Professional Documents
Culture Documents
BW 211 D-40 - Service Training
BW 211 D-40 - Service Training
BW 211 D-40 - Service Training
S-582-0037
S/N 101 583 48 1095> / SN 861 583 55 1001> / S/N 861 583 56 1001> /
S/N 101 582 42 1940> / SN 101 582 43 2399> / S/N 101 582 44 1209> /
S/N 101 582 47 1053> / S/N 101 582 48 1239> / S/N 101 582 49 1019>
Table of contents
1 General................................................................................................................................................... 9
1.1 General......................................................................................................................................... 10
1.2 Concerning your safety.............................................................................................................. 12
1.2.1 General prerequisites................................................................................................................. 12
1.2.2 Definition of responsible persons............................................................................................... 15
1.2.3 Fundamentals for safe operation............................................................................................... 16
1.2.4 Handling fuels and lubricants..................................................................................................... 17
1.2.5 Parking the machine in secured condition................................................................................. 23
1.2.6 Emergency procedures.............................................................................................................. 23
1.2.7 Maintenance work...................................................................................................................... 24
1.2.8 Repair......................................................................................................................................... 27
1.3 Fuels and lubricants................................................................................................................... 28
1.3.1 Fuels and lubricants................................................................................................................... 28
1.4 List of fuels and lubricants........................................................................................................ 35
2 Overview of machine.......................................................................................................................... 37
2.1 Diesel engine............................................................................................................................... 38
2.2 Travel / vibration pump............................................................................................................... 39
2.3 Drum............................................................................................................................................. 41
3 Technical data...................................................................................................................................... 43
3.1 Technical data BW 211 D/PD-40................................................................................................. 44
3.2 Technical data BW 212 D/PD-40 (58243, 58248, 58356)........................................................... 48
3.3 Technical data BW 212 D-40 (58348, 58356)............................................................................. 52
3.4 Technical data BW 213 D/PD-40................................................................................................. 55
3.5 Additional technical data............................................................................................................ 59
4 Electric systems.................................................................................................................................. 63
4.1 Table of fuels and lubricants...................................................................................................... 66
4.2 Central electrics.......................................................................................................................... 73
4.3 Fuse assignment......................................................................................................................... 75
4.3.1 Notes on safety.......................................................................................................................... 75
4.3.2 Central electrics......................................................................................................................... 75
4.3.3 Main fuses.................................................................................................................................. 76
4.3.4 Fuses, cabin............................................................................................................................... 76
4.4 Operator’s stand......................................................................................................................... 78
4.4.1 Monitoring board, A15................................................................................................................ 81
4.5 Wiring........................................................................................................................................... 84
4.6 Starting the engine with jump leads.......................................................................................... 97
4.7 Proximity switches on travel lever, B13 and B14..................................................................... 98
4.8 Differential pressure switch for hydraulic oil filter, B21........................................................ 101
4.9 Level sensor in diesel tank, R03.............................................................................................. 102
4.10 Float switch, coolant tank, B55.............................................................................................. 103
4.11 Air filter vacuum switch, B03................................................................................................. 104
4.12 Sensor for water in fuel, B124................................................................................................ 105
4.13 Fuel pre-heating, R79.............................................................................................................. 106
4.14 Oil pressure switch, B06........................................................................................................ 107
1 General
1.1 General
General This manual:
n addresses the BOMAG customer service or professionally
trained personnel.
n explains the design of the machine and its functions.
n serves as
– document to be used during the training course
– reference book for the purpose of repeating or deepening
the training contents you have learned.
This manual describes components, assemblies and the essential
functions of the machine. (As far as required for the BOMAG After
Sales Service)
Index The index is a reference register that will help you to find informa-
tion in this Service Manual. The index lists keywords in alphabet-
ical order. Cross references (keywords related to page numbers)
enable quick and convenient search/navigation.
Keywords concerning the following subjects are listed in the index:
n Electrical operating means
n Plug designations
n Overviews
n Fault codes
n Troubleshooting
n ...
Documentation For the BOMAG machines described in this manual the following
documentation is additionally available:
n Operating and maintenance instructions
n Spare parts catalogue
n Service information (if necessary)
Spare parts needed for repairs can be taken from the spare parts
catalogue for the machine.
Updating service This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
In case of a new release all necessary changes will be included.
In the course of technical development we reserve the right for
technical modifications without prior notification.
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices
for safe and environment-friendly disposal of fuels
and lubricants as well as replacement parts.
Hard hat To protect the head against falling parts and to protect
against injuries.
n toxicological data
n environmental data
n notes on waste disposal
n information on transport
n legislation
n other data
1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come into contact
with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
Fig. 1 CAUTION!
