
X2:17−2 fuse X20:43 X20:44 1 2 X2:24−2 X2:55 X2:25−2 X2:26−2
5
X2:52 F101 9:12 1 R32 2 X20:10 X2:57
Wiring diagram 920 100 04
X88:54
X88:36
X88:14
X88:4
X88:5
X88:35
X88:15
X88:41
X88:53
X88:33
X88:37
X88:56
X88:57
X88:59
X88:60
X88:32
X88:38
X88:58
CAN3+
CAN3−
X88:28
Messtechnik Rechner
A83
measurement calc. unit
X88:27 X88:26
X88:1
X88:3
X88:6
X88:9
X88:7
X88:31
X88:30
X88:65
X88:66
X88:67
X88:55
X88:23
X88:29
X88:68
X88:47
X88:46
AGND
1 2 X20:20 X20:38 X20:35
+ X1:45
BOMAG
X20:1 X20:2 X20:36 X7:11
B106 −
X20:29
X20:30
X20:27
X20:31
X76:D X76:F _t
X20:34
X20:33
X76:A X20:3
X76:B X20:7
X20:17
X20:18
H04
1
CAN+
CAN−
CAN−
CAN+
+ 8:15 X7:− X7:− 13:5
P34 + R30
X80:1
X79:1
X79:4
X79:3
X80:3
+
X80:4
X78:1
X78:2
15
P28 B85 B84 X107:1 X108:1
P33 _t 2
30
weiß/white
CAN2+ P16 − − G Y140 1 Y141 1
rot/reed
F1 F2
X20:5 X76:G CAN2− X20:39 B97
X80:2 X79:2 2 2
X20:6 X76:H − schw/black
GND − − X78:3 X107:2 X108:2
X1:152
X76:C X76:E option X20:19 X20:24 X20:28 X20:32
AGND
X20:4 X20:8 X1:122 X20:40 X20:37 10:2 X2:51 X20:12 X20:16
8:20 31 31 10:1
_J
Display option Evib−Meter Temperatursensor Aufnehmer Verstellmotor Aufnehmer Beschleunigung links Prop−Ventil Erreger auf
Evib−meter
display temperature switch transducer, motor trancducer, acceleration,left solenoid valve exciter up
Diagnose Temperaturanzeige Aufnehmer Beschleunigung rechts Prop−Ventil Erreger ab
diagnostics
temperature gauge, coolant trancducer, acceleration, right solenoid valve exciter down
Meldeleuchte Betriebsstörung
indicator light, breakdown
01.10.2004
1 1 920 100 04
Kneip Asphalt Manager, Evib−Meter, Temperatur Asphalt
21.4
01.10.2004
925
Nallin asphalt manager, Evib−meter, temperature asphalt 009
926
2:6 K30 K30 14:1
F101
21.4
9:15
9:9 CAN3−
9:9 CAN3+
9:19 RXD
TXD
9:19
X103:F X103:E
ST2:4
ST2:3
GPS Antenne
ST1:3 A77 A76 GPS antenna
X103:K
6:19 F23 Spannungsregler Druckerkontroller
X105:1−32
ST1:4 Voltage regulator printer controller
X20:22 X100:K X101:4 1
F150 A93
32 A87 Sicherung
2
BOMAG
USB−CAN Schnittst. fuse
USB−CAN Interface BCM
X106:1−20
20
ST2:5
ST2:6
ST1:1
ST1:2
ST2:1
ST2:2
X101:3 P11
X101:5 X102:1 X102:2 Drucker
3 printer A92
P15 5
S153
4
GPS Receiver
X75:2 GPS receiver
BCM 05 A94
X100:L X100:I BCM05 BCM 05
Papiervorschub
X103:L X103:I paper formfeed
2:4 K31 K31 11:1
X20:26
GPS
9:15 AGND
GPS Antenne
GPS antenna
31 31 12:1
9:20
ZA
option
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
008 910 92
8:7 V2 11:10 BW190 AD−4 11:6 V2 BW151 AD−4
Y57 BW202 AD−4 BW151 AD−4 AM
8:7 Y57 11:10 BW203 AD−4 11:6 Y57 BW151 AC−4
X1:188 X1:187 X1:189 BW161 AD−4 AM X1:188 X1:187 X1:189
BW190 AD−4 AM
X68:B X68:A X68:C BW202 AD−4 AM X68:B X68:A X68:C
BW203 AD−4 AM
2 3 BW144 AD−4 2 3
BW154 AD−4 1 11:7 X67:A X67:A 15:5
4 BW144 AD−4 AM A51
A51 BW154 AD−4 AM
5 1 5 4
Tachomodul Tachomodul
module, tachograph module, tachograph
5 4 4:1 1:3 2:1 1:2
Wiring diagram 920 100 04
A16 A16
2 1 6 3 7.8.9
1:1
5:5
5:4
5:3
5:2
5:1
3:4
3:3
3:2
3:1
6:1
B3
B4
11:4 11:4 X67:B 11:10
B3
B4
BOMAG
B4 B3 A2 A3 A1
A3 B1
A2 B2
P09
P09 C3 A1 B3
A5 B4
Anzeige
indicator
A6 C3
A5 A6 1
G02 15:9 Anzeige R33
indicator
10:20 K31 2 K31 13:1
1.10.2004
1 1 920 100 04
Kneip Tachograph
21.4
1.10.2004
927
Nallin tachograph 011
928
F04 F04
9:8 17:1
21.4
Lernmodus
to learn
Anzeigetest
diagnose
Lern Test
15/54
15/54
11:20 B15.2 IN A05
−
X2:59
X2:59 ZA
option
X1:194 X1:193 X1:192 X1:194 Geschwindigkeitsanzeige
speedometer
X24:4 X24:3 X24:1 X24:4
BOMAG
BW161 AD−4 BW141 AD−4 BW141 AD−4 AM BW151 AC−4
BW161 ADH−4 BW151 AD−4 BW144 AD−4 AM BW161 AC−4 X32:1 X32:2
X30:1
X30:3
X30:2
BW190 AD−4 BW151 AD−4 AM
BW202 AD−4 BW154 AD−4 AM
BW203 AD−4 BW144 AD−4
BW161 AD−4 AM BW154 AD−4
BR/BN
SW/BK
SW/BK
BR/BN
WS/white
SW/BK
BR/BN
BW190 AD−4 AM
BW202 AD−4 AM
BW203 AD−4 AM
B15 B15 B15 B15
X30:4 X32:3
BL/BU
BL/BU
BL/BU
X24:2
X1:191
10:20 31 31 13:12
Aufnehmer Geschwindigkeit
transducer speed
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
008 910 92
B Box 1
F40 F15
0123 S44 Schalter Kabinenlüfter 7 F42 15:5
BOX 1 BOX 1
switch, cabin ventilator Schalter Kabinenheizung
8 switch, cab heating 6
3
L M H C
4 2 A72:2 5
14:15
low
mid
high
A72
Steuergerät S28
control unit 1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
30 option
X65:4
Wiring diagram 920 100 04
X40:1
X50:1 P18
X40:3
X40:2
2
Thermofühler Heizung E30
X43:1 temperature sensor, heating Heizung
4 X49:2 heater timer
B104 P
Überwachung Kühlmitteldruck LP HP
3
monitoring coolant pressure
BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5
X1:207
X1:18 X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
ge rt or ge rt or X56:1 X54:1
X55:1
X21:1 Y15 1 E30 13:18 13:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
17:5 8:11 M− Magnetventil Heizung 12:20 31 31 17:1
solenoid valve, heating unit
X56:2
X40:4 X55:2
11:20 K31 K31 14:1
Kabinenlüfter
cab ventilator Kraftstoffpumpe
fuel pump heating unit
Klimakompressor
air conditioning compr.
ZA ZA
option option
01.10.2004
1 1 920 100 04
Kneip Heizung, Klimaanlage
21.4
01.10.2004
929
Nallin heating, air conditioning 013
930
K30 X91:A
10:20 K30 16:1
X65:1 30 X51:A
6:10 F119
K32
14:17 X63:8
A72:2
87 13:11
30 30 14 S26 13
K 127 K 128 F115 F116
20A 20A
14:12 14:13
87 87a 87 87a 14 1
X66:1 K 129 30 K 130 30 S53
14:14 14:16
87 87a 87 87a
30 5
K118
14:20
X73:B
87 87a
X72:B
X64:2
A88 A89
X75:B
X74:B
BOMAG
A90 A91
X73:A
X72:A
86 86
K 127 K 128
+ +
X69:1
X70:1
X71:1
X39:1
X75:A
X74:A
E23 E25
E23 + + E25 − − 85 85
86 86
+ + K 129 K 130 86 K32 86 K85 86 K118
+ +
− −
E28 E27 E28 E27
− − 85
− − 85 85 85 85
X69:2
X70:2
X71:2
X39:2
13:19 K31 K31 15:1
Arbeitsscheinwerfer vorne Arbeitsscheinwerfer vorne
working lights, front working lights, front
Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten 14:7 14:9 14:10 14:11 14:4 13:2 14:4
working lights, rear working lights, rear
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
008 910 92
13:11 F42 F27 F28
F41
Box 1 X67:A X67:A Box 1 Box 1
11:20 X67:A
1 option Tachograph 2 3
X67:B
11:14 X67:B
S20 S21
0 1 2 7 2 0 1 2 7 2
01 S163 5
01
30
K141 1
5 4 5 4
Wiring diagram 920 100 04
X67:B 15:19
87 87a
X67:B X67:A
1 +
X63:1
X62:1
X63:2
X62:2
S45
X64:5
X64:3
X64:6
X64:8
S38 A12 Radio
radio
1
5 15 30 E71 1
X64:4 S158 + R80
B51 31 B51 2
2
X48:1 option X61:C X61:A
X64:7
max. 13A
BOMAG
+
E32 X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E70 I 15
K141
− − G02 31
11:13
X67:C X46 +
53
53a
31b
53
53a
31b
3 min
+
XS option X44
+ X67:C
53a
Tachograph
Abfallverzögert
12V
E29 M04 M06 M05 M07
53a
31b 53
31
− 2,5A
− 31 − 31 −
31b 53
31
X61:2 X61:2
15:16 15:14
X48:2 X64:1 X44:31 X46:31 X61:B
01.10.2004
1 1 920 100 04
Kneip Kabine
21.4
01.10.2004
931
Nallin cab 015
932
14:20 K30
Schalter Arbeitsscheinwerfer
21.4
switch, worklamp
14:20 F09
13 A
13 S53
S147 F108
1
14
14
A B 30
13 K135
F113 F114 S26
16:14
1 2,5qmm 2 87 87a
30 C D 14
K127 30
K128
16:7 F115 F116
16:9
87 87a 87 87a 3 4
K129 30 30
K130
16:10 16:11
87 87a
87 87a
2,5qmm
BOMAG
86
+ + K127 86 K128 + +
E23 E25 E23 E25
− − − −
85 85 86 86 86
K135
+ + K129 K130 + +
E28 E27 E28 E27
− − 85 85 85 − −
15:20 K31
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
5:17 F06
F04
12:20
008 910 92
Taster Hundegang
push button, crab walk
S115 3 3
S116
X12:A
4
Wiring diagram 920 100 04
4
K138 30 K03 30
BR/BN
B10 17:16 17:18
87 87a 87 87a
BL/BU
SW/BK
X12:B X12:C X9L:4 X9L:6
BOMAG
X1:56
X7:13
86 86
+ 1 Y19 Y18 1 K138 K03
H02
2 2
−
V16 V17 85 85
13:5 X7:−
X1:127 X1:114 X1:116 X1:127
13:15 31 31 18:1
01.10.2004
1 1 920 100 04
Kneip Hundegang
21.4
01.10.2004
933
Nallin crab walk 017
934
A05 P16
21.4
X7:1−20
9 8 7 6 5 4 3 2 1
X6:1−20
A15
Zentralstecker Sammelanzeige (Ansicht von hinten)
mainplug monitoring module (view from backside)
A83
Messtechnik Rechner
measurement calc. unit
BOMAG
8 16 26 40
5 6 7 13 14 15 22 23 24 25 31 32 33 34 38 39
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
X20
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
X88:1−68
blau blau
(Buchse) blue blue
blau
blue
blau
blue
01.10.2004
1 1
008 910 92
Wiring diagram 920 100 04
2 2
008 910 92
V46
V45
2 2
V44 A04 A71 A03 A68
2
V43
1 1 1 1 1 1
2
3 4 5 6 7 8
V42 K11 K05 K114 K03 K22 K35 K62 K79 K80 K82 K83 K138 K139 K104
1
2
2
Wiring diagram 920 100 04
V41
1
2
1
ZA
option
X2:1−26 asphalt
manager
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
V22
V01
V25
V26
V27
51 52 53 54 55 56 57 5859 X2
X13:A−C
60 61
X14:A−B
X89:A−B
BOMAG
R09
F07
F61
F11
F01
F10
F12
F14
F05
F93
F37
F03
F06
F09
F25
F23
F08
F04
F119
F101
F105
F129
ZA
option
A02
X1:1−208
76
V49
78 80 82 84 86 88 90 110 112 114 116 118 127 137 147 148 168 174 191 X1
75 77 79 81 82 83 100 101 102 103 104 105 106 107 108 109 111 113 115 117 119 120 121 122 123 124 125 126 128 129 130 131 132 133 134 135 136 138 139 140 141 142 143 144 145 146 151 152 165 166 167 173 185186 192 193194 198 199 200 204 205 206 208
85 87 89 91 92 93 94 95 96 97 98 99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 149 150 161 162 163 164 171 172 183 183 187 188 189 190 195 196 197 201 202 203 207
blue
blau
blau
blue
blau
blau
blau
blue
blue
blau
blue
blue
blau
blue
01.10.2004
1 1 920 100 04
Kneip Elektrokasten
21.4
935
cross−bonding box 020
Name Bl. Pf. Benennung title TYP
21.4 A01
A02
A02
005
007
020
11
8
1
Intervallschalter
Blinkrelais
Blinkrelais
intervall switch
indicator relay
indicator relay
Wiring diagram4/6X21
920 100 04
WATT
B10 017 6 Naeherungsinitiator Knickgelenk Proximity switch, articulated joint MAX 0,3A
B11 006 18 Signalhorn Warning horn
Bauteilliste
E23 014 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E23 014 7 Arbeitsscheinwerfer vorne links Working head light, front, lh. 3,5A
E23 016 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 3,5A
E23 016 17 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55 WATT
920 100 04
E25 014 3 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E25 014 9 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 3,5A
E25 016 4 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 3,5A
E25 016 18 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55 WATT
E27 007 1 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
101
E27 014 4 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E27 014 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 3,5A
936 E27 016 6 Arbeitsscheinwerfer hinten links BOMAG
Working head light, rear, lh. 3,5A 008 910 92
Name Bl. Pf. Benennung title TYP
E27
E28
016
Wiring diagram 920 100 04
E28 007
014
19
2
2
Arbeitsscheinwerfer hinten links
Arbeitsscheinwerfer hinten rechts
Arbeitsscheinwerfer hinten rechts
Working head light, rear, lh.
Working head light, rear, rh.
Working head light, rear, rh.
55 WATT
55 WATT
55W
21.4
E28 014 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 016 5 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 016 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E29 015 7 Innenleuchte Kabine Inside light, cabin 21W
E30 013 13 Heizgeraet Heating unit
E32 015 3 Kennleuchte Warning light 55W
E70 015 6 Nachtleuchte Night lamp 5W
E71 015 18 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E73 007 6 Beleuchtung, Evib−Meter Illumination, Evib−meter
F108 016 16 Sicherung Scheinwerfer mitte Fuse, head lights middle 25A
F110 014 4 Sicherung Scheinwerfer aussen Fuse, head lights outside 25A
Bauteilliste
21.4 K62
K62
K79
002
020
005
7
9
12
Relais D+
Relais D+
Relais Berieselungspumpe
Relay, D+
Relay, D+
Relay, sprinkler pump
BOSCHW
Wiring diagram 920 100 04
BOSCHW
K79 020 10 Relais Berieselungspumpe Relay, sprinkler pump
K80 005 11 Relais Berieselungspumpe Relay, sprinkler pump BOSCHW
K80 020 11 Relais Berieselungspumpe Relay, sprinkler pump
K82 005 18 Relais Kantenschneidgeraet ab Relay, edge cutter, up BOSCHW
K82 020 12 Relais Kantenschneidgeraet ab Relay, edge cutter, up
K83 005 19 Relais Kantenschneidgeraet auf Relay, edge cutter, down BOSCHW
K83 020 13 Relais Kantenschneidgeraet auf Relay, edge cutter, down
K85 014 18 Umschaltrelais Relay, switch over BOSCHW
K104 005 10 Relais, Stoermeldungen Relay, failure indication BOSCHW
K104 020 15 Relais, Stoermeldungen Relay, failure indication
K114 006 5 Relais Motordrehzahl Relay, engine rpm BOSCHW
Kneip
30.11. 4
S12 008 2 Vibrationsschalter Fahrhebel links Switch, vibration, travel lever, lh.
S13 008 3 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 007 8 Warnblinkschalter Switch, hazard light
S15 007 18 Beleuchtungsschalter StVZO Switch, lighting StVZO
S19 005 5 Emulsionsberieselungsschalter Switch, emulsion sprinkler system
11
S26 016 11 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
S28 013 17 Schalter Kabinenheizung Switch, cabin heating
S30 002 1 Batterietrennschalter Switch, battery disconnect
S35 008 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 008 12 Vibrationsschalter Switch, vibration
103
S53
015
Wiring diagram 920 100 04
S53 014
016
7
20
14
Schalter Kabineninnenleuchte
Schalter Arbeitsbeleuchtung
Schalter Arbeitsbeleuchtung
Switch, cabin inside light
Switch, working lights
Switch, working lights
21.4
S73 008 15 Schalter Splittstreuer Switch, gravel scratter
S74 008 17 Schalter Splittmenge Switch, gravel quantity
S82 005 18 Taster Kantenschneidgeraet abwaerts Push button, edge cutter, down MAX 0,2A
S83 005 19 Taster Kantenschneidgeraet auf Push button, edge cutter, up MAX 0,2A
S108 005 8 Schalter Berieselung Kantenschneidgeraet Switch,sprinkler sys.edge cutter
S114 005 7 Schalter Wasserpumpe Switch, water pump
S115 017 16 Taster, Hundehang links Push button, crab walk, lh.
S116 017 18 Taster, Hundegang rechts Push button, crab walk, rh.
S117 007 3 Schalter Steckdose Switch, socket
S120 006 4 Schalter Motordrehzahl Switch, engine speed
S147 014 13 Schalter Arbeitsbeleuchtung Switch, working lights
Kneip
30.11. 4
21.4 X1:34
X1:35
X1:36
004
007
007
17
8
8
ELEKTROKASTEN
Elektrokasten
Elektrokasten
Cross−bonding box
Cross−bonding box
Cross−bonding box
Wiring diagram 920 100 04
X1:37 007 8 Elektrokasten Cross−bonding box
X1:38 007 4 Elektrokasten Cross−bonding box
X1:39 007 18 Elektrokasten Cross−bonding box
X1:40 007 18 Elektrokasten Cross−bonding box
X1:41 007 19 Elektrokasten Cross−bonding box
X1:42 006 5 Elektrokasten Cross−bonding box
X1:43 003 11 ELEKTROKASTEN Cross−bonding box
X1:44 004 20 ELEKTROKASTEN Cross−bonding box
X1:45 009 14 ELEKTROKASTEN Cross−bonding box
X1:46 005 7 ELEKTROKASTEN Cross−bonding box
X1:47 003 11 ELEKTROKASTEN Cross−bonding box
Kneip
30.11. 4
X1:127
003
Wiring diagram 920 100 04
X1:127 004
004
8
4
16
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
21.4
X1:127 005 12 ELEKTROKASTEN Cross−bonding box
X1:127 005 18 ELEKTROKASTEN Cross−bonding box
X1:127 006 5 Elektrokasten Cross−bonding box
X1:127 007 12 Elektrokasten Cross−bonding box
X1:127 008 4 ELEKTROKASTEN Cross−bonding box
X1:127 017 6 ELEKTROKASTEN Cross−bonding box
X1:127 017 18 ELEKTROKASTEN Cross−bonding box
X1:128 004 4 ELEKTROKASTEN Cross−bonding box
X1:129 007 4 Elektrokasten Cross−bonding box
X1:130 017 6 ELEKTROKASTEN Cross−bonding box
X1:131 017 6 ELEKTROKASTEN Cross−bonding box
Kneip
30.11. 4
21.4 X2:18−1
X2:18−2
X2:19−1
005
005
007
7
7
14
ELEKTROKASTEN
ELEKTROKASTEN
Elektrokasten
Cross−bonding box
Cross−bonding box
Cross−bonding box
Wiring diagram 920 100 04
X2:19−2 007 14 Elektrokasten Cross−bonding box
X2:20−1 007 16 Elektrokasten Cross−bonding box
X2:20−2 007 17 Elektrokasten Cross−bonding box
X2:21−1 007 19 Elektrokasten Cross−bonding box
X2:21−2 007 19 Elektrokasten Cross−bonding box
X2:22−1 007 20 Elektrokasten Cross−bonding box
X2:22−2 007 20 Elektrokasten Cross−bonding box
X2:23−1 002 7 ELEKTROKASTEN Cross−bonding box
X2:23−2 002 7 ELEKTROKASTEN Cross−bonding box
X2:24−1 009 12 ELEKTROKASTEN Cross−bonding box
X2:24−2 009 12 ELEKTROKASTEN Cross−bonding box
Kneip
30.11. 4
X12:C
017
Wiring diagram 920 100 04
X12:B 017
017
6
6
6
KNICKGELENK
KNICKGELENK
KNICKGELENK
Articulated joint
Articulated joint
Articulated joint
21.4
X13:A 002 11 FAHRERSTAND Operators platform
X13:A−C 020 3 ELEKTROKASTEN Cross−bonding box
X13:B 002 11 FAHRERSTAND Operators platform
X13:C 002 12 FAHRERSTAND Operators platform
X14:A 002 12 FAHRERSTAND Operators platform
X14:A−B 020 2 ELEKTROKASTEN Cross−bonding box
X14:B 002 12 FAHRERSTAND Operators platform
X15:1 005 5 EMULSIONSPUMPE Emulsion sprinkler pump
X15:2 005 5 EMULSIONSPUMPE Emulsion sprinkler pump
X16:1 005 2 BERIESELUNGSPUMPE Sprinkler pump
X16:2 005 2 BERIESELUNGSPUMPE Sprinkler pump
Kneip
30.11. 4
21.4 X30:3
X30:4
X31:1
012
012
003
6
6
18
Bandage
Bandage
LENKSAEULE
Roller drum
Roller drum
Steering column
Wiring diagram 920 100 04
X31:2 003 18 LENKSAEULE Steering column
X32:1 012 14 Bandage Roller drum
X32:2 012 15 Bandage Roller drum
X32:3 012 14 Bandage Roller drum
X39:1 014 4 Kabine cabin
X39:2 014 4 Kabine cabin
X40:1 013 1 Kabine cabin
X40:2 013 2 Kabine cabin
X40:3 013 3 Kabine cabin
X40:4 013 3 Kabine cabin
X42:1 013 2 Kabine cabin
Kneip
30.11. 4
X67:C
015
Wiring diagram 920 100 04
X67:C 015
015
9
9
9
Kabine
Kabine
Kabine
cabin
cabin
cabin
21.4
X67:C 015 9 Kabine cabin
X68:A 011 3 KABINE Cabin
X68:A 011 13 KABINE Cabin
X68:B 011 2 KABINE Cabin
X68:B 011 12 KABINE Cabin
X68:C 011 8 KABINE Cabin
X68:C 011 16 KABINE Cabin
X69:1 014 2 Kabine cabin
X69:2 014 2 Kabine cabin
X70:1 014 2 Kabine cabin
X70:2 014 2 Kabine cabin
Kneip
30.11. 4
21.4 X9L:2
X9L:3
X9L:4
008
017
017
2
16
16
SITZKONSOLE
SITZKONSOLE
SITZKONSOLE
Seating unit
Seating unit
Seating unit
Wiring diagram 920 100 04
X9L:5 017 18 SITZKONSOLE Seating unit
X9L:6 017 18 SITZKONSOLE Seating unit
X9R:1 008 3 SITZKONSOLE Seating unit
X9R:2 008 3 SITZKONSOLE Seating unit
X9R:3 005 18 SITZKONSOLE Seating unit
X9R:4 005 18 SITZKONSOLE Seating unit
X9R:5 005 19 SITZKONSOLE Seating unit
X9R:6 005 19 SITZKONSOLE Seating unit
X100:E 010 8 DRUCKER Printer
X100:F 010 7 DRUCKER Printer
X100:I 010 7 DRUCKER Printer
Kneip
30.11. 4
Y01 002 9 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y01 002 10 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y04 003 10 Magnetventil Bremse Solenoid valve, brake 2,1A
Y04 003 11 Magnetventil Bremse Solenoid valve, brake 2,1A
Y13 003 3 Hubmagnet Motor Shut off solenoid, engine 4A
Y14 013 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit 2A
Y15 013 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y18 017 12 Magnetventil Hundegang Solenoid valve, crab walk 2,5A
component listing
S/N 101 920 001 048 ⇔ 101 920 001 049 BW 141 AD-4
S/N 101 920 201 004 ⇔ 101 920 201 005 BW 141 AD-4 AM
S/N 101 920 101 027 ⇔ 101 920 101 037 BW 151 AC-4
S/N 101 920 411 008 ⇔ 101 920 411 008 BW 151 AC-4 AM
S/N 101 920 011 030 ⇔ 101 920 011 039 BW 151 AD-4
S/N 101 920 211 005 ⇔ 101 920 211 007 BW 151 AD-4 AM
S/N 101 920 311 008 ⇔ 101 920 311 011 BW 154 AD-4
S/N 101 920 511 022 ⇔ 101 920 511 028 BW 154 AD-4 AM
S/N 101 920 111 008 ⇔ 101 920 111 008 BW 161 AC-4
S/N 101 920 021 185 ⇔ 101 920 021 198 BW 161 AD-4
S/N 101 920 041 017 ⇔ 101 920 041 017 BW 161 ADH-4
S/N 101 920 061 016 ⇔ 101 920 061 017 BW 190 AD-4
S/N 101 920 261 014 ⇔ 101 920 261 015 BW 190 AD-4 AM
S/N 101 920 031 048 ⇔ 101 920 031 055 BW 202 AD-4
S/N 101 920 051 006 ⇔ 101 920 051 008 BW 203 AD-4
S/N 101 920 251 005 ⇔ 101 920 251 007 BW 203 AD-4 AM
008 910 92
table of contents: BW 141−4 ....... BW 203−4 family
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 920 100 05 Stromlaufplan Circuit Diagram
002 920 100 05 Versorgung, Starten, Steckdose supply, starting unit, socket
003 920 100 05 Bremse, Sitzkontakt, Not−Aus brake, seat contact, emergency off
004 920 100 05 Überwachung, Warnsummer monitoring unit, warning buzzer
005 920 100 05 Berieselung, Kantenschneidgerät sprinkler system, edge cutter
Wiring diagram 920 100 05
006 920 100 05 Drehzahlverstellung Motor, Signalhorn motor speed, warning horn
007 920 100 05 Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) illumination, working light (StVZO)
008 920 100 05 Vibration,Fahrstufenumsch.,Rückfahrwarns., Splittstreuer vibration, warning buzzer, chip spreader, speed selection
009 920 100 05 Asphalt Manager, Evib−Meter, Temperatur Asphalt asphalt manager, Evib−meter, temperature asphalt
010 920 100 05 Drucker, BCM 05, GPS printer, BCM 05, GPS
011 920 100 05 Tachograph tachograph
012 920 100 05 Geschwindigkeitsanzeige speedometer
013 920 100 05 Heizung, Klimaanlage heating, air conditioning
014 920 100 05 Kabine cab
015 920 100 05 Kabine cab
016 920 100 05 Arbeitsscheinwerfer ROPS worklamp RORS
BOMAG
017 920 100 05 Hundegang crab walk
10.02.2005
001 001
Kneip Stromlaufplan 920 100 05
10.02.2005
21.5
949
circuit diagram 001
Nallin
950
X2:3−1
X2:1−1 X2:1−2
X2:2−1
21.5
F01
X2:5−1 F105
6:1 Sicherung F05
X2:6−1 F37 fuse
5:2 X2:2−2 Sicherung
fuse
X2:4−1 F93
9:2
X2:7−1 30
7:6 30 X2:3−2
30 X13:A K11
P0123
P01 2:19
S00
X89:B
X89:A
87 87a
X91:A Zündstartschalter
K30 10:1 ignition switch 15 54 58 19 17
50a
2 X1:10
X13:B X13:C
15 3:1 K11 6:1
X2:9−1
2 F00 Sicherung F119
fuse
Sicherung Battrie
fuse, battery X2:9−2 F119 F119
1 F119 2:13 2:12 6:1
X2:23−1
V01 X1:104
option 1 Meldeleuchte Ladekontrolle
BW161−4 ...202−4 F15 X2:23−2 indicator light, charge control
Sicherung X6:+ 2:14 30 X6:+
fuse 86 1 K05 2:11 X6:+ 4:5
125A H08 3:8
2 K62 R09 H52
X1:27 X6:14 87 87a
BOMAG
30 (5) 85 2 A13 6:2
K08 2
2:14 X1:101 X6:6
P00
87 (6) W D+ X14:A X14:B X1:206
B+ G02 Betriebsstundenzähler X1:29
2:6 operating hour meter
Generator
+ Batterie generator X6:−
3:13 X1:135 X1:103
battery
G01 B+ B− B+ 2
− 2:3
X51:C
50(5) 15(7) S(2)
K11
86 +
Batterietrennschalter 30 50 XS
S30 3 Y01 Y01 Y139 L(1)
switch battery disconnect 2 1 A13 12V
1 85 −
4 X91:B 1 M01 T(4) R(6) 2 31(3)
K31 10:17 B53
R19 − 1 (R)_t K08
1 M− 3:3
BW161−4 ...203−4 Starter BW161...203−4 BW141...154−4 BW161...203−4 X1:127 X1:53
starter 31 3:1
Heizflansch 4:2 Startmehrmenge Magnetventil Minusabgleich 2:5 Kontrollampe Glühüberwachung 2:14 Steckdose
heating−flange start boost fuel solenoid valve boost−fuel indicator light, glow plug
socket
Temperatursensor
temperature switch
Steuergerät Heizflansch
controll unit, heating−flange
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
008 910 92
X1:66 F25 5:1
X23:A 1
X11:A
Initiator Bremse
proximity switch, brake A03.3
S06 8:5
B63 BR/BN 2 4
86 X23:C X23:B
X1:6 MD+ 4:1
X1:67
K22 X6:12
BL/BU SW/BK
85
X11:C X11:B
+
H20
X1:65 X6:− − X6:−
3:15 4:13
Wiring diagram 920 100 05
Meldeleuchte Sitzkontakt
1(15/54)
8 11 indicator light drivers seat 12 14
K22 30
7
A68 H14
3:10 15 8:3
Modul Sitzkontakt
87 87a
modul seat contact (A8) 1
V48
2
6 4 13
5
B63
8:6 X1:8 X1:202
9 (GND)
3:3
9:13
BOMAG
S01 Not−Aus−Schalter 11 21 31 X7:9
switch, emergency off S01
3:11
Not−Aus−Schalter
22 X1:205
switch, emergency off 12 22 32
X1:195
X31:1
X1:47 +
X1:136 Warnsummer H82
X1:198 warning buzzer
X6:11 −
86 1
2 V03 Y13 1 K05 Y04 1 + H01
Y04 X31:2
V02
30/40Amp
2 −
BW 141..154−4
V41 1 2
(1) 2 85
M− 2:11 X6:− X6:− 3:15
2:18 M− 4:7
BW 141..154−4 BW 161..203−4
X1:137 X1:63 X1:127 X1:118 X1:53
31 X1:137
2:20 31 4:1
Hubmagnet 2:12 3:3 Bremsventil Meldeleuchte Bremskontrolle Überwachungsmodul
shut off solenoid, engine solenoid valve, brake indicator light, brake monitoring module
10.02.2005
1 1 920 100 05
Kneip Bremse, Sitzkontakt, Not−Aus
21.5
10.02.2005
951
Nallin brake, seat contact, emergency off 003
952
3:20 15
X2:13−1
F129
X2:12−1 F04
21.5
X1:72
X6:5 X6:16 X6:17 X6:15 X6:13
X7:15
X1:44
X7:2
R21
R22
H70
Tankanzeige
R20
level gauge
Q
X6:3
X6:4
P01
X1:17 X1:20 X1:21 X1:22 X1:23 Q X1:54 P19
1 X6:2
V42 Wasservorrat
(A2) water gauge
2
B20
3:17
BOMAG
X1:97
X7:− 17:5
X1:196
X1:197
30 X1:24 X1:34
B21 1 30
K62 K104
5:10
2:7 X6:− X6:−
X1:92 X1:91 X1:94 X1:95 X1:96 3:16 7:6
87 87a p 2 X1:125 X1:185
87 87a
X10:2 X10:1
X1:128
X27:1
X1:199
X1:200
gn/gr
1 1 1 1 B33
R03
P _t p
2 2 2 2
br/br B124
p 2 2
X6:10 X7:10
X27:2
ws/wh
3:20 MD+ MD+ 5:1 3:5 M− M− 6:11
X10:3
X1:53 X1:127 X1:127 X1:53
3:20 31 31 5:1
Kühlmittelvorrat Motor Meldeleuchte Wasser im Diesel Wasserrestmenge
indicator light, eng. coolant res. indicator light, water in fuel water tank residual quantity
Wasserabscheider Geber Kraftstofftank
option sensor, water seperator fuel sender, level gauge
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
F37 X2:18−1
2:5 Sicherung
fuse F06
008 910 92
Sicherung
X2:7−1 fuse X2:18−2
F06
F61 F37 17:1
X1:46 4 A03 Modul Vibration
fuse
modul vibration
X1:124
X2:7−2 X2:6−2
Sicherung
Schalter Berieselungspumpe 43 23 33 7
switch, water pump 13
102 X1:69 X9R:3 X9R:5
S114 0
X18:2
8,5VOLT 8:1
44 24 34 14 S82 3 3
X18:1
GND 8:3 S83
Wiring diagram 920 100 05
+
Intervallschalter X18:3 4 4
30 30 interval switch
X1:12
30 30
X1:14
K79 K80 Emulsionsberieselung A01 1−12 X9R:4 X9R:6
emulsion sprinkler K82 K83
5:12 5:11 5:18 5:19
X1:139 X1:140
87a 87 87 87a 87 87a 87 87a
23 13
1 0 2
S19 10
Taster Kantenschneitgerät auf
push button, edge cutter, up
Taster Kantenschneitgerät ab
push button, edge cutter,down
S108
24 14
5:8
X1:119 X1:120
13 5:8 X1:109 X1:111
15/54 A04
BOMAG
Modul Berieselung
S108
30 modul, sprinkler system
X1:145 X1:146 X1:50
87 X1:51
X17:1 X16:1 X1:173
13
+ + S108 86 86
X15:1 14 1 Y20 1
M02 M18 + X1:52 K82 K83
86 86 86
X1:117 2 Y21 2
− − M03 V14 V15 85 85
K104 K80 K79
X17:2 X16:2 − 1 Y99
85 85 85
nur AC−Version
only AC−version
X15:2
2
X1:147 X1:174 X1:118 X1:53 V29 X1:110 X1:112
X1:127 X1:127
4:20 31 31 6:1
ZA Kantenschneidgerät
option edge cutter
10.02.2005
1 1 920 100 05
Kneip Berieselung, Kantenschneidgerät
21.5
10.02.2005
953
Nallin sprinkler system, edge cutter 005
954
K11 K11 7:1
2:19
21.5
2:5 F105
X2:14−1
X2:14−2
F23
10:2
K35 30 K114 30
6:12 6:5
87a 87
87a 87
X1:42 X1:30
86 86 X1:138
K139 K35 2
3
L0R 33 11 23 85 85
S120 0 S03
Meldeleuchte Motordrehzahl Taster Signalhorn
incicator light, motor speed 4
switch warning horn
BOMAG
34 12 24
Schalter Motordrehzahl 4:19 X7:+
switch motor speed X1:102
X1:105
X1:106
+ H60
X1:60
2:14 A13 −
X7:5
X1:134
X1:16 X1:28
2
87 87a
AUX
86 + AW +
(A7) 2 HW
K114 V47 K139 Y120 B11
85 1 6:11 − −
30 Signalhorn
warning horn
4:13 M− M− 7:8
X1:127 X1:137
5:20 31 31 7:1
Motordrehzahl
motor speed
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
008 910 92
Schalter Beleuchtung
X1:38 X6:7
H06 X6:18 X6:19 not. incl. if switch head lights
StVZO Illumination 012
2:5 30 is assembled A15 S15
7:20 31 31 8:1
13 F07 X7:8
Sicherung 12 24
15A Schalter Blinker
fuse switch indicator option
S26 S14 S14
X2:7−2 7:11 7:9
14 Warnblinkschalter X6:8 StVZO Beleuchtung
Schalter Arbeitsbeleuchtung X1:37 S37 S37 StVZO illumination
hazard light 7:12 7:10
X1:41
X1:40
entfällt bei
X57:8 X25:4 − 31 31
ZA Splittstreuer
only acc. to option
deliting chip spreader
X58:2 − X58:1 + − + X58:4 X58:7 + − + X58:5
E09 E11 E13 E15
− − −
−
BOMAG
X25:5
X1:35
X1:36
E02 E73 E04 X25:6
+ + + + + + +
X94:1 X5:R2
E11
E10
E13
E15
E12
E14
E09
E09 E11 E13 E15
X25:1
56b − − − − 7:10 7:11 7:12 − − 7:14 7:15 7:16 7:17 −
56b
56b E27 E28 56b E18 E19 49 49a
7:10 7:11 7:12 7:14 7:15 7:16 7:17
31 31 A02
X58:3
31 31
E11
E10
E13
E15
E12
E14
E09
rechts X57:3
right 31
links/left
links X5L:C X5L:C
rechts/right
left Bel. Temp. Asphalt 7:13 7:10
X25:2 illum. temp. asphalt
X5:LC X5:R5
X58:3 7:13 X94:2 Bel. Evib−Meter
illum. Evib−meter M− M− X4:5 X58:3
X1:148 6:20 7:18 7:2 7:11 M− M− 8:9
31 X1:53 X1:110 X1:127
6:20 31 7:9
Arbeitsscheinwerfer Blinkrelais Blinkleuchte VL Blinkleuchte VR Parkleuchte links Parkleuchte rechts Scheinwerfer links
Arbeitsscheinwerfer parking light lh. parking light rh.