Health hazard caused by contact with diesel
fuel!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according
to regulations.
1.2.4.3 Safety regulations and environmental protection regulations for handling AdBlue®/DEF
CAUTION!
Health hazard caused by ammonia vapours!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale ammonia vapours.
– Avoid contact and consumption.
1.2.4.4 Safety regulations and environmental protection regulations for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into contact with hot
components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
Fig. 3 CAUTION!
Health hazard caused by contact with oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
– Immediately bind spilled oil with an oil-binding
agent.
– Dispose of oil and oil filter according to regula-
tions.
1.2.4.5 Safety regulations and environmental protection regulations for handling hydraulic oil
WARNING!
Danger of injury caused by escaping pressure
fluid!
– Always depressurize the hydraulic system
before starting work in the hydraulic system.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact
with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with hydraulic
oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
– Immediately bind spilled oil with an oil-binding
agent.
– Dispose of oil and oil filter according to regula-
tions.
1.2.4.6 Safety regulations and environmental protection regulations for handling coolants
WARNING!
Danger of scalding by hot fluid!
– Open the compensation tank only when the
engine is cold.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
CAUTION!
Fig. 5 Health hazard caused by contact with coolant
and coolant additives!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled coolant!
– Immediately bind spilled coolant with an oil-
binding agent.
ENVIRONMENT!
Coolant is an environmentally hazardous sub-
stance!
– Always keep coolant and coolant additives in
proper containers.
– Immediately bind spilled coolant with an oil-
binding agent and dispose of it according to
regulations.
– Dispose of coolant according to regulations.
1.2.4.7 Safety regulations and environmental protection regulations for handling battery acid
WARNING!
Danger of cauterization with acid!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
– Do not allow clothes, skin or eyes to come into
contact with acid.
– Rinse off spilled battery acid immediately with
lots of water.
Fig. 6:
Rinse acid off clothes, skin or eyes immediately
with lots of clean water.
Immediately call for medical advice in case of cau-
terization.
WARNING!
Danger of injury caused by exploding gas mix-
ture!
– Remove the plugs before starting to recharge
the battery.
– Ensure adequate ventilation.
– Smoking and open fire is prohibited!
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
ENVIRONMENT!
Battery acid is an environmentally hazardous
substance!
– Dispose of battery and battery acid according
to regulations.
NOTICE!
Danger of engine damage!
– Do not shut down the engine all of a sudden
from full load speed, but let it idle for about two
minutes.
Fig. 7
Fig. 8
Fig. 9
Always ensure the correct tyre pressure and do not exceed the
specified maximum pressure.
When checking the tyre pressure stand in the extended path of the
tyre track. Use an at least 6 meter air hose, so that you can keep a
safe distance to the tyre.
Always consider the heavy weight of a wheel during disassembly
and assembly. Use a crane or forklift truck equipped with suitable
claws or a belt-type hoisting device.
1.2.8 Repair
Identify a defective machine with a warning sign.
Only operate the machine after it has been repaired.
Repairs must only be performed by an expert/qualified person.
When replacing safety relevant components, only original spare
parts must be used.
1.3.1.2 Fuel
1.3.1.2.1 Fuel quality
You should preferably use commercial diesel fuel with a sulphur
content of less than 0.5 %.
When using a diesel fuel with a high sulphur content of 0.5 % to
1.0 % the oil change intervals must be halved.
Fuels with a sulphur content of more than 1.0 % are not permitted.
NOTICE!
Danger of engine damage!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
1.3.1.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
1.3.1.3 Coolant
1.3.1.3.1 General
For fluid cooled engines the cooling fluid must be prepared by
admixing a cooling system protection agent to the fresh water and
should be checked within the specified maintenance intervals.
This prevents damage caused by corrosion, cavitation, freezing
and overheating.
Analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chlorine-ion content max. 100 mg/l
Sulphate ion content max. 100 mg/l
Water hardness (ion content of max. 3.56 mmol/l
calcium and magnesium )
max: 356 mg/l (ppm)
Germ degree: max. 20 °dH
English degree: max: 25 °eH
French degree: max: 35.6 °fH
Bacteria, fungi, yeasts not permitted
NOTICE!
Danger of engine damage!
– Another analysis must be made after the fresh
water has been prepared.
NOTICE!
Danger of engine damage!
– Do not mix different coolants and additives of
any other kind.
– Before changing the product you must clean
the entire cooling system.
– Consult our customer service if in doubt.
– The cooling system protection agent must be
used all year round, to provide adequate corro-
sion protection.