working head light indicator relay indicator front,lh. indicator front,rh. head light LH
working head lights
Bel. Geschwindigkeitsanz. Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts Scheinwerfer rechts
ZA illum. speedometer indicator rear,lh indicator rear,rh. tail light,lh tail light,rh head light RH
Splittstreuer
option
Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts
chip spreader indicator rear,lh indicator rear,rh. tail light,lh tail light,rh
10.02.2005
1 1 920 100 05
Kneip Blinkbegrenzung, Arbeitsbeleuchtung (StVZO)
21.5
10.02.2005
955
Nallin illumination, working light (StVZO) 007
956
7:20 K11 K11 9:1
fuse X2:15−2 switch, vibration, man./autom. speed range selector Schalter vorne hinten Schalter Splittstreuer Schalter Splittmenge
5:13 8,5VOLT 8,5VOLT 12:1 switch front/rear switch, gravel scratter switch quantity,chip
X1:31 8:11 X1:31
8:9
B39 3 X1:31 BW161...BW203−4 13 23
X93:2
23 23 VBH
S36
2
S08 S36 13 13 23
1 L0R
X93:1 X93:3 3:9 B63 14 24 S73 0
24 24 S74
5:12 GND 14
X1:143 X1:70 X1:144 X1:49 X1:1 X1:7 X1:9 X1:11 14 24
1 (15/54)
9 (8,5V) 11 (GND) 8
1 (15/54)
14 16 12 14 11 15 X1:13 X1:15
Y31
A71
A03
Modul Vibration 8:10 Modul Vibrationsverriegelung
modul vibration, interlock
modul vibration A71
8:15
15
10 (GND)
13 6 3 5 12 13 5 4 7 8 6
9 (GND)
8:9 3:20 9:1 A03
10 (GND)
R 8:2
9:2
K G 11 23 8:9 A71
1 Schalter Vibration klein/groß
S35 switch, vibration low/high
V46 V45
3:20 H14 (A6) (A5) 12 24
1 2
X1:3 X1:5 V44 (4)
BOMAG
X1:64
1 2
BW161AD...BW203AD−4 8:10
A73
X1:126
Y31
9:2
X9L:2
X9R:2
Y57 X1:75 X1:186
X3:1 11:1 X1:83 X1:81
Asphalt
S12 3 S13 3 Manager X77:1 X90:1 X1:89
+ V2 11:1 X1:87
X28:1 X29:1 X1:118 X1:171
H14
− V08
4 4 X1:77 X1:79 Y30 Y31 V12 V11 V18
1 1
X8:1 X9:1 1 1 Y54 1 1 1 V19 V21 1
1
X3:2
Y56 Y57 2 2 Y131
X9L:1
X9R:1
2 2 2 2 2 Y55 2 2 2 2
V43 X28:2 X29:2
V49 (4) Y66 Y67
X8:2 1 X9:2 X77:2 X90:2
1
X1:118 X1:63 X1:127 7:20 M− M−13:6 X1:84 X1:82 X1:172 X1:88 X1:90
X1:78 X1:137 X1:80
7:10 31 31 9:1
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
8:6 A03.3
008 910 92
A73
8:13 fuse
5:17 MD+
X20:9 X2:4−2
X2:53 X2:54 X20:25
X2:27−2
F10 RXD
7:17 V27 31 10:2
K11 X2:17−1 X1:59 X2:24−1 X2:25−1 X2:26−1 X20:23
8:20 CAN3+ 10:2 S01 TXD 10:2
V22 3:11 V25 V26
F101 CAN3− 10:2
Sicherung 32
X2:27−1
X20:13 R31 X20:14 B15.2 11:1
X2:17−2 fuse X20:43 X20:44 1 2 X2:24−2 X2:55 X2:25−2 X2:26−2
5
X2:52 F101 9:12 1 R32 2 X20:10 X2:57
Wiring diagram 920 100 05
X88:54
X88:36
X88:14
X88:4
X88:5
X88:35
X88:15
X88:41
X88:53
X88:33
X88:37
X88:56
X88:57
X88:59
X88:60
X88:32
X88:38
X88:58
CAN3+
CAN3−
X88:28
Messtechnik Rechner
A83
measurement calc. unit
X88:27 X88:26
X88:1
X88:3
X88:6
X88:9
X88:7
X88:31
X88:30
X88:65
X88:66
X88:67
X88:55
X88:23
X88:29
X88:68
X88:47
X88:46
AGND
1 2 X20:20 X20:38 X20:35
+
BOMAG
X20:1 X20:2 X20:36
B106 −
X20:29
X20:30
X20:27
X20:31
X76:D X76:F _t
X20:34
X20:33
X76:A X20:3
X76:B X20:7
X20:17
X20:18
1
CAN+
CAN−
CAN−
CAN+
+
P34 + R30
X80:1
X79:1
X79:4
X79:3
X80:3
+
X80:4
X78:1
X78:2
15
P28 B85 B84 X107:1 X108:1
P33 _t 2
30
weiß/white
CAN2+ P16 − − G Y140 1 Y141 1
rot/reed
F1 F2
X20:5 X76:G CAN2− X20:39 B97
X80:2 X79:2 2 2
X20:6 X76:H − schw/black
GND − − X78:3 X107:2 X108:2
X1:152
X76:C X76:E option X20:19 X20:24 X20:28 X20:32
AGND
X20:4 X20:8 X1:122 X20:40 X20:37 10:2 X2:51 X20:12 X20:16
8:20 31 31 10:1
_J
Display option Evib−Meter Temperatursensor Aufnehmer Verstellmotor Aufnehmer Beschleunigung links Prop−Ventil Erreger auf
Evib−meter
display temperature switch transducer, motor trancducer, acceleration,left solenoid valve exciter up
Diagnose Temperaturanzeige Aufnehmer Beschleunigung rechts Prop−Ventil Erreger ab
diagnostics
temperature gauge, coolant trancducer, acceleration, right solenoid valve exciter down
10.02.2005
1 1 920 100 05
Kneip Asphalt Manager, Evib−Meter, Temperatur Asphalt
21.5
10.02.2005
957
Nallin asphalt manager, Evib−meter, temperature asphalt 009
958
2:6 K30 K30 14:1
F101
21.5
9:15
9:9 CAN3−
9:9 CAN3+
9:19 RXD
TXD
9:19
X103:F X103:E
ST2:4
ST2:3
GPS Antenne
ST1:3 A77 A76 GPS antenna
X103:K
6:19 F23 Spannungsregler Druckerkontroller
X105:1−32
ST1:4 Voltage regulator printer controller
X20:22 X100:K X101:4 1
F150 A93
32 A87 Sicherung
2
BOMAG
USB−CAN Schnittst. fuse
USB−CAN Interface BCM
X106:1−20
20
ST2:5
ST2:6
ST1:1
ST1:2
ST2:1
ST2:2
X101:3 P11
X101:5 X102:1 X102:2 Drucker
3 printer A92
P15 5
S153
4
GPS Receiver
X75:2 GPS receiver
BCM 05 A94
X100:L X100:I BCM05 BCM 05
Papiervorschub
X103:L X103:I paper formfeed
2:4 K31 K31 11:1
X20:26
GPS
9:15 AGND
GPS Antenne
GPS antenna
31 31 12:1
9:20
ZA
option
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
008 910 92
8:7 V2 11:10 BW190 AD−4 11:6 V2 BW151 AD−4
Y57 BW202 AD−4 BW151 AD−4 AM
8:7 Y57 11:10 BW203 AD−4 11:6 Y57 BW151 AC−4
X1:188 X1:187 X1:189 BW161 AD−4 AM X1:188 X1:187 X1:189
BW190 AD−4 AM
X68:B X68:A X68:C BW202 AD−4 AM X68:B X68:A X68:C
BW203 AD−4 AM
2 3 BW144 AD−4 2 3
BW154 AD−4 1 11:7 X67:A X67:A 15:5
4 BW144 AD−4 AM A51
A51 BW154 AD−4 AM
5 1 5 4
Tachomodul Tachomodul
module, tachograph module, tachograph
5 4 4:1 1:3 2:1 1:2
Wiring diagram 920 100 05
A16 A16
2 1 6 3 7.8.9
1:1
5:5
5:4
5:3
5:2
5:1
3:4
3:3
3:2
3:1
6:1
B3
B4
11:4 11:4 X67:B 11:10
B3
B4
BOMAG
B4 B3 A2 A3 A1
A3 B1
A2 B2
P09
P09 C3 A1 B3
A5 B4
Anzeige
indicator
A6 C3
A5 A6 1
G02 15:9 Anzeige R33
indicator
10:20 K31 2 K31 13:1
10.02.2005
1 1 920 100 05
Kneip Tachograph
21.5
10.02.2005
959
Nallin tachograph 011
960
F04 F04
9:8 17:1
21.5
Lernmodus
to learn
Anzeigetest
diagnose
Lern Test
15/54
15/54
11:20 B15.2 IN A05
−
X2:59
X2:59 ZA
option
X1:194 X1:193 X1:192 X1:194 Geschwindigkeitsanzeige
speedometer
X24:4 X24:3 X24:1 X24:4
BOMAG
BW161 AD−4 BW141 AD−4 BW141 AD−4 AM BW151 AC−4
BW161 ADH−4 BW151 AD−4 BW144 AD−4 AM BW161 AC−4 X32:1 X32:2
X30:1
X30:3
X30:2
BW190 AD−4 BW151 AD−4 AM
BW202 AD−4 BW154 AD−4 AM
BW203 AD−4 BW144 AD−4
BW161 AD−4 AM BW154 AD−4
BR/BN
SW/BK
SW/BK
BR/BN
WS/white
SW/BK
BR/BN
BW190 AD−4 AM
BW202 AD−4 AM
BW203 AD−4 AM
B15 B15 B15 B15
X30:4 X32:3
BL/BU
BL/BU
BL/BU
X24:2
X1:191
10:20 31 31 13:12
Aufnehmer Geschwindigkeit
transducer speed
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
008 910 92
B Box 1
F40 F15
0123 S44 Schalter Kabinenlüfter 7 F42 15:5
BOX 1 BOX 1
switch, cabin ventilator Schalter Kabinenheizung
8 switch, cab heating 6
3
L M H C
4 2 A72:2 5
14:15
low
mid
high
A72
Steuergerät S28
control unit 1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
30 option
X65:4
Wiring diagram 920 100 05
X40:1
X50:1 P18
X40:3
X40:2
2
Thermofühler Heizung E30
X43:1 temperature sensor, heating Heizung
4 X49:2 heater timer
B104 P
Überwachung Kühlmitteldruck LP HP
3
monitoring coolant pressure
BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5
X1:207
X1:18 X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
ge rt or ge rt or X56:1 X54:1
X55:1
X21:1 Y15 1 E30 13:18 13:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
8:11 M− Magnetventil Heizung 12:20 31 31 17:1
solenoid valve, heating unit
X56:2
X40:4 X55:2
11:20 K31 K31 14:1
Kabinenlüfter
cab ventilator Kraftstoffpumpe
fuel pump heating unit
Klimakompressor
air conditioning compr.
ZA ZA
option option
10.02.2005
1 1 920 100 05
Kneip Heizung, Klimaanlage
21.5
10.02.2005
961
Nallin heating, air conditioning 013
962
K30 X91:A
10:20 K30 16:1
X65:1 30 X51:A
6:10 F119
K32
14:17 X63:8
A72:2
87 13:11
30 30 14 S26 13
K 127 K 128 F115 F116
20A 20A
14:12 14:13
87 87a 87 87a 14 1
X66:1 K 129 30 K 130 30 S53
14:14 14:16
87 87a 87 87a
30 5
K118
14:20
X73:B
87 87a
X72:B
X64:2
A88 A89
X75:B
X74:B
BOMAG
A90 A91
X73:A
X72:A
86 86
K 127 K 128
+ +
X69:1
X70:1
X71:1
X39:1
X75:A
X74:A
E23 E25
E23 + + E25 − − 85 85
86 86
+ + K 129 K 130 86 K32 86 K85 86 K118
+ +
− −
E28 E27 E28 E27
− − 85
− − 85 85 85 85
X69:2
X70:2
X71:2
X39:2
13:19 K31 K31 15:1
Arbeitsscheinwerfer vorne Arbeitsscheinwerfer vorne
working lights, front working lights, front
Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten 14:7 14:9 14:10 14:11 14:4 13:2 14:4
working lights, rear working lights, rear
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
008 910 92
13:11 F42 F27 F28
F41
Box 1 X67:A X67:A Box 1 Box 1
11:20 X67:A
1 option Tachograph 2 3
X67:B
11:14 X67:B
S20 S21
0 1 2 7 2 0 1 2 7 2
01 S163 5
01
30
K141 1
5 4 5 4
Wiring diagram 920 100 05
X67:B 15:19
87 87a
X67:B X67:A
1 +
X63:1
X62:1
X63:2
X62:2
S45
X64:5
X64:3
X64:6
X64:8
S38 A12 Radio
radio
1
5 15 30 E71 1
X64:4 S158 + R80
B51 31 B51 2
2
X48:1 option X61:C X61:A
X64:7
max. 13A
BOMAG
+
E32 X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E70 I 15
K141
− − G02 31
11:13
X67:C X46 +
53
53a
31b
53
53a
31b
3 min
+
XS option X44
+ X67:C
53a
Tachograph
Abfallverzögert
12V
E29 M04 M06 M05 M07
53a
31b 53
31
− 2,5A
− 31 − 31 −
31b 53
31
X61:2 X61:2
15:16 15:14
X48:2 X64:1 X44:31 X46:31 X61:B
10.02.2005
1 1 920 100 05
Kneip Kabine
21.5
10.02.2005
963
Nallin cab 015
964
14:20 K30
Schalter Arbeitsscheinwerfer
21.5
switch, worklamp
14:20 F09
13 A
13 S53
S147 F108
1
14
14
A B 30
13 K135
F113 F114 S26
16:14
1 2,5qmm 2 87 87a
30 C D 14
K127 30
K128
16:7 F115 F116
16:9
87 87a 87 87a 3 4
K129 30 30
K130
16:10 16:11
87 87a
87 87a
2,5qmm
BOMAG
86
+ + K127 86 K128 + +
E23 E25 E23 E25
− − − −
85 85 86 86 86
K135
+ + K129 K130 + +
E28 E27 E28 E27
− − 85 85 85 − −
15:20 K31
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
5:17 F06
F04
12:20
008 910 92
Taster Hundegang
push button, crab walk
S115 3 3
S116
X12:A
4
Wiring diagram 920 100 05
4
K138 30 K03 30
BR/BN
B10 17:16 17:18
87 87a 87 87a
BL/BU
SW/BK
X12:B X12:C X9L:4 X9L:6
BOMAG
X1:56
X7:13
86 86
+ 1 Y19 Y18 1 K138 K03
H02
2 2
−
V16 V17 85 85
4:20 X7:−
X1:127 X1:114 X1:116 X1:127
13:15 31 31 18:1
10.02.2005
1 1 920 100 05
Kneip Hundegang
21.5
10.02.2005
965
Nallin crab walk 017
966
21.5
A68 A05
option
A71 A04
AC−Maschine
A83
0000 Messtechnik Rechner
measurement calc. unit
A03
option
BOMAG
P16
8 16 26 40
5 6 7 13 14 15 22 23 24 25 31 32 33 34 38 39
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
X20
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
X88:1−68
blau blau
(Buchse) blue blue
blau
blue
blau
blue
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
2 2
K11 K05 K114 K03 K22 K35 K62 K79 K80 K82 K83 K138 K139 K104
008 910 92
V46
V45
2 2
V44 ZA
option
2
V43 ZA
1 1 1 1 1 1
2
3 4 5 6 7 8
option
V42
1
2
2
FM1
Wiring diagram 920 100 05
X2:1−26 asphalt
V41 manager
1
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
V22
V01
V25
V26
V27
51 52 53 54 55 56 57 5859 X2
60 61
F07
F61
F11
F01
F10
F12
F14
F05
F93
F37
F03
F06
F09
F25
F23
F08
F04
F119
F101
F105
F129
R09
X13:A−C
X14:A−B
X89:A−B
BOMAG
X1:1−208
V49
76 78 80 82 84 86 88 90 110 112 114 116 118 127 137 147 148 168 174 191 X1
75 77 79 81 82 83 100 101 102 103 104 105 106 107 108 109 111 113 115 117 119 120 121 122 123 124 125 126 128 129 130 131 132 133 134 135 136 138 139 140 141 142 143 144 145 146 151 152 165 166 167 173 185186 192 193194 198 199 200 204 205 206 208
85 87 89 91 92 93 94 95 96 97 98 99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 149 150 161 162 163 164 171 172 183 183 187 188 189 190 195 196 197 201 202 203 207
blue
blau
blau
blue
blau
blau
blau
blue
blue
blau
blue
blue
blau
blue
10.02.2005
1 1 920 100 04
Kneip Elektrokasten
21.5
967
cross−bonding box 020
968
X7:1−20 X6:1−20
21.5
9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1
A15 A15
Zentralstecker Sammelanzeige (Ansicht von hinten) Zentralstecker Sammelanzeige (Ansicht von hinten)
mainplug monitoring module (view from backside) mainplug monitoring module (view from backside)
BOMAG
1 4 6
3 2 1 3 2 1 2 1
5 4 3 2 1
5 3
1
4 3 2 1
2 3 4 5
A16
A51 Elektronik Tachograph
Platine Frequenzanzeige electronic system, tachograph
Printed circuit board,frequenzy m. 1 2 3
10.02.2005
1 1
008 910 92
Wiring diagram 920 100 05
A02
005
Wiring diagram 920 100 05
A02 007
020
11
8
17
Intervallschalter
Blinkrelais
Blinkrelais
intervall switch
indicator relay
indicator relay
4/6X21 WATT 21.5
A03 005 10 Modul Vibration modul, vibration
A03 008 4 Modul Vibration modul, vibration
A03 019 7 Modul Vibration modul, vibration
A04 005 5 Modul Berieselung modul, sprinkler system
A04 019 11 Modul Berieselung modul, sprinkler system
A05 012 16 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer
A05 019 11 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer
A12 015 9 Radio Radio
A13 002 13 Steuergeraet Heizung Control unit, heating
A15 003 20 Ueberwachungsmodul monitoring module
A15 007 15 Ueberwachungsmodul monitoring module
11.2.05
Kneip
11. 2. 5
E23 014 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E23 014 7 Arbeitsscheinwerfer vorne links Working head light, front, lh. 3,5A
E23 016 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 3,5A
E23 016 17 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55 WATT
920 100 05
E25 014 3 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E25 014 9 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 3,5A
E25 016 4 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 3,5A
E25 016 18 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55 WATT
E27 007 1 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
101
E27 014 4 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E27 014 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 3,5A
008 910
E27 92 016 6 Arbeitsscheinwerfer hinten links BOMAG
Working head light, rear, lh. 3,5A 969
Name Bl. Pf. Benennung title TYP
21.5 E27
E28
E28
016
007
014
19
2
2
Arbeitsscheinwerfer hinten links
Arbeitsscheinwerfer hinten rechts
Arbeitsscheinwerfer hinten rechts
Working head light, rear, lh.
Working head light, rear, rh.
Working head light, rear, rh.
55 WATT
Wiring diagram 920 100 05
55 WATT
55W
E28 014 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 016 5 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 016 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E29 015 7 Innenleuchte Kabine Inside light, cabin 21W
E30 013 13 Heizgeraet Heating unit
E32 015 3 Kennleuchte Warning light 55W
E70 015 6 Nachtleuchte Night lamp 5W
E71 015 18 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E73 007 6 Beleuchtung, Evib−Meter Illumination, Evib−meter
F110 014 4 Sicherung Scheinwerfer aussen Fuse, head lights outside 25A
F113 014 7 Sicherung Xenon Arbeitsscheinwerfer 1 Fuse, xenon worklamp 1 20A
F113 016 3 Sicherung Xenon Arbeitsscheinwerfer 1 Fuse, xenon worklamp 1 20A
F114 014 9 Sicherung Xenon Arbeitsscheinwerfer 2 Fuse, xenon worklamp 2 20A
F114 016 4 Sicherung Xenon Arbeitsscheinwerfer 2 Fuse, xenon worklamp 2 20A
F115 014 10 Sicherung Xenon Arbeitsscheinwerfer 3 Fuse, xenon worklamp 3 20A
F115 016 5 Sicherung Xenon Arbeitsscheinwerfer 3 Fuse, xenon worklamp 3 20A
F116 014 11 Sicherung Xenon Arbeitsscheinwerfer 4 Fuse, xenon worklamp 4 20A
F116 016 7 Sicherung Xenon Arbeitsscheinwerfer 4 Fuse, xenon worklamp 4 20A
F119 002 11 Sicherung Motor Fuse, motor 7,5A
F129 004 2 Sicherung, MD+ Fuse, MD+ 15A
F150 010 18 Sicherung GPS Receiver Fuse, GPS receiver 5 AMP
K83
005
Wiring diagram 920 100 05
K82 020
005
18
12
19
Relais Kantenschneidgeraet ab
Relais Kantenschneidgeraet ab
Relais Kantenschneidgeraet auf
Relay, edge cutter, up
Relay, edge cutter, up
Relay, edge cutter, down
BOSCHW
BOSCHW
21.5
K83 020 13 Relais Kantenschneidgeraet auf Relay, edge cutter, down
K85 014 18 Umschaltrelais Relay, switch over BOSCHW
K104 005 10 Relais, Stoermeldungen Relay, failure indication BOSCHW
K104 020 15 Relais, Stoermeldungen Relay, failure indication
K114 006 5 Relais Motordrehzahl Relay, engine rpm BOSCHW
K114 020 6 Relais Motordrehzahl Relay, engine rpm
K118 014 20 Relais Arbeisscheinwerfer Relay, working lights BOSCHW
K127 014 12 Relay, xenon worklamp 1 elay, xenon worklamp 1 BOSCHW
K127 016 7 Relay, xenon worklamp 1 elay, xenon worklamp 1 BOSCHW
K128 014 13 Relay, xenon worklamp 2 elay, xenon worklamp 2 BOSCHW
K128 016 9 Relay, xenon worklamp 2 elay, xenon worklamp 2 BOSCHW
11.2.05
Kneip
11. 2. 5
S26 007 4 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
S26 014 16 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
S26 016 11 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
S28 013 17 Schalter Kabinenheizung Switch, cabin heating
S30 002 1 Batterietrennschalter Switch, battery disconnect
11
21.5 S83
S108
S114
005
005
005
19
8
7
Taster Kantenschneidgeraet auf
Schalter Berieselung Kantenschneidgeraet
Schalter Wasserpumpe
Push button, edge cutter, up
Switch,sprinkler sys.edge cutter
Switch, water pump
MAX 0,2A
Wiring diagram 920 100 05
S115 017 16 Taster, Hundehang links Push button, crab walk, lh.
S116 017 18 Taster, Hundegang rechts Push button, crab walk, rh.
S117 007 3 Schalter Steckdose Switch, socket
S120 006 4 Schalter Motordrehzahl Switch, engine speed
S147 014 13 Schalter Arbeitsbeleuchtung Switch, working lights
S147 016 9 Schalter Arbeitsbeleuchtung Switch, working lights
S153 010 8 Papiervorschub Paper formfeed
S158 015 6 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 015 19 Schalter Heckscheibenheizung switch rear screen heating unit
S166 010 18 Schalter GPS Switch, GPS
11.2.05
Kneip
11. 2. 5
X1:43
007
Wiring diagram 920 100 05
X1:42 006
003
19
5
11
Elektrokasten
Elektrokasten
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
21.5
X1:44 004 20 ELEKTROKASTEN Cross−bonding box
X1:46 005 7 ELEKTROKASTEN Cross−bonding box
X1:47 003 11 ELEKTROKASTEN Cross−bonding box
X1:49 008 7 ELEKTROKASTEN Cross−bonding box
X1:50 005 8 ELEKTROKASTEN Cross−bonding box
X1:51 005 8 ELEKTROKASTEN Cross−bonding box
X1:52 005 8 ELEKTROKASTEN Cross−bonding box
X1:53 002 20 ELEKTROKASTEN Cross−bonding box
X1:53 003 18 ELEKTROKASTEN Cross−bonding box
X1:53 004 14 ELEKTROKASTEN Cross−bonding box
X1:53 004 18 ELEKTROKASTEN Cross−bonding box
11.2.05
Kneip
11. 2. 5
21.5 X1:127
X1:128
X1:129
017
004
007
18
17
4
ELEKTROKASTEN
ELEKTROKASTEN
Elektrokasten
Cross−bonding box
Cross−bonding box
Cross−bonding box
Wiring diagram 920 100 05
X1:130 017 6 ELEKTROKASTEN Cross−bonding box
X1:131 017 6 ELEKTROKASTEN Cross−bonding box
X1:132 007 14 Elektrokasten Cross−bonding box
X1:133 007 17 Elektrokasten Cross−bonding box
X1:134 006 18 Elektrokasten Cross−bonding box
X1:135 002 14 ELEKTROKASTEN Cross−bonding box
X1:136 003 11 ELEKTROKASTEN Cross−bonding box
X1:137 003 2 ELEKTROKASTEN Cross−bonding box
X1:137 003 11 ELEKTROKASTEN Cross−bonding box
X1:137 006 7 Elektrokasten Cross−bonding box
X1:137 008 7 ELEKTROKASTEN Cross−bonding box
11.2.05
Kneip
11. 2. 5
X2:24−1
002
Wiring diagram 920 100 05
X2:23−2 002
009
7
7
12
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
21.5
X2:24−2 009 12 ELEKTROKASTEN Cross−bonding box
X2:25−1 009 16 ELEKTROKASTEN Cross−bonding box
X2:25−2 009 16 ELEKTROKASTEN Cross−bonding box
X2:26−1 009 16 ELEKTROKASTEN Cross−bonding box
X2:26−2 009 16 ELEKTROKASTEN Cross−bonding box
X2:27−1 009 12 ELEKTROKASTEN Cross−bonding box
X2:27−2 009 12 ELEKTROKASTEN Cross−bonding box
X2:51 009 17 ELEKTROKASTEN Cross−bonding box
X2:52 009 2 ELEKTROKASTEN Cross−bonding box
X2:53 009 16 ELEKTROKASTEN Cross−bonding box
X2:54 009 16 ELEKTROKASTEN Cross−bonding box
11.2.05
Kneip
11. 2. 5
21.5 X19:2
X19:3
X19:4
018
018
018
5
5
5
KEYBOARD
KEYBOARD
KEYBOARD
Keyboard
Keyboard
Keyboard
Wiring diagram 920 100 05
X19:5 018 5 KEYBOARD Keyboard
X19:7 018 5 KEYBOARD Keyboard
X19:8 018 12 KEYBOARD Keyboard
X19:9 018 5 KEYBOARD Keyboard
X19:10 018 5 KEYBOARD Keyboard
X19:11 018 5 KEYBOARD Keyboard
X19:12 018 5 KEYBOARD Keyboard
X20:1 009 3 ELEKTROKASTEN Cross−bonding box
X20:1−40 019 16 ELEKTROKASTEN Cross−bonding box
X20:2 009 4 ELEKTROKASTEN Cross−bonding box
X20:3 009 1 ELEKTROKASTEN Cross−bonding box
11.2.05
Kneip
11. 2. 5
X44:53
013
Wiring diagram 920 100 05
X44:31 015
015
7
12
12
FAHRERSTAND
Kabine
Kabine
Operators platform
cabin
cabin
21.5
X44:31b 015 13 Kabine cabin
X44:53a 015 12 Kabine cabin
X45:1 013 3 Kabine cabin
X45:2 013 4 Kabine cabin
X45:3 013 3 Kabine cabin
X45:4 013 3 Kabine cabin
X46:31 015 15 Kabine cabin
X46:53 015 15 Kabine cabin
X46:31b 015 16 Kabine cabin
X46:53a 015 15 Kabine cabin
X48:1 015 3 Kabine cabin
11.2.05
Kneip
11. 2. 5
21.5 X74:2
X74:7
X74:A
010
010
014
15
14
10
BCM05
BCM05
Kabine
BCM05
BCM05
cabin
Wiring diagram 920 100 05
X74:B 014 10 Kabine cabin
X75:1 010 16 BCM05 BCM05
X75:2 010 16 BCM05 BCM05
X75:A 014 11 Kabine cabin
X75:B 014 11 Kabine cabin
X76:A 009 1 ARMATURENPULT Instrument board
X76:B 009 2 ARMATURENPULT Instrument board
X76:C 009 3 ARMATURENPULT Instrument board
X76:D 009 3 ARMATURENPULT Instrument board
X76:E 009 3 ARMATURENPULT Instrument board
X76:F 009 4 ARMATURENPULT Instrument board
11.2.05
Kneip
11. 2. 5
X101:5
010
Wiring diagram 920 100 05
X101:4 010
010
6
4
7
DRUCKER
DRUCKER
DRUCKER
Printer
Printer
Printer
21.5
X102:1 010 8 DRUCKER Printer
X102:2 010 9 DRUCKER Printer
X103:E 010 8 LENKKONSOLE Steering box
X103:F 010 7 LENKKONSOLE Steering box
X103:I 010 7 LENKKONSOLE Steering box
X103:K 010 3 LENKKONSOLE Steering box
X103:L 010 6 LENKKONSOLE Steering box
X105:1−32 010 9 DRUCKER Printer
X106:1−20 010 10 DRUCKER Printer
X107:1 009 18 MOTORRAUM Engine room
X107:2 009 18 MOTORRAUM Engine room
11.2.05
Kneip
11. 2. 5
Y01 002 9 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y01 002 10 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y04 003 10 Magnetventil Bremse Solenoid valve, brake 2,1A
Y04 003 11 Magnetventil Bremse Solenoid valve, brake 2,1A
Y13 003 3 Hubmagnet Motor Shut off solenoid, engine 4A
Y14 013 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit 2A
Y15 013 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y18 017 12 Magnetventil Hundegang Solenoid valve, crab walk 2,5A
Y19 017 10 Magnetventil Hundegang Solenoid valve, crab walk 2,5A
Y20 005 14 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 2,5A
Y21 005 16 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 2,5A
Y30 008 9 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 1,5A
Y31 008 10 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 1,5A
Y54 008 12 Magnetventil Vibration hinten ein Solenoid valve, vibration rear on 3A
Y55 008 13 Magnetventil Vibration vorne ein Solenoid valve, vibration front on 3A
Y56 008 7 Vibration klein Vibration low 2,1A
Y57 008 8 Vibration gross Vibration high 2,1A
Y66 008 15 Magnetventil Hydromotor Solenoid valve, hydraulic motor 1,5A
Y67 008 16 Magnetventil Verstellzylinder Solenoid valve, ajustable zylinder 1,5A
Y99 005 8 Magnetventil Berieselung Kantenschneidgeraet So.valve,sprinkler.sys.edge cutter 1,5A
Y120 006 12 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high 70A/1A
Y131 008 19 Magnetventil Verstellzylinder Solenoid valve, ajustable zylinder 2,1A
Y138 013 9 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
Y139 002 11 Magnetventil Minusangleichung solenoid−valve boost−fuel 4,5AMP.
Y140 009 18 Magnetventil Erreger auf solenoid valve exciter up 1,26A
Y141 009 20 Magnetventil Erreger ab solenoid valve exciter down 1,26A
component listing
Bauteilliste
11
11
920 100 05
111
S/N 101 920 001 050 ⇔ 101 920 001 070 BW 141 AD-4
S/N 101 920 201 006 ⇔ 101 920 201 014 BW 141 AD-4 AM
S/N 101 920 101 038 ⇔ 101 920 101 042 BW 151 AC-4
S/N 101 920 011 039 ⇔ 101 920 011 050 BW 151 AD-4
S/N 101 920 211 008 ⇔ 101 920 211 009 BW 151 AD-4 AM
S/N 101 920 311 012 ⇔ 101 920 311 014 BW 154 AD-4
S/N 101 920 511 029 ⇔ 101 920 511 031 BW 154 AD-4 AM
S/N 101 920 111 009 ⇔ 101 920 111 010 BW 161 AC-4
S/N 101 920 021 199 ⇔ 101 920 021 215 BW 161 AD-4
S/N 101 920 041 018 ⇔ 101 920 041 019 BW 161 ADH-4
S/N 101 920 061 018 ⇔ 101 920 061 020 BW 190 AD-4
S/N 101 920 261 016 ⇔ 101 920 261 018 BW 190 AD-4 AM
S/N 101 920 031 056 ⇔ 101 920 031 058 BW 202 AD-4
S/N 101 920 051 009 ⇔ 101 920 051 011 BW 203 AD-4
S/N 101 920 251 008 ⇔ 101 920 251 011 BW 203 AD-4 AM
008 910 92
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing ï no.
001 920 100 06 Stromlaufplan Circuit Diagram
002 920 100 06 Versorgung, Starten, Steckdose supply, starting unit, socket
003 920 100 06 Bremse, Sitzkontakt, NotïAus brake, seat contact, emergency off
004 920 100 06 Überwachung, Warnsummer monitoring unit, warning buzzer
005 920 100 06 Berieselung, Kantenschneidgerät sprinkler system, edge cutter
Wiring diagram 920 100 06
006 920 100 06 Drehzahlverstellung Motor, Signalhorn motor speed, warning horn
007 920 100 06 Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) illumination, working light (StVZO)
008 920 100 06 Vibration,Fahrstufenumsch.,Rückfahrwarns,Splittstr. vibration, warning buzzer, chip spreader, speed selection
009 920 100 06 ZA Stellkammer Fahrpumpe, PhaseïSynchro option control chamber trav.ïpump, phaseïsynchro
010 920 100 06 Asphalt Manager, EvibïMeter, Temperatur Asphalt asphalt manager, Evibïmeter, temperature asphalt
011 920 100 06 Drucker, BCM 05, GPS printer, BCM 05, GPS
012 920 100 06 Tachograph tachograph
013 920 100 06 Geschwindigkeitsanzeige speedometer
014 920 100 06 Heizung, Klimaanlage heating, air conditioning
015 920 100 06 Kabine cab
016 920 100 06 Kabine cab
BOMAG
017 920 100 06 Arbeitsscheinwerfer ROPS worklamp RORS
018 920 100 06 Hundegang crab walk
019 920 100 06 Diebstahlschutz System anti ï theft system
020
021 920 100 06 Elektrokasten crossïbonding box
022 920 100 06 Elektrokasten crossïbonding box
101 920 100 06 Bauteilliste component listing
21.10.05
001 001
Seis Stromlaufplan 920 100 06
21.10.05
21.6
983
circuit diagram 001
Vogt
984
X2:3ï1
X2:1ï1 X2:1ï2
X2:2ï1
21.6
F01
X2:5ï1 F105
6:1 Sicherung F05
X2:6ï1 F37 fuse
5:2 X2:2ï2 Sicherung
fuse
X2:4ï1 F93
10:2
X2:7ï1 30
7:6 30 X2:3ï2
30 X13:A K11
P0123
P01 2:19
S00
X89:B
X89:A
87 87a
X91:A Zündstartschalter
K30 11:1 ignition switch 15 54 58 19 17
50a
2 X1:10
X13:B X13:C
15 3:1 K11 6:1
X2:9ï1
2 F00 Sicherung F119
fuse
Sicherung Battrie
fuse, battery X2:9ï2 F119 F119
1 F119 2:13 2:12 6:1
X2:23ï1
V01 X1:104
option 1 Meldeleuchte Ladekontrolle
BW161ï4 ...202ï4 F15 X2:23ï2 indicator light, charge control
Sicherung X6:+ 2:14 30 X6:+
fuse 86 1 K05 2:11 X6:+ 4:5
125A H08 3:8
2 K62 R09 H52
X1:27 X6:14 87 87a
BOMAG
30 (5) 85 2 A13 6:2
K08 2
X1:27
2:14 X1:101 9:12 X6:6
P00
87 (6) W D+ X14:A X14:B X1:206
B+ G02 Betriebsstundenzähler X1:29
2:6 operating hour meter
Generator
+ Batterie generator X6:ï
3:13 X1:135 X1:103
battery 2
G01 B+ Bï B+
ï 2:3
X51:C
S182 S182 50(5) 15(7) S(2)
A 2 K11
86 +
Batterietrennschalter 30 50 T XS
S30 3 B 3 L(1)
switch battery disconnect Y01 2 Y01 1 Y139 1 A13 12V
85 ï
4 X91:B 1 M01 T(4) R(6) 2 31(3)
K31 11:17 B53
R19 ï 1 (R)_t K08
1 Mï 3:3
BW161ï4 ...203ï4 Starter BW161...203ï4 BW141...154ï4 BW161...203ï4 X1:127 X1:53
starter 31 3:1
Heizflansch 4:2 Startmehrmenge Magnetventil Minusabgleich 2:5 Kontrollampe Glühüberwachung 2:14 Steckdose
heatingïflange start boost fuel solenoid valve boostïfuel indicator light, glow plug
socket
Schalter Startmehrmenge Temperatursensor
switch boostïfuel temperature switch
Schalter Startmehrmenge Steuergerät Heizflansch
switch boostïfuel controll unit, heatingïflange
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
008 910 92
X1:66 F25 5:1
X23:A 1
X11:A
Initiator Bremse
proximity switch, brake A03.3
S06 8:5
B63 BR/BN 2 4
86 X23:C X23:B
X1:6 MD+ 4:1
X1:67
K22 X6:12
BL/BU SW/BK
85
X11:C X11:B
+
H20
X1:65 X6:ï ï X6:ï
3:15 4:13
Wiring diagram 920 100 06
Meldeleuchte Sitzkontakt
1(15/54)
8 11 indicator light drivers seat 12 14
30 7
K22 A68 H14
15 8:3
3:10 Modul Sitzkontakt
87 87a modul seat contact (A8) 1
V48
2
6 4 13
5
B63
8:6 X1:8 X1:202
9 (GND)
3:3
10:13
BOMAG
S01 NotïAusïSchalter 11 21 31 X7:9
switch, emergency off S01
3:11
NotïAusïSchalter
22 X1:205
switch, emergency off 12 22 32
X1:195
X31:1
X1:47 +
X1:136 Warnsummer H82
X1:198 warning buzzer
X6:11 ï
86 1
2 V03 Y13 1 K05 Y04 1 + H01
Y04 X31:2
V02
30/40Amp
2 ï
BW 141..154ï4
V41 1 2
(1) 2 85
Mï 2:11 X6:ï X6:ï 3:15
2:18 Mï 4:7
BW 141..154ï4 BW 161..203ï4
X1:137 X1:63 X1:127 X1:118 X1:53
31 X1:137
2:20 31 4:1
Hubmagnet 2:12 3:3 Bremsventil Meldeleuchte Bremskontrolle Überwachungsmodul
shut off solenoid, engine solenoid valve, brake indicator light, brake monitoring module
26.07.2005
1 1 920 100 06
Kneip Bremse, Sitzkontakt, NotïAus
10.02.2005
21.6
985
Nallin brake, seat contact, emergency off 003
986
3:20 15
X2:13ï1
F129
X2:12ï1 F04
21.6
X1:72
X6:5 X6:16 X6:17 X6:15 X6:13
X7:15
X1:44
X7:2
R21
R22
H70
Tankanzeige
R20
level gauge
Q
X6:3
X6:4
P01
X1:17 X1:20 X1:21 X1:22 X1:23 Q X1:54 P19
1 X6:2
V42 Wasservorrat
(A2) water gauge
2
B20
3:17
BOMAG
X1:97
X7:ï 18:5
X1:196
X1:197
30 X1:24 X1:34
B21 1 30
K62 K104
5:10
2:7 X6:ï X6:ï
X1:92 X1:91 X1:94 X1:95 X1:96 3:16 7:6
87 87a p 2 X1:125 X1:185
87 87a
X10:2 X10:1
X1:128
X27:1
X1:199
X1:200
gn/gr
1 1 1 B33
R03
P _t p
2 2 2
br/br B124
2 2
X6:10 X7:10
X27:2
ws/wh
3:20 MD+ MD+ 5:1 3:5 Mï Mï 6:11
X10:3
X1:53 X1:127 X1:127 X1:53
3:20 31 31 5:1
Kühlmittelvorrat Motor Meldeleuchte Wasser im Diesel Wasserrestmenge
indicator light, eng. coolant res. indicator light, water in fuel water tank residual quantity
Wasserabscheider Geber Kraftstofftank
option sensor, water seperator fuel sender, level gauge
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
F37 X2:18ï1
2:5 Sicherung
fuse F06
008 910 92
Sicherung
X2:7ï1 fuse X2:18ï2
F06
F61 F37 18:1
X1:46 4 A03 Modul Vibration
fuse
modul vibration
X1:124
X2:7ï2 X2:6ï2
Sicherung
Schalter Berieselungspumpe 43 23 33 7
switch, water pump 13
102 X1:69 X9R:3 X9R:5
S114 0
X18:2
8,5VOLT 8:1
44 24 34 14 S82 3 3
X18:1
GND 8:3 S83
Wiring diagram 920 100 06
+
Intervallschalter X18:3 4 4
30 30 interval switch
X1:12
30 30
X1:14
K79 K80 Emulsionsberieselung A01 1ï12 X9R:4 X9R:6
emulsion sprinkler K82 K83
5:12 5:11 5:18 5:19
X1:139 X1:140
87a 87 87 87a 87 87a 87 87a
23 13
1 0 2
S19 10
Taster Kantenschneitgerät auf
push button, edge cutter, up
Taster Kantenschneitgerät ab
push button, edge cutter,down
S108
24 14
5:8
X1:119 X1:120
13 5:8 X1:109 X1:111
15/54 A04
BOMAG
Modul Berieselung
S108
30 modul, sprinkler system
X1:145 X1:146 X1:50
87 X1:51
X17:1 X16:1 X1:173
13
+ + S108 86 86
X15:1 14 1 Y20 1
M02 M18 + X1:52 K82 K83
86 86 86
X1:117 2 Y21 2
ï ï M03 V14 V15 85 85
K104 K80 K79
X17:2 X16:2 ï 1 Y99
85 85 85
nur ACïVersion
only ACïversion
X15:2
2
X1:147 X1:174 X1:118 X1:53 V29 X1:110 X1:112
X1:127 X1:127
4:20 31 31 6:1
ZA Kantenschneidgerät
option edge cutter
26.07.2005
1 1 920 100 06
Kneip Berieselung, Kantenschneidgerät
10.02.2005
21.6
987
Nallin sprinkler system, edge cutter 005
988
K11 K11 7:1
2:19
21.6
2:5 F105
X2:14ï1
X2:14ï2
F23
11:2
K35 30 K114 30
6:12 6:5
87a 87
87a 87
X1:42 X1:30
86 86 X1:138
K139 K35 2
3
L0R 33 11 23 85 85
S120 0 S03
Meldeleuchte Motordrehzahl Taster Signalhorn
incicator light, motor speed 4
switch warning horn
BOMAG
34 12 24
Schalter Motordrehzahl 4:19 X7:+
switch motor speed X1:102
X1:105
X1:106
+ H60
X1:60
2:14 A13 ï
X7:5
X1:134
X1:16 X1:28
2
87 87a
AUX
86 + AW +
(A7) 2 HW
K114 V47 K139 Y120 B11
85 1 6:11 ï ï
30 Signalhorn
warning horn
4:13 Mï Mï 7:8
X1:127 X1:137
5:20 31 31 7:1
Motordrehzahl
motor speed
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
008 910 92
Schalter Beleuchtung
X1:38 X6:7
H06 X6:18 X6:19 not. incl. if switch head lights
StVZO Illumination 012
2:5 30 is assembled A15 S15
7:20 31 31 8:1
13 F07 X7:8
Sicherung 12 24
15A Schalter Blinker
fuse switch indicator option
S26 S14 S14
X2:7ï2 7:11 7:9
14 Warnblinkschalter X6:8 StVZO Beleuchtung
Schalter Arbeitsbeleuchtung X1:37 S37 S37 StVZO illumination
hazard light 7:12 7:10
X1:41
X1:40
entfällt bei
X57:8 X25:4 ï 31 31
ZA Splittstreuer
only acc. to option
deliting chip spreader
X58:2 ï X58:1 + ï + X58:4 X58:7 + ï + X58:5
E09 E11 E13 E15
ï ï ï
ï
BOMAG
X25:5
X1:35
X1:36
E02 E73 E04 X25:6
+ + + + + + +
X94:1 X5:R2
E11
E10
E13
E15
E12
E14
E09
E09 E11 E13 E15
X25:1
56b ï ï ï ï 7:10 7:11 7:12 ï ï 7:14 7:15 7:16 7:17 ï
56b
56b E27 E28 56b E18 E19 49 49a
7:10 7:11 7:12 7:14 7:15 7:16 7:17
31 31 A02
X58:3
31 31
E11
E10
E13
E15
E12
E14
E09
rechts X57:3
right 31
links/left
links X5L:C X5L:C
rechts/right
left Bel. Temp. Asphalt 7:13 7:10
X25:2 illum. temp. asphalt
X5:LC X5:R5
X58:3 7:13 X94:2 Bel. EvibïMeter
illum. Evibïmeter Mï Mï X4:5 X58:3
X1:148 6:20 7:18 7:2 7:11 Mï Mï 8:9
31 X1:53 X1:110 X1:127
6:20 31 7:9
Begrenzungsleuchte rechts
Arbeitsscheinwerfer Arbeitsscheinwerfer Blinkrelais Blinkleuchte VL Blinkleuchte VR limitation light rh. Scheinwerfer links
working head light indicator relay indicator front,lh. indicator front,rh. Begrenzungsleuchte links head light LH
working head lights
limitation light lh.