NOTICE!
Danger of engine damage!
– A proportion of more than 50% of cooling
system protection agent causes a drop in
cooling power.
– The use of corrosion protection oils as cooling
system protection agents is not permitted.
NOTICE!
Risk of damage!
– Check the filter more frequently after this
change.
– Perform regular oil analyses for content of
water and mineral oil.
– Replace the hydraulic oil filter element every
500 operating hours.
2 Overview of machine
Fig. 11
4 Y07
MB
Y08
5
M3 B
3 MA 6
2
1 M1
B
M2
L1
M3
D
S
E
M2
L1
M1
A
S
L2
MA
MB
S-582-0038
Fig. 12
1 Travel pump
2 Multi-function valve, travel pump
3 Multi-function valve, travel pump
4 Solenoid valve vibration (Y07), high amplitude
5 Solenoid valve vibration (Y08), low amplitude
6 Vibration pump
M3 Charge pressure, 26+ 3 bar
1/MA Travel pressure against block, forward travel, MA 420 bar
1/MB Travel pressure against block, backward travel, MA 420 bar
6/MA Vibration pressure, MA 420 bar
6/MB Vibration pressure, MB 420 bar
Vibration pump
High amplitude Low amplitude
Current on coil C1 C2
Plugs Y07 Y08
Pressure on port A B
2.3 Drum
Fig. 13
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel motor
5 Drum shell
6 Rubber buffer
7 Rectangular rubber buffers
8 Travel bearings
3 Technical data
Fig. 14
Weights
Max. operating weight 13000 kg 28660 lbs
Operating weight (CECE) with ROPS-cabin 9500 kg 20944 lbs
Axle load, drum (CECE) 5750 kg 12677 lbs
Axle load, wheels (CECE) 3750 kg 8267 lbs
Static linear load 27.0 kg/cm 151.2 pli
Travel characteristics
Travel speed (1) 0 – 6 km/h 0 – 3.7 mph
Travel speed (2) 0 – 10 km/h 0 – 6.2 mph
Max. gradability without/with vibration (soil 45% / 43% 45% / 43%
dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2012 C BF4M 2012 C
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 98 kW 98 kW
Rated power SAE J 1995 132 hp 132 hp
Rated speed 2300 min-1 2300 rpm
Electrical equipment 12 V 12 V
Drive system Hydrostatic Hydrostatic
Permissible ambient temperatures -20 .... +50 °C -4 .... +122 °F
Brakes
Service brake Hydrostatic Hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation Hydrostatic Hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in
Vibration
Drive system Hydrostatic Hydrostatic
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.80/0.95 mm 0.071 – 0.037 in
Centrifugal force (1/2) 236/170 kN 53055/ 38218 lbf
Tyres
Tyre size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.1 bar 16 psi
Air pressure, range 0.8 – 1.4 bar 12 – 20 psi
Filling capacities
Fuel (diesel) 250 l 66 gal us
Fig. 15
Weights
Max. operating weight 12620 kg 27822 lbs
Operating weight (CECE) with ROPS-cabin 11350 kg 25022 lbs
Axle load, drum (CECE) 6750 kg 14881 lbs
Axle load, wheels (CECE) 4600 kg 10141 lbs
Travel characteristics
Travel speed (1) 0 – 6 km/h 0 – 3.7 (machine type
dependent)
Travel speed (2) 0 – 10 km/h 0 – 6.2 (machine type
dependent)
Max. gradability without/with vibration (soil 49% / 46% 49% / 46%
dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2012 C BF4M 2012 C
Cooling Water Water
Number of cylinders 4 4
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in
Vibration
Drive system hydrostatic hydrostatic
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.70/0.95 mm 0.067 – 0.037 in
Centrifugal force (1/2) 275/202 kN 61822/ 45411 lbf
Tires
Tire size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.4 bar 20 psi
Air pressure, span 0.8 – 1.4 bar 12 – 20 psi
Padfeet, quantity 150 150
Height of padfeet 100 100
Area of one padfoot 137 cm2 21.2 in2
Filling capacities
Fuel (diesel) 250 l 66 gal us
Fig. 16
Weights
Max. operating weight 14670 kg 32342 lbs
Operating weight (CECE) with ROPS-cabin 10900 kg 24030 lbs
Axle load, drum (CECE) 7150 kg 15763 lbs
Axle load, wheels (CECE) 3750 kg 8267 lbs
Static linear load 33.6 kg/cm 188.1 pli
Travel characteristics
Travel speed (1) 0 – 6 km/h 0 – 3.7 mph
Travel speed (2) 0 – 10 km/h 0 – 6.2 mph
Max. gradability without/with vibration (soil 45% / 43% 45% / 43%
dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2012 C BF4M 2012 C
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 98 kW 98 kW