ZA Bel. Geschwindigkeitsanz. Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts Scheinwerfer rechts
Splittstreuer illum. speedometer indicator rear,lh indicator rear,rh. tail light,lh tail light,rh head light RH
option
Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts
chip spreader indicator rear,lh indicator rear,rh. tail light,lh tail light,rh
26.07.2005
1 1 920 100 06
Kneip Blinkbegrenzung, Arbeitsbeleuchtung (StVZO)
10.02.2005
21.6
989
Nallin illumination, working light (StVZO) 007
990
7:20 K11 K11 10:1
fuse X2:15ï2 switch, vibration, man./autom. speed range selector Schalter vorne hinten Schalter Splittstreuer Schalter Splittmenge
5:13 8,5VOLT 8,5VOLT 13:1 switch front/rear switch, gravel scratter switch quantity,chip
X1:31 X1:31 8:11
8:10 X1:31 X1:31 9:1
B39 3 X1:31 BW161...BW203ï4 13 23
X93:2
23 23 VBH
S36
2
S08 S02 13 13 23
1 L0R
X93:1 X93:3 3:9 B63 14 24 S73 0
24 24 S74
5:12 GND 14
X1:143 X1:70 X1:144 X1:49 X1:1 X1:7 X1:9 X1:11 14 24
1 (15/54)
9 (8,5V) 11 (GND) 8
1 (15/54)
14 16 12 14 11 15 X1:13 X1:15
Y31
A71
A03
Modul Vibration 8:10 Modul Vibrationsverriegelung
modul vibration, interlock
modul vibration A71
8:15
15
10 (GND)
13 6 3 5 12 13 5 4 7 8 6
9 (GND)
8:9 R 9:12
10 (GND)
10:2
A03
K G 11 23 8:2 8:9 A71
1 Schalter Vibration klein/groß
S35 switch, vibration low/high
V46 V45
3:20 H14 (A6) (A5) 12 24 GA 10:8
1 2
X1:5 V44 (4)
BOMAG
X1:64 X1:3
1 2
BW161AD...BW203ADï4 8:10
Y31
10:2
X9L:2
X9R:2
Y57 X1:75 X1:186 X1:83 9:12
X3:1 12:1
Asphalt X1:81
S12 3 S13 3 Manager X77:1 X90:1 9:12 X1:89
+ V2 12:1 X1:87
X28:1 X29:1 X1:118 X1:171
H14 X1:83 X1:81
ï V08
4 4 X1:77 X1:79 Y30 Y31 V12 V11 V18
1 1
X8:1 X9:1 1 1 Y54 1 1 1 V19 V21 1
1
X3:2
Y56 Y57 2 2 Y131
X9L:1
X9R:1
2 2 2 2 2 Y55 2 2 2 2
V43 X28:2 X29:2
V49 (4) Y66 Y67
X8:2 1 X9:2 X77:2 X90:2
1
X1:118 X1:63 X1:127 7:20 Mï Mï14:6 X1:84 X1:82 X1:172 X1:88 X1:90
X1:78 X1:137 X1:80
7:10 31 31 9:1
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
008 910 92
2:8 X1:27
15/54 GND X1:2
8:9 B16 B17
X1:83
X110:1 X20:54
X110:2 X20:57
X111:1 X20:58
X111:2 X20:61
8:13
+
+
SPEED
SPEED
2
14 CAN+ CANï
X110:4 DIR
X110:3
X111:4 DIR
X111:3
X2:49ï2
diagnosis phaseïsynchro
Diagnose PhaseïSynchro
Wiring diagram 920 100 06
Vib front
Vib rear
Vib on
D+
X20:55
X20:60
(15/54)
X1:153
X109:1
X109:15
X109:16
X109:13
X109:12 X20:59
X109:14 X20:56
X109:2
X109:8
X109:4
X1:155 X109:9
BOMAG
X109:5
X109:6
X20:52 X20:50
2.41A
2.41A
2.41A
Y165 Y172
Y11 1 1
Stellkammer 1
control chamber
2 2 2
8:20 31 31 10:1
Magnetventil PhaseïSynchro 2
solenoid phaseïsynchro 2
Magnetventil PhaseïSynchro 1
solenoid phaseïsynchro 1
18.10.2005
1 1 920 100 06
Seis ZA Stellkammer Fahrpumpe, PhaseïSynchro
18.10.2005
21.6
991
Vogt option control chamber trav.ïpump, phaseïsynchro 009
992
8:4 R
9:6 A03.3
21.6
X2:24ï1
X2:27ï2
CAN3+ 11:2 S01 11:2
V22 V27 3:11 V25 V26
F101 CAN3ï 11:2
Sicherung 32
X20:13 R31 X20:14 B15.2 12:1
X2:17ï2 fuse X20:43 X20:44 1 2 X2:25ï2 X2:26ï2
5
X2:27ï1
1 R32 2 X20:10 X2:57
X2:24ï2
X2:52 F101 10:12
X88:54
X88:36
X88:14
X88:4
X88:5
X88:35
X88:15
X88:41
X88:53
X88:33
X88:37
X88:56
X88:57
X88:59
X88:60
X88:32
X88:38
X88:58
CAN3+
CAN3ï
X88:28
Messtechnik Rechner
A83
measurement calc. unit
X88:27 X88:26
X88:1
X88:3
X88:6
X88:9
X88:7
X88:31
X88:39
X88:30
X88:65
X88:66
X88:67
X88:55
X88:23
X88:29
X88:68
X88:47
X88:46
8:9 GA
AGND
BOMAG
1 2 X20:20 X20:38 X20:35
+
X20:1 X20:2 X20:36
B106 ï
X20:29
X20:30
X20:27
X20:31
X76:D X76:F _t
X20:34
X20:33
X76:A X20:3
X76:B X20:7
X20:17
X20:18
1
CAN+
CANï
CANï
CAN+
+
P34 + R30
X80:1
X79:1
X79:4
X79:3
X80:3
+
X80:4
X78:1
X78:2
15
P28 B85 B84 X107:1 X108:1
P33 _t 2
30
weiß/white
CAN2+ P16 ï ï G Y140 1 Y141 1
rot/reed
F1 F2
X20:5 X76:G CAN2ï X20:39 B97
X80:2 X79:2 2 2
X20:6 X76:H ï schw/black
GND ï ï X78:3 X107:2 X108:2
X1:152
X76:C X76:E option X20:19 X20:24 X20:28 X20:32
AGND
X20:4 X20:8 X1:122 X20:40 X20:37 11:2 X2:51 X20:12 X20:16
9:20 31 31 11:1
_J
Display EvibïMeter Temperatursensor Aufnehmer Verstellmotor Aufnehmer Beschleunigung links PropïVentil Erreger auf
Evibïmeter
display temperature switch transducer, motor trancducer, acceleration,left solenoid valve exciter up
Diagnose Temperaturanzeige Aufnehmer Beschleunigung rechts PropïVentil Erreger ab
diagnostics
temperature gauge, coolant trancducer, acceleration, right solenoid valve exciter down
ZA EïVIBïMeter
option EVIBïmeter
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
10:15 F101
008 910 92
10:9 CAN3ï
10:9 CAN3+
10:19 RXD
TXD
10:19
X103:F X103:E
option TM2
Switch, GPS
1
CAN3+ CAN3ï S166
X101:2 X101:1 X74:7 X74:2 X75:1
5
ST2:4
ST2:3
GPS Antenne
ST1:3 A77 A76 GPS antenna
X103:K
6:19 F23 Spannungsregler Druckerkontroller
X105:1ï32
ST1:4 Voltage regulator printer controller
X20:22 X100:K X101:4 1
F150 A93
32 A87 Sicherung
2
USBïCAN Schnittst. fuse
USBïCAN Interface BCM
BOMAG
X106:1ï20
20
ST2:5
ST2:6
ST1:1
ST1:2
ST2:1
ST2:2
X101:3 P11
X101:5 X102:1 X102:2 Drucker
3 printer A92
P15 5
S153
4
GPS Receiver
X75:2 GPS receiver
BCM 05 A94
X100:L X100:I BCM05 BCM 05
Papiervorschub
X103:L X103:I paper formfeed
2:4 K31 K31 12:1
X20:26
GPS
10:15 AGND
GPS Antenne
GPS antenna
31 31 13:1
10:20
ZA
option
26.07.2005
1 1 920 100 06
Kneip Drucker, BCM 05, GPS
10.02.2005
21.6
993
Nallin printer, BCM 05, GPS 011
994
10:20 B15.2 B15.2 13:1
21.6
5 1 5 4
Tachomodul Tachomodul
module, tachograph module, tachograph
5 4 4:1 1:3 2:1 1:2
A16 A16
2 1 6 3 7.8.9
1:1
5:5
5:4
5:3
5:2
5:1
3:4
3:3
3:2
3:1
6:1
B3
B4
12:4 12:4 X67:B 12:10
B3
B4
BOMAG
B4 B3 A2 A3 A1
A3 B1
A2 B2
P09
P09 C3 A1 B3
A5 B4
Anzeige
indicator
A6 C3
A5 A6 1
G02 16:9 Anzeige R33
indicator
11:20 K31 2 K31 14:1
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
008 910 92
Lernmodus
to learn
Anzeigetest
diagnose
Lern Test
15/54
15/54
12:20 B15.2
IN A05
FM1
Multifuse P04
ï
X2:59
X2:59 ZA
option
X1:194 X1:193 X1:192 X1:194 Geschwindigkeitsanzeige
speedometer
X24:4 X24:3 X24:1 X24:4
BOMAG
BW161 ADï4 BW141 ADï4 BW141 ADï4 AM BW151 ACï4
BW161 ADHï4 BW151 ADï4 BW151 ADï4 AM BW161 ACï4 X32:1 X32:2
X30:1
X30:3
X30:2
BW190 ADï4 BW154 ADï4 AM
BW202 ADï4 BW154 ADï4
BW203 ADï4
BW190 ADï4 AM
BR/BN
SW/BK
SW/BK
BR/BN
WS/white
SW/BK
BR/BN
BW203 ADï4 AM
X30:4 X32:3
BL/BU
BL/BU
BL/BU
X24:2
X1:191
11:20 31 31 14:12
Aufnehmer Geschwindigkeit
transducer speed
26.07.2005
1 1 920 100 06
Kneip Geschwindigkeitsanzeige
10.02.2005
21.6
995
Nallin speedometer 013
996
F31 15:1
D
F31 F40
21.6
Box 1 G 15:2
low
mid
high
A72
Steuergerät S28
control unit 1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
30 option
X65:4
K85 X63:7 X63:4 X63:6 X53:6
15:18
X52:1 15 1 4 7 6
87 87a 1
Diagnose
B103 X49:1 diagnostics
Thermofühler Klimaanlage _t
temperature sensor 2 1
X52:2
_t B131
X40:1
X50:1 P18
X40:3
X40:2
2
Thermofühler Heizung E30
X43:1 temperature sensor, heating Heizung
4 X49:2 heater timer
B104 P
Überwachung Kühlmitteldruck LP HP
3
BOMAG
monitoring coolant pressure
X43:3 X43:4 5 8 10
X53:3
X53:5
X1:207
X1:18 X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
ge rt or ge rt or X56:1 X54:1
X55:1
X21:1 Y15 1 E30 14:18 14:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
8:11 Mï Magnetventil Heizung 13:20 31 31 18:1
solenoid valve, heating unit
X56:2
X40:4 X55:2
12:20 K31 K31 15:1
Kabinenlüfter
cab ventilator Kraftstoffpumpe
fuel pump heating unit
Klimakompressor
air conditioning compr.
ZA ZA
option option
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
008 910 92
15:17 X63:8
A72:2
87 14:11
30 30 14 S26 13
K 127 K 128 F115 F116
20A 20A
15:12 15:13
Wiring diagram 920 100 06
87 87a 87 87a 14 1
X66:1 K 129 30 K 130 30 S53
15:14 15:16
87 87a 87 87a
30 5
K118
15:20
87 87a
X73:B
X72:B
X64:2
A88 A89
X75:B
X74:B
A90 A91
BOMAG
X73:A
X72:A
86 86
K 127 K 128
+ +
X69:1
X70:1
X71:1
X39:1
X75:A
X74:A
E23 E25
E23 + + E25 ï ï 85 85
86 86
+ + K 129 K 130 86 K32 86 K85 86 K118
+ +
ï ï
E28 E27 E28 E27
ï ï 85
ï ï 85 85 85 85
X69:2
X70:2
X71:2
X39:2
14:19 K31 K31 16:1
Arbeitsscheinwerfer vorne Arbeitsscheinwerfer vorne
working lights, front working lights, front
Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten 15:7 15:9 15:10 15:11 15:4 14:2 15:4
working lights, rear working lights, rear
26.07.2005
1 1 920 100 06
Kneip Kabine
10.02.2005
21.6
997
Nallin cab 015
998
15:12 F31 Wischer vorne Wischer hinten
windscreen wiper, front windscreen wiper, rear
21.6
15:12 F15
A B C 1
14:11 F42 F27 F28 F143
F41
Box 1 X67:A X67:A Box 1 Box 1 InlineïFuse
12:20 X67:A
1 option Tachograph 2 3 2
X67:B
12:14 X67:B
S20 S21
0 1 2 7 2 0 1 2 7 2
01 S163 5
01
30
K141 1
5 4 5 4
X67:B 16:19
87 87a
X67:B X67:A
1 +
X63:1
X62:1
X63:2
X62:2
+ S45
X64:5
X64:3
X64:6
X64:8
S38 A12 Radio
E72
radio
ï 1
5 15 30 E71 1
4Stck/4pcs
X64:4 S158 + R80
B51 31 B51 2
2
X48:1 option X61:C X61:A
BOMAG
X64:7
max. 13A
+
E32 X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E70 I 15
K141
ï ï G02 31
12:13
X67:C X46 +
53
53a
31b
53
53a
31b
3 min
+
XS option X44
+ X67:C
53a
Tachograph
Abfallverzögert
12V
E29 M04 M06 M05 M07
53a
31b 53
31
ï 2,5A
ï 31 ï 31 ï
31b 53
31
X61:2 X61:2
16:16 16:14
X48:2 X64:1 X44:31 X46:31 X61:B
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
Schalter Arbeitsscheinwerfer
switch, worklamp
008 910 92
15:20 F09
13 A
13 S53
S147 F108
1
14
14
A B 30
13 K135
F113 F114 S26
17:14
Wiring diagram 920 100 06
1 2,5qmm 2 87 87a
30 C D 14
K127 30
K128
17:7 F115 F116
17:9
87 87a 87 87a 3 4
K129 30 30
K130
17:10 17:11
87 87a
87 87a
2,5qmm
86
BOMAG
+ + K127 86 K128 + +
E23 E25 E23 E25
ï ï ï ï
85 85 86 86 86
K135
+ + K129 K130 + +
E28 E27 E28 E27
ï ï 85 85 85 ï ï
16:20 K31
26.07.2005
1 1 920 100 06
Kneip Arbeitsscheinwerfer ROPS
10.02.2005
21.6
999
Nallin worklamp RORS 017
1000
5:20 F25
5:17 F06
21.6
F04
13:20
Taster Hundegang
push button, crab walk
S115 3 3
S116
X12:A
4
4
K138 30 K03 30
BR/BN
B10 18:16 18:18
87 87a 87 87a
BL/BU
SW/BK
X12:B X12:C X9L:4 X9L:6
BOMAG
X1:130
X1:56
X7:13
86 86
+ 1 Y19 Y18 1 K138 K03
H02
2 2
ï
V16 V17 85 85
4:20 X7:ï
X1:127 X1:114 X1:116 X1:127
14:15 31 31 19:1
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
008 910 92
option
A71 A04
Wiring diagram 920 100 06
ACïMaschine
A83
0000 Messtechnik Rechner
measurement calc. unit
A03
option
P16
BOMAG
P35
8 16 26 40 51 57
5 6 7 13 14 15 22 23 24 25 31 32 33 34 38 39 50 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37 52 53 58 59 6061
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
X20
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
X88:1ï68
blau blau
(Buchse) blue blue
blau
blue
blau
blue
blau
blue
26.07.2005
1 1 920 100 06
Kneip Elektrokasten
21.6
1001
crossïbonding box 020
1002
V48
21.6
A02
V47
2 2
K11 K05 K114 K03 K22 K35 K62 K79 K80 K82 K83 K138 K139 K104
V46
V45
2 2
V44 ZA
option
2
V43 ZA
1 1 1 1 1 1
2
3 4 5 6 7 8
option
V42
1
2
ZA
2
option FM1
X2:1ï61 asphalt
V41 manager
1
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 49
191
V22
V01
V25
V26
V27
V28
51 52 53 54 55 56 57 5859 X2 X1
192 193194 198 199 200 204 205 206 208
60 61
187 188 189 190 195 196 197 201 202 203 207
F07
F61
F11
F01
F10
F12
F14
F05
F93
F37
F03
F06
F09
F25
F23
F08
F04
F119
F101
F105
F129
R09
BOMAG
X13:AïC
X14:AïB
X89:AïB
blau
X1:1ï208 blue
blau
blue
blau
blue
V49
76 78 80 82 84 86 88 90 110 112 114 116 118 122 127 137 147 148 156 168 174
75 77 79 81 82 83 100 101 102 103 104 105 106 107 108 109 111 113 115 117 119 120 121 123 124 125 126 128 129 130 131 132 133 134 135 136 138 139 140 141 142 143 144 145 146 151 152 155 165 166 167 173 185186
85 87 89 91 92 93 94 95 96 97 98 99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 149 150 153154 161 162 163 164 171 172 183 183
X1
blue
blau
blau
blue
blau
blau
blau
blue
blue
blau
blue
blue
26.07.2005
1 1
008 910 92
Wiring diagram 920 100 06
008 910 92
201918 1716151413 121110 201918 1716151413 121110
A15 A15
Wiring diagram 920 100 06
Zentralstecker Sammelanzeige (Ansicht von hinten) Zentralstecker Sammelanzeige (Ansicht von hinten)
mainplug monitoring module (view from backside) mainplug monitoring module (view from backside)
1 4 6
BOMAG
3 2 1 3 2 1 2 1
5 4 3 2 1
5 3
1
4 3 2 1
2 3 4 5
A16
A51 Elektronik Tachograph
Platine Frequenzanzeige electronic system, tachograph
Printed circuit board,frequenzy m. 1 2 3
26.07.2005
1 1 920 100 06
Kneip Elektrokasten
21.6
1003
crossïbonding box 022
Name Bl. Pf. Benennung title TYP
21.6 021 14
021 14 Wiring diagram 920 100 06
A01 005 11 Intervallschalter intervall switch
A02 007 8 Blinkrelais indicator relay 4/6X21 WATT
A02 021 17 Blinkrelais indicator relay
A03 005 10 Modul Vibration modul vibration
A03 008 4 Modul Vibration modul vibration
A03 020 7 Modul Vibration modul vibration
A04 005 5 Modul Berieselung modul sprinkler system
A04 020 11 Modul Berieselung modul sprinkler system
A05 013 16 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer
A05 020 11 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer
A12 016 9 Radio Radio
Vogt
21.10.05
Seis
21.10.05
E23 017 17 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55 WATT
E25 015 3 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
1004 E25 015 9 Arbeitsscheinwerfer vorne rechts BOMAG
Working head light, front, rh. 3,5A 008 910 92
Name Bl. Pf. Benennung title TYP
E25
E27
017
Wiring diagram 920 100 06
E25 017
007
4
18
1
Arbeitsscheinwerfer vorne rechts
Arbeitsscheinwerfer vorne rechts
Arbeitsscheinwerfer hinten links
Working head light, front, rh.
Working head light, front, rh.
Working head light, rear, lh.
3,5A
55 WATT
55 WATT
21.6
E27 015 4 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E27 015 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 3,5A
E27 017 6 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 3,5A
E27 017 19 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
E28 007 2 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E28 015 2 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E28 015 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 017 5 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 017 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E29 016 7 Innenleuchte Kabine Inside light, cabin 21W
E30 014 13 Heizgeraet Heating unit
Vogt
21.10.05
Seis
21.10.05
K22 003 10 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K22 021 7 Relais Hubmagnet Motor Relay, shut off solenoid, engine
008 910
K32 92 015 17 Relais Kabine BOMAG
Relay, cabin BOSCHL 1005
Name Bl. Pf. Benennung title TYP
21.6 K35
K35
K62
006
021
002
12
8
7
Relais Selbsthaltung
Relais Selbsthaltung
Relais D+
Relay, holding contact
Relay, holding contact
Relay, D+
BOSCHW
Wiring diagram 920 100 06
BOSCHW
K62 021 9 Relais D+ Relay, D+
K79 005 12 Relais Berieselungspumpe Relay, sprinkler pump BOSCHW
K79 021 10 Relais Berieselungspumpe Relay, sprinkler pump
K80 005 11 Relais Berieselungspumpe Relay, sprinkler pump BOSCHW
K80 021 11 Relais Berieselungspumpe Relay, sprinkler pump
K82 005 18 Relais Kantenschneidgeraet ab Relay, edge cutter, up BOSCHW
K82 021 12 Relais Kantenschneidgeraet ab Relay, edge cutter, up
K83 005 19 Relais Kantenschneidgeraet auf Relay, edge cutter, down BOSCHW
K83 021 13 Relais Kantenschneidgeraet auf Relay, edge cutter, down
K85 015 18 Umschaltrelais Relay, switch over BOSCHW
K104 005 10 Relais, Stoermeldungen Relay, failure indication BOSCHW
Vogt
21.10.05
Seis
21.10.05
S13 008 3 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 007 8 Warnblinkschalter Switch, hazard light
S15 007 18 Beleuchtungsschalter StVZO Switch, lighting StVZO
S19 005 5 Emulsionsberieselungsschalter Switch, emulsion sprinkler system
920 100 06
S38
008
Wiring diagram 920 100 06
S37 007
016
12
12
3
Vibrationsschalter
Schalter Blinker
Schalter Kennleuchte
Switch, vibration
Switch, indicator
Switch, warning light
21.6
S44 014 1 Schalter Kabinenluefter Switch, cabin ventilator
S45 016 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S49 009 3 Schalter Bremse Switch, brake
S53 015 20 Schalter Arbeitsbeleuchtung Switch, working lights
S53 017 14 Schalter Arbeitsbeleuchtung Switch, working lights
S73 008 15 Schalter Splittstreuer Switch, gravel scratter
S74 008 17 Schalter Splittmenge Switch, gravel quantity
S82 005 18 Taster Kantenschneidgeraet abwaerts Push button, edge cutter, down MAX 0,2A
S83 005 19 Taster Kantenschneidgeraet auf Push button, edge cutter, up MAX 0,2A
S108 005 8 Schalter Berieselung Kantenschneidgeraet Switch,sprinkler sys.edge cutter
S114 005 7 Schalter Wasserpumpe Switch, water pump
Vogt
21.10.05
Seis
21.10.05
S115 018 16 Taster, Hundehang links Push button, crab walk, lh.
S116 018 18 Taster, Hundegang rechts Push button, crab walk, rh.
S117 007 3 Schalter Steckdose Switch, socket
S120 006 4 Schalter Motordrehzahl Switch, engine speed
S147 015 13 Schalter Arbeitsbeleuchtung Switch, working lights
S147 017 9 Schalter Arbeitsbeleuchtung Switch, working lights
S153 011 8 Papiervorschub Paper formfeed
S158 016 6 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 016 19 Schalter Heckscheibenheizung switch rear screen heating unit
S166 011 18 Schalter GPS Switch, GPS
S182 002 9 Schalter Startmehrmengenunterdrückung switch boostïfuel rejection LU DEUTZ
S182 002 10 Schalter Startmehrmengenunterdrückung switch boostïfuel rejection
21.6 X1:27
X1:28
X1:29
002
006
002
9
9
16
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Crossïbonding box
Crossïbonding box
Crossïbonding box
Wiring diagram 920 100 06
X1:30 006 6 Elektrokasten Crossïbonding box
X1:31 008 5 ELEKTROKASTEN Crossïbonding box
X1:32 013 16 ELEKTROKASTEN Crossïbonding box
X1:33 013 16 ELEKTROKASTEN Crossïbonding box
X1:34 004 16 ELEKTROKASTEN Crossïbonding box
X1:35 007 8 Elektrokasten Crossïbonding box
X1:36 007 8 Elektrokasten Crossïbonding box
X1:37 007 8 Elektrokasten Crossïbonding box
X1:38 007 4 Elektrokasten Crossïbonding box
X1:39 007 18 Elektrokasten Crossïbonding box
X1:40 007 18 Elektrokasten Crossïbonding box
Vogt
21.10.05
Seis
21.10.05
X1:125
003
Wiring diagram 920 100 06
X1:124 005
004
3
9
15
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Crossïbonding box
Crossïbonding box
Crossïbonding box
21.6
X1:126 008 4 ELEKTROKASTEN Crossïbonding box
X1:127 002 19 ELEKTROKASTEN Crossïbonding box
X1:127 003 8 ELEKTROKASTEN Crossïbonding box
X1:127 004 15 ELEKTROKASTEN Crossïbonding box
X1:127 004 17 ELEKTROKASTEN Crossïbonding box
X1:127 005 12 ELEKTROKASTEN Crossïbonding box
X1:127 005 18 ELEKTROKASTEN Crossïbonding box
X1:127 006 5 Elektrokasten Crossïbonding box
X1:127 007 12 Elektrokasten Crossïbonding box
X1:127 008 4 ELEKTROKASTEN Crossïbonding box
X1:127 018 6 ELEKTROKASTEN Crossïbonding box
Vogt
21.10.05
Seis
21.10.05
21.6 X2:14ï2
X2:15ï1
X2:15ï2
006
008
008
18
5
4
Elektrokasten
ELEKTROKASTEN
ELEKTROKASTEN
Crossïbonding box
Crossïbonding box
Crossïbonding box
Wiring diagram 920 100 06
X2:16ï1 007 3 Elektrokasten Crossïbonding box
X2:16ï2 007 4 Elektrokasten Crossïbonding box
X2:17ï1 010 2 ELEKTROKASTEN Crossïbonding box
X2:17ï2 010 2 ELEKTROKASTEN Crossïbonding box
X2:18ï1 005 7 ELEKTROKASTEN Crossïbonding box
X2:18ï2 005 7 ELEKTROKASTEN Crossïbonding box
X2:19ï1 007 14 Elektrokasten Crossïbonding box
X2:19ï2 007 14 Elektrokasten Crossïbonding box
X2:20ï1 007 16 Elektrokasten Crossïbonding box
X2:20ï2 007 17 Elektrokasten Crossïbonding box
X2:21ï1 007 19 Elektrokasten Crossïbonding box
Vogt
21.10.05
Seis
21.10.05
X13:A
018
Wiring diagram 920 100 06
X12:C 018
002
6
6
11
KNICKGELENK
KNICKGELENK
FAHRERSTAND
Articulated joint
Articulated joint
Operators platform
21.6
X13:AïC 021 4 ELEKTROKASTEN Crossïbonding box
X13:B 002 11 FAHRERSTAND Operators platform
X13:C 002 12 FAHRERSTAND Operators platform
X14:A 002 12 FAHRERSTAND Operators platform
X14:AïB 021 3 ELEKTROKASTEN Crossïbonding box
X14:B 002 12 FAHRERSTAND Operators platform
X15:1 005 5 EMULSIONSPUMPE Emulsion sprinkler pump
X15:2 005 5 EMULSIONSPUMPE Emulsion sprinkler pump
X16:1 005 2 BERIESELUNGSPUMPE Sprinkler pump
X16:2 005 2 BERIESELUNGSPUMPE Sprinkler pump
X17:1 005 1 BERIESELUNGSPUMPE Sprinkler pump
Vogt
21.10.05
Seis
21.10.05
21.6 X25:6
X26:1
X26:2
007
004
004
14
20
20
BLENDE HINTEN
WASSERTANK
WASSERTANK
Screen rear
Water tank
Water tank
Wiring diagram 920 100 06
X27:1 004 17 WASSERTANK Water tank
X27:2 004 17 WASSERTANK Water tank
X28:1 008 9 MOTORRAUM Engine room
X28:2 008 9 MOTORRAUM Engine room
X29:1 008 10 MOTORRAUM Engine room
X29:2 008 10 MOTORRAUM Engine room
X30:1 013 5 Bandage Roller drum
X30:2 013 6 Bandage Roller drum
X30:3 013 6 Bandage Roller drum
X30:4 013 6 Bandage Roller drum
X31:1 003 18 LENKSAEULE Steering column
Vogt
21.10.05
Seis
21.10.05
X65:2
016
Wiring diagram 920 100 06
X65:1 015
014
15
3
1
Kabine
Kabine
Kabine
cabin
cabin
cabin
21.6
X65:3 014 2 Kabine cabin
X65:4 014 2 Kabine cabin
X66:1 015 4 Kabine cabin
X67:A 016 8 Kabine cabin
X67:A 016 9 Kabine cabin
X67:A 016 9 Kabine cabin
X67:B 016 8 Kabine cabin
X67:B 016 8 Kabine cabin
X67:B 016 9 Kabine cabin
X67:C 016 9 Kabine cabin
X67:C 016 9 Kabine cabin
Vogt
21.10.05
Seis
21.10.05
21.6 X89:A
X89:AïB
X89:B
002
021
002
1
2
2
FAHRERSTAND
ELEKTROKASTEN
FAHRERSTAND
Operators platform
Crossïbonding box
Operators platform
Wiring diagram 920 100 06
X90:1 008 10 MOTORRAUM Engine room
X90:2 008 10 MOTORRAUM Engine room
X91:A 002 4 MOTORRAUM Engine room
X91:A 015 3 MOTORRAUM Engine room
X91:B 002 3 MOTORRAUM Engine room
X93:1 008 3 SITZKONSOLE Seating unit
X93:2 008 2 SITZKONSOLE Seating unit
X93:3 008 3 SITZKONSOLE Seating unit
X94:1 007 4 Blende hinten Screen rear
X94:2 007 5 Blende hinten Screen rear
X9L:1 008 2 SITZKONSOLE Seating unit
Vogt
21.10.05
Seis
21.10.05
Y01 002 9 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y01 002 10 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y04 003 10 Magnetventil Bremse Solenoid valve, brake 2,1A
Y04 003 11 Magnetventil Bremse Solenoid valve, brake 2,1A
Y11 009 3 Magnetventil Stellkammer Fahrpumpe Sol. valve, control chamber travel pump 2.41A
Y13 003 3 Hubmagnet Motor Shut off solenoid, engine 4A
Y14 014 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit 2A
Y15 014 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y18 018 12 Magnetventil Hundegang Solenoid valve, crab walk 2,5A
Y19 018 10 Magnetventil Hundegang Solenoid valve, crab walk 2,5A
Y20 005 14 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 2,5A
11
Vogt
21.10.05
Y172 009 12 Magnetventil Phasensynchronisation 2
Wiring diagram 920 100 06
solenoid phaseïsynchro 2 2.41A
21.6
Seis
21.10.05
component listing
Bauteilliste
12
12
920 100 06
112
S/N 101 920 001 071 ⇔ 101 920 001 ... BW 141 AD-4
S/N 101 920 201 015 ⇔ 101 920 201 ... BW 141 AD-4 AM
S/N 101 920 101 043 ⇔ 101 920 101 ... BW 151 AC-4
S/N 101 920 411 009 ⇔ 101 920 411 ... BW 151 AC-4 AM
S/N 101 920 011 051 ⇔ 101 920 011 ... BW 151 AD-4
S/N 101 920 211 010 ⇔ 101 920 211 ... BW 151 AD-4 AM
S/N 101 920 311 015 ⇔ 101 920 311 ... BW 154 AD-4
S/N 101 920 511 032 ⇔ 101 920 511 ... BW 154 AD-4 AM
S/N 101 920 111 011 ⇔ 101 920 111 ... BW 161 AC-4
S/N 101 920 021 216 ⇔ 101 920 021 ... BW 161 AD-4
S/N 101 920 041 020 ⇔ 101 920 041 ... BW 161 ADH-4
S/N 101 920 061 021 ⇔ 101 920 061 ... BW 190 AD-4
S/N 101 920 261 019 ⇔ 101 920 261 ... BW 190 AD-4 AM
S/N 101 920 031 059 ⇔ 101 920 031 ... BW 202 AD-4
S/N 101 920 051 012 ⇔ 101 920 051 ... BW 203 AD-4
S/N 101 920 251 012 ⇔ 101 920 251 ... BW 203 AD-4 AM
008 910 92
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 920 100 07 Stromlaufplan Circuit Diagram
002 920 100 07 Versorgung, Starten, Steckdose supply, starting unit, socket
003 920 100 07 Motor Vorglühanlage engine grid−heater, glow−plug
004 920 100 07 Bremse, Sitzkontakt, Not−Aus brake, seat contact, emergency off
005 920 100 07 Überwachung, Warnsummer monitoring unit, warning buzzer
Wiring diagram 920 100 07
BOMAG
017 920 100 07 Kabine cab
018 920 100 07 Arbeitsscheinwerfer ROPS worklamp RORS
019 920 100 07 Hundegang crab walk
020 920 100 07 Diebstahlschutz System anti − theft system
021
022 920 100 07 Elektrokasten cross−bonding box
023 920 100 07 Elektrokasten cross−bonding box
101 920 100 07 Bauteilliste component listing
12.6.2006
001 001
Seis Stromlaufplan 920 100 07
13.6.2006
21.7
1019
circuit diagram 001
Vogt
X2:3−1
1020
X2:1−1 X2:1−2
X2:2−1
21.7
F01
X2:5−1 F105
7:1 Sicherung F05
X2:6−1 F37 fuse
6:2 X2:2−2 Sicherung
fuse
X2:4−1 F93
11:2
X2:7−1 30
8:6 30 X2:3−2
30 X13:A K11
P0123
P01 2:17
S00
X89:B
X89:A
87 87a
X91:A Zündstartschalter
K30 12:1 ignition switch 15 54 58 19 17
50a
2 X1:10
X13:B X13:C
15 4:1 K11 7:1
X2:9−1
2 F00 Sicherung F119
fuse
Sicherung Battrie
fuse, battery X2:9−2 F119 F119
1 F119 2:15 2:14 3:4
X2:23−1
K14 3:2 V01
Meldeleuchte Ladekontrolle
X2:23−2 indicator light, charge control
X6:+ 3:8 30
86 1 K05
K62 R09 H08 4:8
X1:27 X6:14 87 87a
BOMAG
85 2
2
X1:27
X1:101 10:12
P00
W D+ X14:A X14:B
G02 Betriebsstundenzähler
operating hour meter
Generator
+ Batterie generator X6:−
4:13
battery 2 50
G01 B− B+ 3:4
−
X51:C
S182 S182
A 2 K11
86 +
Batterietrennschalter 30 50 T XS
S30 3 B 3
switch battery disconnect Y01 2 Y01 1 Y139 1 12V
85 −
4 X91:B M01
K31 12:17
− 1
M− 3:1
Starter BW161...203−4 BW141...154−4 X1:127 X1:53
starter 31 3:1
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
2:15 50
1
X6:6 1
F158 F159
Wiring diagram 920 100 07
X1:104 X1:103
A13
7:2
F48 1 X1:206 1
Sicherung R23
fuse
BOMAG
125A
2 X1:135 220K−OHM 2
50(5) 15(7) S(2) 15 TK 50 30 86 30
30 (5) K14
K08 L(1) L K14
3:6 A13
A13 3:16 87
87 (6) 85
T(4) R(6) 31(3) 31 H R
2
1 1 1
R19 K08 220Amp R02 R02
2000 WATT
50A 50A
B53 1
(R)_t
M− X1:78
2:14 M− 4:3
2:20 31 31 4:1
12.06.2006
1 1 920 100 07
Seis Motor Vorglühanlage
21.7
13.06.2006
1021
Vogt engine grid−heater, glow−plug 003
15
1022
2:12 15 5:1
1(15/54)
8 11 indicator light drivers seat 12 14
30 7
K22 A68 H14
15 9:3
4:10 Modul Sitzkontakt
87 87a modul seat contact (A8) 1
V48
2
6 4 13
5
B63
9:6 X1:8 X1:202
9 (GND)
BOMAG
X6:9
21
X1:43
4:3
11:13
S01 Not−Aus−Schalter 11 21 31 X7:9
switch, emergency off S01
4:11
Not−Aus−Schalter
22 X1:205
switch, emergency off 12 22 32
X1:195
X31:1
X1:47 +
X1:136 Warnsummer H82
X1:198 warning buzzer
X6:11 −
86 1
2 V03 Y13 1 K05 Y04 1 + H01
Y04 X31:2
V02
30/40Amp
2 −
BW 141..154−4
V41 1 2
(1) 2 85
M− 2:13 X6:− X6:− 4:15
3:20 M− 5:7
BW 141..154−4 BW 161..203−4
X1:137 X1:63 X1:127 X1:118 X1:53
31 X1:137
3:20 31 5:1
Hubmagnet 2:14 4:3 Bremsventil Meldeleuchte Bremskontrolle Überwachungsmodul
shut off solenoid, engine solenoid valve, brake indicator light, brake monitoring module
16.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
008 910 92
X2:12−2
F04
11:6
X1:57
Meldeleuchte Wasserrestmenge X1:71
Meldeleuchte Motorüberhitzung indicator light, water res.