Rated power SAE J 1995 132 hp 132 hp
Rated speed 2300 min-1 2300 rpm
Electrical equipment 12 V 12 V
Drive system Hydrostatic Hydrostatic
Permissible ambient temperatures -20 .... +50 °C -4 .... +122 °F
Brakes
Service brake Hydrostatic Hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation Hydrostatic Hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in
Vibration
Drive system Hydrostatic Hydrostatic
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.80/0.95 mm 0.071 – 0.037 in
Centrifugal force (1/2) 236/170 kN 53055/ 38218 lbf
Tyres
Tyre size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.1 bar 16 psi
Air pressure, range 0.8 – 1.4 bar 12 – 20 psi
Filling capacities
Fuel (diesel) 250 l 66 gal us
Fig. 17
Weights
Max. operating weight 13320 kg 29366 lbs
Operating weight (CECE) with ROPS-cabin 12750 kg 28109 lbs
Axle load, drum (CECE) 8150 kg 17968 lbs
Axle load, wheels (CECE) 4600 kg 10141 lbs
Travel characteristics
Travel speed (1) 0 – 6 km/h 0 – 3.7 (machine type
dependent)
Travel speed (2) 0 – 10 km/h 0 – 6.2 (machine type
dependent)
Max. gradability without/with vibration (soil 49% / 46% 49% / 46%
dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2012 C BF4M 2012 C
Cooling Water Water
Number of cylinders 4 4
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in
Vibration
Drive system hydrostatic hydrostatic
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.70/0.95 mm 0.067 – 0.037 in
Centrifugal force (1/2) 275/202 kN 61822/ 45411 lbf
Tires
Tire size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.4 bar 20 psi
Air pressure, span 0.8 – 1.4 bar 12 – 20 psi
Padfeet, quantity 150 150
Height of padfeet 100 100
Area of one padfoot 137 cm2 21.2 in2
Filling capacities
Fuel (diesel) 250 l 66 gal us
Fig. 18
Dimensions in mm A B D H H2 K L O1 O2 S W
BW 212 D-40 2960 2250 1500 2268 2985 490 5840 60 60 25 2130
Travel characteristics
Travel speed (1) km/h 0–6
Travel speed (2) km/h 0 – 10
Max. gradability without/with vibration (soil dependent) % 45/43
Drive
Engine manufacturer Deutz
Type BF4M 2012C
Cooling Water
Number of cylinders 4
Brakes
Service brake hydrostatic
Parking brake hydr.-mech.
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering/oscillation angle ±° 35/12
Inner track radius mm 3494
Vibration
Drive system hydrostatic
Frequency (1/2) Hz 30/36
Amplitude (1/2) mm 1.8/0.95
Centrifugal force (1/2) kN 236/125
Tires
Tire size 23.1-26/12PR
Air pressure, nominal value bar 1.4
Air pressure, range bar 0.8 - 1.4
Filling capacities
Motor l approx. 10,5
Fuel l approx. 250
Hydraulic oil l approx. 80
Coolant l approx. 16
Fig. 19
Weights
Max. operating weight 15040 kg 33157 lbs
Operating weight (CECE) with ROPS-cabin 12420 kg 27381 lbs
Axle load, drum (CECE) 7820 kg 17240 lbs
Axle load, wheels (CECE) 4600 kg 10141 lbs
Static linear load 36.7 kg/cm 188.1 pli
Travel characteristics
Travel speed (1) 0 – 6 km/h 0 – 3.7 mph
Travel speed (2) 0 – 10 km/h 0 – 6.2 mph
Max. gradability without/with vibration (soil 45% / 43% 45% / 43%
dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2012 C BF4M 2012 C
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 98 kW 98 kW
Rated power SAE J 1995 132 hp 132 hp
Rated speed 2300 min-1 2300 rpm
Electrical equipment 12 V 12 V
Drive system Hydrostatic Hydrostatic
Permissible ambient temperatures -20 .... +50 °C -4 .... +122 °F
Brakes
Service brake Hydrostatic Hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation Hydrostatic Hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in
Vibration
Drive system Hydrostatic Hydrostatic
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.90/0.96 mm 0.075 – 0.038 in
Centrifugal force (1/2) 275/202 kN 61822/ 45411 lbf
Tyres
Tyre size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.1 bar 16 psi
Air pressure, range 0.8 – 1.4 bar 12 – 20 psi
Filling capacities
Fuel (diesel) 250 l 66 gal us
Fig. 20
Weights
Max. operating weight 14190 kg 31284 lbs
Operating weight (CECE) with ROPS-cabin 12870 kg 28373 lbs
Axle load, drum (CECE) 8270 kg 18232 lbs
Axle load, wheels (CECE) 4600 kg 10141 lbs
Travel characteristics