idicator ligh, engine overheating X26:1
Meldeleuchte Luftfilter 1 br
indicator light, air cleaner R14 p
X6:20 X7:20
Meldeleuchte Motoröl Differenzdruck Hy.
indicator light, engine oil pressure idicator ligh, hydr.oil filter X7:+ 2 gn
3:11 X6:+ 7:8
H73 H09 H49 H15 H23
H79 X26:2
X1:72
X6:5 X6:16 X6:17 X6:15 X6:13
X7:15
Wiring diagram 920 100 07
X1:44
X7:2
R21
R22
H70
Tankanzeige
R20
level gauge
Q
X6:3
X6:4
P01
X1:17 X1:20 X1:21 X1:22 X1:23 Q X1:54 P19
1 X6:2
V42 Wasservorrat
(A2) water gauge
2
B20
4:17
X1:97
X7:− 19:5
BOMAG
X1:196
X1:197
30 X1:24 X1:34
B21 1 30
K62 K104
6:10
2:7 X6:− X6:−
X1:92 X1:91 X1:94 X1:95 X1:96 4:16 8:6
87 87a p 2 X1:125 X1:185
87 87a
X10:2 X10:1
X1:128
X27:1
X1:199
X1:200
gn/gr
1 1 1 B33
R03
P _t p
2 2 2
br/br B124
2 2
X6:10 X7:10
X27:2
ws/wh
4:20 MD+ MD+ 6:1 4:5 M− M− 7:11
X10:3
X1:53 X1:127 X1:127 X1:53
4:20 31 31 6:1
Kühlmittelvorrat Motor Meldeleuchte Wasser im Diesel Wasserrestmenge
indicator light, eng. coolant res. indicator light, water in fuel water tank residual quantity
Wasserabscheider Geber Kraftstofftank
option sensor, water seperator fuel sender, level gauge
12.06.2006
1 1 920 100 07
Seis Überwachung, Warnsummer
21.7
13.06.2006
1023
Vogt monitoring unit, warning buzzer 005
1024
4:20 F25 F25 19:1
F37 X2:18−1
2:5 Sicherung
fuse F06
Sicherung
X2:7−1 fuse X2:18−2
F06
F61 F37 19:1
X1:46 4 A03 Modul Vibration
fuse
modul vibration
X1:124
X2:7−2 X2:6−2
Sicherung
Schalter Berieselungspumpe 43 23 33 7
switch, water pump 13
102 X1:69 X9R:3 X9R:5
S114 0
X18:2
8,5VOLT 9:1
44 24 34 14 S82 3 3
X18:1
− GND 9:3 S83
+
Intervallschalter X18:3 4 4
30 30 interval switch
X1:12
30 30
X1:14
K79 K80 Emulsionsberieselung A01 1−12 X9R:4 X9R:6
emulsion sprinkler K82 K83
6:12 6:11 6:18 6:19
X1:139 X1:140
87a 87 87 87a 87 87a 87 87a
23 13
1 0 2
S19 10
Taster Kantenschneitgerät auf
push button, edge cutter, up
Taster Kantenschneitgerät ab
push button, edge cutter,down
S108
24 14
6:8
X1:119 X1:120
BOMAG
13 6:8 X1:109 X1:111
15/54 A04
Modul Berieselung
S108
30 modul, sprinkler system
X1:145 X1:146 X1:50
87 X1:51
X17:1 X16:1 X1:173
13
+ + S108 86 86
X15:1 14 1 Y20 1
M02 M18 + X1:52 K82 K83
86 86 86
X1:117 2 Y21 2
− − M03 V14 V15 85 85
K104 K80 K79
X17:2 X16:2 − 1 Y99
85 85 85
nur AC−Version
only AC−version
X15:2
2
X1:147 X1:174 X1:118 X1:53 V29 X1:110 X1:112
X1:127 X1:127
5:20 31 31 7:1
ZA Kantenschneidgerät
option edge cutter
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
2:5 F105
X2:14−1
008 910 92
3:7 F119 F119 10:7
F105 Sicherung Sicherung
fuse F23
fuse
X2:5−2
X2:14−2
F23
12:2
K35 30 K114 30
7:12 7:5
87a 87
87a 87
Wiring diagram 920 100 07
X1:42 X1:30
86 86 X1:138
K139 K35 2
3
L0R 33 11 23 85 85
S120 0 S03
Meldeleuchte Motordrehzahl Taster Signalhorn
incicator light, motor speed 4
switch warning horn
34 12 24
Schalter Motordrehzahl 5:19 X7:+
BOMAG
switch motor speed X1:102
X1:105
X1:106
+ H60
X1:60
3:6 A13 −
X7:5
X1:134
X1:16 X1:28
2
87 87a
AUX
86 + AW +
(A7) 2 HW
K114 V47 K139 Y120 B11
85 1 7:11 − −
30 Signalhorn
warning horn
5:13 M− M− 8:8
X1:127 X1:137
6:20 31 31 8:1
Motordrehzahl
motor speed
12.06.2006
1 1 920 100 07
Seis Drehzahlverstellung Motor, Signalhorn
21.7
13.06.2006
1025
Vogt motor speed, warning horn 007
K11
1026
7:20 K11 9:1
Meldeleuchte Warnblinker
X2:16−1 Meldeleuchte Blinker H05
F08 indicatot light, indicators indicator light,hazard light
Sicherung Brücke entfällt X1:39
21.7
13 F07 X7:8
Sicherung 12 24
15A Schalter Blinker
fuse switch indicator option
S26 S14 S14
X2:7−2 8:11 8:9
14 Warnblinkschalter X6:8 StVZO Beleuchtung
Schalter Arbeitsbeleuchtung X1:37 S37 S37 StVZO illumination
hazard light 8:12 8:10
X1:41
X1:40
entfällt bei
X57:8 X25:4 − 31 31
ZA Splittstreuer
only acc. to option
deliting chip spreader
X58:2 − X58:1 + − + X58:4 X58:7 + − + X58:5
E09 E11 E13 E15
BOMAG
− − −
−
X25:5
X1:35
X1:36
E02 E73 E04 X25:6
+ + + + + + +
X94:1 X5:R2
E11
E10
E13
E15
E12
E14
E09
E09 E11 E13 E15
X25:1
56b − − − − 8:10 8:11 8:12 − − 8:14 8:15 8:16 8:17 −
56b
56b E27 E28 56b E18 E19 49 49a
8:10 8:11 8:12 8:14 8:15 8:16 8:17
31 31 A02
X58:3
31 31
E11
E10
E13
E15
E12
E14
E09
rechts X57:3
right 31
links/left
links X5L:C X5L:C
rechts/right
left Bel. Temp. Asphalt 8:13 8:10
X25:2 illum. temp. asphalt
X5:LC X5:R5
X58:3 8:13 X94:2 Bel. Evib−Meter
illum. Evib−meter M− M− X4:5 X58:3
X1:148 7:20 8:18 8:2 8:11 M− M− 9:9
31 X1:53 X1:110 X1:127
7:20 31 8:9
Begrenzungsleuchte rechts
Arbeitsscheinwerfer Arbeitsscheinwerfer Blinkrelais Blinkleuchte VL Blinkleuchte VR limitation light rh. Scheinwerfer links
working head light indicator relay indicator front,lh. indicator front,rh. Begrenzungsleuchte links head light LH
working head lights
limitation light lh.
ZA Bel. Geschwindigkeitsanz. Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts Scheinwerfer rechts
Splittstreuer illum. speedometer indicator rear,lh indicator rear,rh. tail light,lh tail light,rh head light RH
option
Blinkleuchte HL Blinkleuchte HR Schlußleuchte links Schlußleuchte rechts
chip spreader indicator rear,lh indicator rear,rh. tail light,lh tail light,rh
12.062006
1 1
008 910 92
Wiring diagram 920 100 07
008 910 92
X1:31 9:11
9:10 X1:31 X1:31 10:1
B39 3 X1:31 BW161...BW203−4 13 23
X93:2
23 23 VBH
S36
2
S08 S02 13 13 23
1 L0R
X93:1 X93:3 4:9 B63 14 24 S73 0
24 24 S74
6:12 GND 14
X1:143 X1:70 X1:144 X1:49 X1:1 X1:7 X1:9 X1:11 14 24
1 (15/54)
9 (8,5V) 11 (GND) 8
1 (15/54)
14 16 12 14 11 15 X1:13 X1:15
Y31
A71
Wiring diagram 920 100 07
A03
Modul Vibration 9:10 Modul Vibrationsverriegelung
modul vibration, interlock
modul vibration A71
9:15
15
10 (GND)
13 6 3 5 12 13 5 4 7 8 6
9 (GND)
9:9 R 10:12
10 (GND)
11:2
A03
K G 11 23 9:2 9:9 A71
1 Schalter Vibration klein/groß
S35 switch, vibration low/high
V46 V45
4:20 H14 (A6) (A5) 12 24 GA 11:8
1 2
X1:5 V44 (4)
X1:64 X1:3
1 2
BOMAG
BW161AD...BW203AD−4 9:10
Y31
11:2
X9L:2
X9R:2
Y57 X1:75 X1:186 X1:83 10:12
X3:1 13:1
Asphalt X1:81
S12 3 S13 3 Manager X77:1 X90:1 10:12 X1:89
+ V2 13:1 X1:87
X28:1 X29:1 X1:118 X1:171
H14 X1:83 X1:81
− V08
4 4 X1:77 X1:79 Y30 Y31 V12 V11 V18
1 1
X8:1 X9:1 1 1 Y54 1 1 1 V19 V21 1
1
X3:2
Y56 Y57 2 2 Y131
X9L:1
X9R:1
2 2 2 2 2 Y55 2 2 2 2
V43 X28:2 X29:2
V49 (4) Y66 Y67
X8:2 1 X9:2 X77:2 X90:2
1
X1:118 X1:63 X1:127 8:20 M− M−15:6 X1:84 X1:82 X1:172 X1:88 X1:90
X1:78 X1:137 X1:80
8:10 31 31 10:1
12.06.2006
1 1 920 100 07
Seis Vibration, Fahrstufenumschaltung, Rückfahrwarnsummer, Splittstreuer
21.7
13.06.2006
1027
Vogt vibration, warning buzzer, chip spreader, speed selection 009
A03.3 Aufn. Vibrationsfrequenz vorn
1028
9:6 A03.3 11:1
transducer vibration frequency front
9:19 X1:31
Aufn. Vibrationsfrequenz hinten
transducer vibration frequency rear
21.7
X2:53
2:8 X1:27
15/54 GND X1:2
9:9 B16 B17
X1:83
X110:1 X20:54
X110:2 X20:57
X111:1 X20:58
X111:2 X20:61
9:13
+
+
SPEED
SPEED
2
14 CAN+ CAN−
X110:4 DIR
X110:3
X111:4 DIR
X111:3
X2:49−2
diagnosis phase−synchro
Diagnose Phase−Synchro
Vib front
Vib rear
Vib on
D+
X20:55
X20:60
(15/54)
X1:153
X109:1
X109:15
X109:16
X109:13
X109:12 X20:59
X109:14 X20:56
X109:2
X109:8
X109:4
X1:155 X109:9
BOMAG
X109:5
X109:6
X20:52 X20:50
2.41A
2.41A
2.41A
Y165 Y172
Y11 1 1
Stellkammer 1
control chamber
2 2 2
9:20 31 31 11:1
Magnetventil Phase−Synchro 2
solenoid phase−synchro 2
Magnetventil Phase−Synchro 1
solenoid phase−synchro 1
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
10:6 A03.3
008 910 92
A73
9:13 fuse
6:17 MD+
X2:55 X20:9 X2:4−2
X2:53 X2:54 X20:25
F10 RXD
8:17 31 12:2
K11 X2:17−1 X1:59 X2:25−1 X2:26−1 X20:23
9:20 TXD
X2:24−1
X2:27−2
CAN3+ 12:2 S01 12:2
V22 V27 4:11 V25 V26
F101 CAN3− 12:2
Sicherung 32
X20:13 R31 X20:14 B15.2 13:1
X2:17−2 fuse X20:43 X20:44 1 2 GPS X2:25−2 X2:26−2
5
X2:27−1
1 R32 2 X20:10 X2:57
X2:24−2
X2:52 F101 11:12
Wiring diagram 920 100 07
X88:54
X88:36
X88:14
X88:4
X88:5
X88:35
X88:15
X88:41
X88:53
X88:33
X88:37
X88:56
X88:57
X88:59
X88:60
X88:32
X88:38
X88:25
X88:58
CAN3+
CAN3−
X88:28
Messtechnik Rechner
A83
measurement calc. unit
X88:27 X88:26
X88:1
X88:3
X88:6
X88:9
X88:7
X88:31
X88:39
X88:30
X88:65
X88:66
X88:67
X88:55
X88:23
X88:29
X88:68
X88:47
X88:46
9:9 GA
AGND
1 2 X20:20 X20:38 X20:35
+
BOMAG
X20:1 X20:2 X20:36
B106 −
X20:29
X20:30
X20:27
X20:31
X76:D X76:F _t
X20:34
X20:33
X76:A X20:3
X76:B X20:7
X20:17
X20:18
1
CAN+
CAN−
CAN−
CAN+
+
P34 + R30
X80:1
X79:1
X79:4
X79:3
X80:3
+
X80:4
X78:1
X78:2
15
P28 B85 B84 X107:1 X108:1
P33 _t 2
30
weiß/white
CAN2+ P16 − − G Y140 1 Y141 1
rot/reed
F1 F2
X20:5 X76:G CAN2− X20:39 B97
X80:2 X79:2 2 2
X20:6 X76:H − schw/black
GND − − X78:3 X107:2 X108:2
X1:152
X76:C X76:E option X20:19 X20:24 X20:28 X20:32
AGND
X20:4 X20:8 X1:122 X20:40 X20:37 12:2 X2:51 X20:12 X20:16
10:20 31 31 12:1
Display Evib−Meter Temperatursensor Aufnehmer Verstellmotor Aufnehmer Beschleunigung links Prop−Ventil Erreger auf
Evib−meter
display temperature switch transducer, motor trancducer, acceleration,left solenoid valve exciter up
Diagnose Temperaturanzeige Aufnehmer Beschleunigung rechts Prop−Ventil Erreger ab
diagnostics
temperature gauge, coolant trancducer, acceleration, right solenoid valve exciter down
ZA E−VIB−Meter
option EVIB−meter
12.06.2006
1 1 920 100 07
Seis Asphalt Manager, Evib−Meter, Temperatur Asphalt
21.7
13.06.2006
1029
Vogt asphalt manager, Evib−meter, temperature asphalt 011
1030
2:6 K30 K30 16:1
21.7
11:15 F101
11:9 CAN3−
11:9 CAN3+
11:19 RXD
TXD
11:19
X103:F X103:E
ST2:4
ST2:3
GPS Antenne
ST1:3 A77 A76 GPS antenna
X103:K
7:19 F23 Spannungsregler Druckerkontroller
X105:1−32
ST1:4 Voltage regulator printer controller
X20:22 X100:K X101:4 1
F150 A93
32 A87 Sicherung
2
BOMAG
USB−CAN Schnittst. fuse
USB−CAN Interface BCM
X106:1−20
20
ST2:5
ST2:6
ST1:1
ST1:2
ST2:1
ST2:2
X101:3 P11
X101:5 X102:1 X102:2 Drucker
3 printer A92
P15 5
S153
4
GPS Receiver
X75:2 GPS receiver
BCM 05 A94
X100:L X100:I BCM05 BCM 05
Papiervorschub
X103:L X103:I paper formfeed
2:4 K31 K31 13:1
X20:26
GPS
11:15 AGND
GPS Antenne
GPS antenna
31 31 14:1
11:20
ZA
option
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
008 910 92
9:7 V2 13:10 BW190 AD−4 13:6 BW151 AD−4
Y57 BW202 AD−4 Y57 BW151 AD−4 AM
9:7 Y57 13:10 BW203 AD−4 13:6 BW151 AC−4
X1:188 X1:187 X1:189 BW161 AD−4 AM X1:188 X1:187 X1:189
BW190 AD−4 AM
X68:B X68:A X68:C BW202 AD−4 AM X68:B X68:A X68:C
BW203 AD−4 AM
2 3 BW144 AD−4 2 3
BW154 AD−4 1 X67:A
4 BW144 AD−4 AM A51 13:7 17:5
A51 BW154 AD−4 AM
5 1 5 4
P09:A3
13:14
5 4 4:1 1:3 2:1 1:2
Wiring diagram 920 100 07
Tachomodul Tachomodul
A16 module, tachograph A16 module, tachograph
2 1 6 3 7.8.9
1:1
5:5
5:4
5:3
5:2
5:1
3:4
3:3
3:2
3:1
6:1
B3
B4
13:4 13:4 X67:B 13:10
13:14
13:4 13:4 X67:A 13:17
B3
B4
P09:A3
BOMAG
B4 B3 A2 A3 A1
A3 B1
A2 B2
P09
P09 C3 A1 B3
A5 B4
Anzeige
indicator
A6 C3
A5 A6 1 1
G02 17:9 Anzeige R33 R24
indicator
12:20 K31 2 2 K31 15:1
12.06.2006
1 1 920 100 07
Seis Tachograph
21.7
13.06.2006
1031
Vogt tachograph 013
1032
F04 F04
11:8 19:1
21.7
Lernmodus
to learn
Anzeigetest
diagnose
Lern Test
15/54
15/54
13:20 B15.2
IN A05
−
X2:59
X2:59 ZA
option
X1:194 X1:193 X1:192 X1:194 Geschwindigkeitsanzeige
speedometer
X24:4 X24:3 X24:1 X24:4 X1:53
BOMAG
BW161 AD−4 BW141 AD−4 BW141 AD−4 AM BW151 AC−4
BW161 ADH−4 BW151 AD−4 BW151 AD−4 AM BW161 AC−4 X32:1 X32:2
X30:1
X30:3
X30:2
BW190 AD−4 BW154 AD−4 AM
BW202 AD−4 BW154 AD−4
BW203 AD−4 BW151 AC−4 AM
BW190 AD−4 AM
BR/BN
SW/BK
SW/BK
BR/BN
WS/white
SW/BK
BR/BN
BW203 AD−4 AM
X30:4 X32:3
BL/BU
BL/BU
BL/BU
X24:2
X1:191
12:20 31 31 15:12
Aufnehmer Geschwindigkeit
transducer speed
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
008 910 92
B Box 1
F40 F15
0123 S44 Schalter Kabinenlüfter 7 F42 17:5
BOX 1 BOX 1
switch, cabin ventilator Schalter Kabinenheizung
8 switch, cab heating 6
3
L M H C
4 2 A72:2 5
16:15
low
mid
high
A72
Steuergerät S28
control unit 1
6 11 12 6 2 1 3
ZA
X65:3
X65:2
30 option
X65:4
Wiring diagram 920 100 07
X40:1
X50:1 P18
X40:3
X40:2
2
Thermofühler Heizung E30
X43:1 temperature sensor, heating Heizung
4 X49:2 heater timer
B104 P
Überwachung Kühlmitteldruck LP HP
3
monitoring coolant pressure
BOMAG
X43:3 X43:4 5 8 10
X53:3
X53:5
X1:207
X1:18 X43:2
X45:3
X42:3
X45:2
X42:2
X45:4
X42:4
ge rt or ge rt or X56:1 X54:1
X55:1
X21:1 Y15 1 E30 15:18 15:14 E30
M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
9:11 M− Magnetventil Heizung 14:20 31 31 19:1
solenoid valve, heating unit
X56:2
X40:4 X55:2
13:20 K31 K31 16:1
Kabinenlüfter
cab ventilator Kraftstoffpumpe
fuel pump heating unit
Klimakompressor
air conditioning compr.
ZA ZA
option option
12.06.2003
1 1 920 100 07
Seis Heizung, Klimaanlage
21.7
13.06.2006
1033
Vogt heating, air conditioning 015
X91:A
1034
12:20 K30 K30 18:1
X65:1 30 X51:A
10:19 F119
K32
16:17 X63:8
A72:2
87 15:11
30 30 14 S26 13
K 127 K 128 F115 F116
20A 20A
16:12 16:13
87 87a 87 87a 14 1
X66:1 K 129 30 K 130 30 S53
16:14 16:16
87 87a 87 87a
30 5
K118
16:20
X73:B
87 87a
X72:B
X64:2
A88 A89
X75:B
X74:B
BOMAG
A90 A91
X73:A
X72:A
86 86
K 127 K 128
+ +
X69:1
X70:1
X71:1
X39:1
X75:A
X74:A
E23 E25
E23 + + E25 − − 85 85
86 86
+ + K 129 K 130 86 K32 86 K85 86 K118
+ +
− −
E28 E27 E28 E27
− − 85
− − 85 85 85 85
X69:2
X70:2
X71:2
X39:2
15:19 K31 K31 17:1
Arbeitsscheinwerfer vorne Arbeitsscheinwerfer vorne
working lights, front working lights, front
Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten 16:7 16:9 16:10 16:11 16:4 15:2 16:4
working lights, rear working lights, rear
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
008 910 92
15:11 F42 F27 F28 F143
F41
Box 1 X67:A X67:A Box 1 Box 1 Inline−Fuse
13:18 X67:A
1 option Tachograph 2 3 2
X67:B
13:14 X67:B
S20 S21
0 1 2 7 2 0 1 2 7 2
01 S163 5
01
30
K141 1
5 4 5 4
Wiring diagram 920 100 07
X67:B 17:19
87 87a
X67:B X67:A
1 +
X63:1
X62:1
X63:2
X62:2
+ S45
X64:5
X64:3
X64:6
X64:8
S38 A12 Radio
E72
radio
− 1
5 15 30 E71 1
4Stck/4pcs
X64:4 S158 + R80
B51 31 B51 2
2
X48:1 option X61:C X61:A
X64:7
max. 13A
BOMAG
+
E32 X67:C
X46:31b
X46:53
X44:31b
X44:53
X46:53a
X44:53a
E70 I 15
K141
− − G02 31
13:8
X67:C X46 +
53
53a
31b
53
53a
31b
3 min
+
XS option X44
+ X67:C
53a
Tachograph
Abfallverzögert
12V
E29 M04 M06 M05 M07
53a
31b 53
31
− 2,5A
− 31 − 31 −
31b 53
31
X61:2 X61:2
17:16 17:14
X48:2 X64:1 X44:31 X46:31 X61:B
12.062006
1 1 920 100 07
Seis Kabine
21.7
13.06.2006
1035
Vogt cab 017
1036
16:20 K30
Schalter Arbeitsscheinwerfer
21.7
switch, worklamp
16:20 F09
A
13 11
S147 S53 F108
1−0 1
14 12
A B 30
13 K135
F113 F114 S26
18:14
1 2,5qmm 2 87 87a
30 C D 14
K127 30
K128
18:7 F115 F116
18:9
87 87a 87 87a 3 4
K129 30 30
K130
18:10 18:11
87 87a
87 87a
2,5qmm
BOMAG
86
+ + K127 86 K128 + +
E23 E25 E23 E25
− − − −
85 85 86 86 86
K135
+ + K129 K130 + +
E28 E27 E28 E27
− − 85 85 85 − −
17:20 K31
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
6:17 F06
F04
14:20
008 910 92
Taster Hundegang
push button, crab walk
S115 3 3
S116
X12:A
4
Wiring diagram 920 100 07
4
K138 30 K03 30
BR/BN
B10 19:16 19:18
87 87a 87 87a
BL/BU
SW/BK
X12:B X12:C X9L:4 X9L:6
BOMAG
X1:56
X7:13
86 86
+ 1 Y19 Y18 1 K138 K03
H02
2 2
−
V16 V17 85 85
5:20 X7:−
X1:127 X1:114 X1:116 X1:127
15:15 31 31 20:1
12.06.2006
1 1 920 100 07
Seis Hundegang
21.7
13.06.2006
1037
Vogt crab walk 019
1038
21.7
A67 1 2 3
Keyboard
keyboard
4 5 6
7 8 9
* 0
X22:1
X22:2
A66
Steuereinheit
control unit
BOMAG
ZA
option
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
Seis
13.06.2006
Vogt 020
A68 A05 A101
Steuerung Phase−Synchro
controller phase−synchro
008 910 92
option
A71 A04
Wiring diagram 920 100 07
AC−Maschine
A83
0000 Messtechnik Rechner
measurement calc. unit
A03
option
P16
BOMAG
P35
8 16 26 40 51 57
5 6 7 13 14 15 22 23 24 25 31 32 33 34 38 39 50 54 55 56
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 2 3 4 9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37 52 53 58 59 6061
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
X20
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
X88:1−68
blau blau
(Buchse) blue blue
blau
blue
blau
blue
blau
blue
12.06.2006
1 1 920 100 07
Seis Elektrokasten
21.7
13.06.2006
1039
Vogt cross−bonding box 021
1040
V48
21.7
A02
V47
2 2
K11 K05 K114 K03 K22 K35 K62 K79 K80 K82 K83 K138 K139 K104
V46
V45
2 2
V44 ZA
option
2
V43 ZA
1 1 1 1 1 1
2
3 4 5 6 7 8
option
V42
1
2
ZA
2
option FM1
X2:1−61 asphalt
V41 manager
1
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 49
V22
V01
V25
V26
V27
V28
51 52 53 54 55 56 57 5859 X2
60 61
F07
F61
F11
F01
F10
F12
F14
F05
F93
F37
F03
F06
F09
F25
F23
F08
F04
F119
F101
F105
F129
R09
BOMAG
X13:A−C
X14:A−B
X89:A−B
X1:1−208
V49
76 78 80 82 84 86 88 90 110 112 114 116 118 122 127 137 147 148 156 174 191
75 77 79 81 82 83 100 101 102 103 104 105 106 107 108 109 111 113 115 117 119 120 121 123 124 125 126 128 129 130 131 132 133 134 135 136 138 139 140 141 142 143 144 145 146 151 152 155 173 185186 192 193194 198 199 200 204 205 206 208
85 87 89 91 92 93 94 95 96 97 98 99
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 149 150 153154 171 172 183 183 187 188 189 190 195 196 197 201 202 203 207
X1
blue
blau
blau
blue
blau
blau
blau
blue
blue
blau
blue
blue
blau
blue
12.06.2006
1 1
008 910 92
Wiring diagram 920 100 07
008 910 92
201918 1716151413 121110 201918 1716151413 121110
A15 A15
Wiring diagram 920 100 07
Zentralstecker Sammelanzeige (Ansicht von hinten) Zentralstecker Sammelanzeige (Ansicht von hinten)
mainplug monitoring module (view from backside) mainplug monitoring module (view from backside)
1 4 6
BOMAG
3 2 1 3 2 1 2 1
5 4 3 2 1
5 3
1
4 3 2 1
2 3 4 5
A16
A51 Elektronik Tachograph
Platine Frequenzanzeige electronic system, tachograph
Printed circuit board,frequenzy m. 1 2 3
12.06.2006
1 1 920 100 07
Seis Elektrokasten
21.7
13.06.2006
1041
Vogt cross−bonding box 023
Name Bl. Pf. Benennung title TYP
21.7 022 14
022 14 Wiring diagram 920 100 07
A01 006 11
A02 008 8 Blinkrelais indicator relay 4/6X21 WATT
A02 022 17 Blinkrelais indicator relay
A03 006 10 Modul Vibration modul vibration
A03 009 4 Modul Vibration modul vibration
A03 021 7 Modul Vibration modul vibration
A04 006 5 Modul Berieselung modul sprinkler system
A04 021 11 Modul Berieselung modul sprinkler system
A05 014 16 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer
A05 021 11 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer
A12 017 9 Radio Radio
Vogt
13.06.2006
Seis
12.06.2006
E23 018 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 3,5A
E23 018 17 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55 WATT
1042 E25 016 3 Arbeitsscheinwerfer vorne rechts BOMAG
Working head light, front, rh. 55W 008 910 92
Name Bl. Pf. Benennung title TYP
E25
E25
016
Wiring diagram 920 100 07
E25 018
018
9
4
18
Arbeitsscheinwerfer vorne rechts
Arbeitsscheinwerfer vorne rechts
Arbeitsscheinwerfer vorne rechts
Working head light, front, rh.
Working head light, front, rh.
Working head light, front, rh.
3,5A
3,5A
55 WATT
21.7
E27 008 1 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
E27 016 4 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E27 016 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 3,5A
E27 018 6 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 3,5A
E27 018 19 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
E28 008 2 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E28 016 2 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E28 016 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 018 5 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 3,5A
E28 018 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E29 017 7 Innenleuchte Kabine Inside light, cabin 21W
Vogt
13.06.2006
Seis
12.06.2006
21.7 K22
K32
K35
022
016
007
7
17
12
Relais Hubmagnet Motor
Relais Kabine
Relais Selbsthaltung
Relay, shut off solenoid, engine
Relay, cabin
Relay, holding contact
Wiring diagramBOSCHL
920 100 07
BOSCHW
K35 022 8 Relais Selbsthaltung Relay, holding contact
K62 002 7 Relais D+ Relay, D+ BOSCHW
K62 022 9 Relais D+ Relay, D+
K79 006 12 Relais Berieselungspumpe Relay, sprinkler pump BOSCHW
K79 022 10 Relais Berieselungspumpe Relay, sprinkler pump
K80 006 11 Relais Berieselungspumpe Relay, sprinkler pump BOSCHW
K80 022 11 Relais Berieselungspumpe Relay, sprinkler pump
K82 006 18 Relais Kantenschneidgeraet ab Relay, edge cutter, up BOSCHW
K82 022 12 Relais Kantenschneidgeraet ab Relay, edge cutter, up
K83 006 19 Relais Kantenschneidgeraet auf Relay, edge cutter, down BOSCHW
K83 022 13 Relais Kantenschneidgeraet auf Relay, edge cutter, down
Vogt
13.06.2006
Seis
12.06.2006
S12 009 2 Vibrationsschalter Fahrhebel links Switch, vibration, travel lever, lh.
S13 009 3 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 008 8 Warnblinkschalter Switch, hazard light
S15 008 18 Beleuchtungsschalter StVZO Switch, lighting StVZO
S19 006 5 Emulsionsberieselungsschalter Switch, emulsion sprinkler system
103
S28
016
Wiring diagram 920 100 07
S26 018
015
16
11
17
Schalter Arbeitsbeleuchtung hinten
Schalter Arbeitsbeleuchtung hinten
Schalter Kabinenheizung
Switch, working head lights, rear
Switch, working head lights, rear
Switch, cabin heating
21.7
S30 002 1 Batterietrennschalter Switch, battery disconnect
S35 009 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 009 12 Vibrationsschalter Switch, vibration
S37 008 12 Schalter Blinker Switch, indicator
S38 017 3 Schalter Kennleuchte Switch, warning light
S44 015 1 Schalter Kabinenluefter Switch, cabin ventilator
S45 017 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S49 010 3 Schalter Bremse Switch, brake
S53 016 20 Schalter Arbeitsbeleuchtung Switch, working lights
S53 018 14 Schalter Arbeitsbeleuchtung Switch, working lights
S73 009 15 Schalter Splittstreuer Switch, gravel scratter
Vogt
13.06.2006
Seis
12.06.2006
21.7 X1:22
X1:23
X1:24
005
005
005
11
12
15
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
Wiring diagram 920 100 07
X1:25 008 11 Elektrokasten Cross−bonding box
X1:26 008 10 Elektrokasten Cross−bonding box
X1:27 002 9 ELEKTROKASTEN Cross−bonding box
X1:28 007 9 ELEKTROKASTEN Cross−bonding box
X1:29 003 9 ELEKTROKASTEN Cross−bonding box
X1:30 007 6 Elektrokasten Cross−bonding box
X1:31 009 5 ELEKTROKASTEN Cross−bonding box
X1:32 014 16 ELEKTROKASTEN Cross−bonding box
X1:33 014 16 ELEKTROKASTEN Cross−bonding box
X1:34 005 16 ELEKTROKASTEN Cross−bonding box
X1:35 008 8 Elektrokasten Cross−bonding box
Vogt
13.06.2006
Seis
12.06.2006
X1:118
006
Wiring diagram 920 100 07
X1:118 009
009
6
1
14
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
21.7
X1:119 006 5 ELEKTROKASTEN Cross−bonding box
X1:120 006 6 ELEKTROKASTEN Cross−bonding box
X1:121 011 6 ELEKTROKASTEN Cross−bonding box
X1:122 011 6 ELEKTROKASTEN Cross−bonding box
X1:123 004 3 ELEKTROKASTEN Cross−bonding box
X1:124 006 9 ELEKTROKASTEN Cross−bonding box
X1:125 005 15 ELEKTROKASTEN Cross−bonding box
X1:126 009 4 ELEKTROKASTEN Cross−bonding box
X1:127 002 17 ELEKTROKASTEN Cross−bonding box
X1:127 004 8 ELEKTROKASTEN Cross−bonding box
X1:127 005 15 ELEKTROKASTEN Cross−bonding box
Vogt
13.06.2006
Seis
12.06.2006
21.7 X2:11−1
X2:11−2
X2:12−1
004
004
005
2
3
1
ELEKTROKASTEN
ELEKTROKASTEN
ELEKTROKASTEN
Cross−bonding box
Cross−bonding box
Cross−bonding box
Wiring diagram 920 100 07
X2:12−2 005 2 ELEKTROKASTEN Cross−bonding box
X2:13−1 005 15 ELEKTROKASTEN Cross−bonding box
X2:13−2 005 14 ELEKTROKASTEN Cross−bonding box
X2:14−1 007 18 Elektrokasten Cross−bonding box
X2:14−2 007 18 Elektrokasten Cross−bonding box
X2:15−1 009 5 ELEKTROKASTEN Cross−bonding box
X2:15−2 009 4 ELEKTROKASTEN Cross−bonding box
X2:16−1 008 3 Elektrokasten Cross−bonding box
X2:16−2 008 4 Elektrokasten Cross−bonding box
X2:17−1 011 2 ELEKTROKASTEN Cross−bonding box
X2:17−2 011 2 ELEKTROKASTEN Cross−bonding box
Vogt
13.06.2006
Seis
12.06.2006
X10:2
017
Wiring diagram 920 100 07
X10:1 005
005
5
16
15
Steckdose
KRAFTSTOFFTANK
KRAFTSTOFFTANK
Socket
Fuel tank
Fuel tank
21.7
X10:3 005 15 KRAFTSTOFFTANK Fuel tank
X11:A 004 8 FAHRHEBEL Travel lever
X11:B 004 8 FAHRHEBEL Travel lever
X11:C 004 7 FAHRHEBEL Travel lever
X12:A 019 6 KNICKGELENK Articulated joint
X12:B 019 6 KNICKGELENK Articulated joint
X12:C 019 6 KNICKGELENK Articulated joint
X13:A 002 11 FAHRERSTAND Operators platform
X13:A−C 022 4 ELEKTROKASTEN Cross−bonding box
X13:B 002 11 FAHRERSTAND Operators platform
X13:C 002 12 FAHRERSTAND Operators platform
Vogt
13.06.2006
Seis
12.06.2006
21.7 X24:3
X24:4
X24:4
014
014
014
6
5
11
Bandage
Bandage
Bandage
Roller drum
Roller drum
Roller drum
Wiring diagram 920 100 07
X25:1 008 4 BLENDE HINTEN Screen rear
X25:2 008 5 BLENDE HINTEN Screen rear
X25:3 008 10 BLENDE HINTEN Screen rear
X25:4 008 14 BLENDE HINTEN Screen rear
X25:5 008 10 BLENDE HINTEN Screen rear
X25:6 008 14 BLENDE HINTEN Screen rear
X26:1 005 20 WASSERTANK Water tank
X26:2 005 20 WASSERTANK Water tank
X27:1 005 17 WASSERTANK Water tank
X27:2 005 17 WASSERTANK Water tank
X28:1 009 9 MOTORRAUM Engine room
Vogt
13.06.2006
Seis
12.06.2006
X64:2
016
Wiring diagram 920 100 07
X64:1 017
016
17
7
20
KABINE
Kabine
Kabine
Cabin
cabin
cabin
21.7
X64:3 017 12 Kabine cabin
X64:4 017 3 Kabine cabin
X64:5 017 12 Kabine cabin
X64:6 017 13 Kabine cabin
X64:7 017 5 Kabine cabin
X64:8 017 15 Kabine cabin
X65:1 016 3 Kabine cabin
X65:2 015 1 Kabine cabin
X65:3 015 2 Kabine cabin
X65:4 015 2 Kabine cabin
X66:1 016 4 Kabine cabin
Vogt
13.06.2006
Seis
12.06.2006
21.7 X88:56
X88:57
X88:58
011
011
011
14
15
15
ELEKTRONIK VARIOMATIC
ELEKTRONIK VARIOMATIC
ELEKTRONIK VARIOMATIC
Electronic variomatic
Electronic variomatic
Electronic variomatic
Wiring diagram 920 100 07
X88:59 011 15 ELEKTRONIK VARIOMATIC Electronic variomatic
X88:60 011 16 ELEKTRONIK VARIOMATIC Electronic variomatic
X88:65 011 16 ELEKTRONIK VARIOMATIC Electronic variomatic
X88:66 011 16 ELEKTRONIK VARIOMATIC Electronic variomatic
X88:67 011 17 ELEKTRONIK VARIOMATIC Electronic variomatic
X88:68 011 17 ELEKTRONIK VARIOMATIC Electronic variomatic
X89:A 002 1 FAHRERSTAND Operators platform
X89:A−B 022 2 ELEKTROKASTEN Cross−bonding box
X89:B 002 2 FAHRERSTAND Operators platform
X90:1 009 10 MOTORRAUM Engine room
X90:2 009 10 MOTORRAUM Engine room
Vogt
13.06.2006
Seis
12.06.2006
Y01 002 9 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y01 002 11 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
11
Y15 015 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y18 019 12 Magnetventil Hundegang Solenoid valve, crab walk 2,5A
Y19 019 10 Magnetventil Hundegang Solenoid valve, crab walk 2,5A
Y20 006 14 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 2,5A
920 100 07
Y120
009
Wiring diagram 920 100 07
Y99 006
007
16
8
12
Magnetventil Verstellzylinder
Magnetventil Berieselung Kantenschneidgeraet
Magnetventil Motordrehzahl hoch
Solenoid valve, ajustable zylinder
So.valve,sprinkler.sys.edge cutter
Solenoid valve, rpm engine high
1,5A
1,5A
70A/1A
21.7
Y131 009 19 Magnetventil Verstellzylinder Solenoid valve, ajustable zylinder 2,1A
Y138 015 9 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
Y139 002 12 Magnetventil Minusangleichung solenoid−valve boost−fuel 4,5AMP.
Y140 011 18 Magnetventil Erreger auf solenoid valve exciter up 1,26A
Y141 011 20 Magnetventil Erreger ab solenoid valve exciter down 1,26A
Y165 010 11 Magnetventil Phasensynchronisation 1 solenoid phase−synchro 1 2.41A
Y172 010 12 Magnetventil Phasensynchronisation 2 solenoid phase−synchro 2 2.41A
Vogt
13.06.2006
Seis
12.06.2006
component listing
Bauteilliste
12
12
920 100 07
112
Fig. 1
Fig. 1
Fig. 1
22.6 Machine