Travel speed (1) 0 – 6 km/h 0 – 3.7 (machine type
dependent)
Travel speed (2) 0 – 10 km/h 0 – 6.2 (machine type
dependent)
Max. gradability without/with vibration (soil 49% / 46% 49% / 46%
dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2012 C BF4M 2012 C
Cooling Water Water
Number of cylinders 4 4
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydrostatic hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in
Vibration
Drive system hydrostatic hydrostatic
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.70/0.86 mm 0.067 – 0.034 in
Centrifugal force (1/2) 275/202 kN 61822/ 45411 lbf
Tires
Tire size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.4 bar 20 psi
Air pressure, span 0.8 – 1.4 bar 12 – 20 psi
Padfeet, quantity 150 150
Height of padfeet 100 100
Area of one padfoot 137 cm2 21.2 in2
Filling capacities
Fuel (diesel) 250 l 66 gal us
Travel pump
Manufacturer Sauer
Type 90R 075
System Axial piston/swash plate
Max. displacement cm3/rev 75
Max. pumping delivery l/min 172.9
High pressure limitation bar 400 + 20
Charge pressure, high idle bar 26 + 3
Vibration pump
Manufacturer Sauer
Type 42R 041
System Axial piston/swash plate
Max. displacement cm3/rev 41
Starting pressure bar 420 + 20
Operating pressure (soil dependent) bar approx. 100
Integrated charge pump cm3/rev 11
Vibration motor
Type A10FM 45
System Axial piston/swash plate
Displacement cm3/rev 45
Flushing rate l/min 6
Flushing pressure limitation bar 13
Steering/charge pump
Type HY/ZFS11/16
System Gear
Displacement cm3/rev 16
Max. steering pressure when steered against end stops bar 200 + 20
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Rear axle
Manufacturer Dana
Type CHC 192/51HD
Differential No-Spin
4 Electric systems
Fig. 21
1 Machine with Telematic
2 GPS satellite
3 Mobile communications network
4 External partner
5 Internet (Cloud)
6 User
7 Telematic server
BOMAG TELEMATIC is a Fleet Management System. BOMAG
TELEMATIC enhances the effective use of machines. The POWER
variant enables continuous recording of the fuel consumption.
With BOMAG TELEMATIC the machine operator can localize his
machines and also detect and save operating states. Actual oper-
ating hours are documented. Maintenance planning and documen-
tation is entirely mapped in BOMAG TELEMATIC.
BOMAG TELEMATIC is able to recognize unauthorized use or
theft. Many insurance companies award this with reduced insur-
ance premiums.
The system consists of a machine integrated hardware and an
internet application. All data are saved in a database. Access is
individual for each user and password protected.
Optional modules In addition, the system can also be extended with further modules.
The technical requirements for surface covering compaction con-
trol are achieved with BOMAG COMPACTION METER (BCM) and
GPS, the satellite-assisted location system. This means that all
compaction data of a construction project can be recorded, pro-
cessed, managed, graphically displayed and, if required, printed
out.
Fig. 23
n To exactly 22 cm
n No local referencing station
The assignment of the individual measuring values to the meas-
uring position is accomplished with the help of an automatic posi-
tion acquisition system.
X3
X38
X37 A124
X36
X1
F150
8 R10 K05
8 88 80
X1
P16 K06
X2
K22
K35
A02
K48
K16 K61
K11 K36
K114
K09
K26
K69
A68
F23 F25
A05 F14 F39
X44 K04 F18
29 F24
F08
F10 28 30
27 F03
A83 F09 26 31
F19 25
24 32
F22
23
F07 22
F11 21
F105 19
18
F68 17
F13 16
15
37
35
34
33
X1 F124
F146
F148 F84
S-582-0034
Fig. 24
A68 Only when a seat contact is installed
K04 Only when no seat contact is installed
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings
and do not bridge fuses.
WARNING!
Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
Fig. 26
Fig. 27
Fig. 28
Fig. 31
1 [S00] Starter switch
2 [A15] Instrument cluster
3 [S44] Rotary switch for cabin fan (optional equipment)
4 [A108] Rotary switch for air conditioning (optional equipment)
5 Vent for heating and ventilation, driver
6 Vent for heating and ventilation, footwell
7 [S13] Push button for vibration
8 Travel lever
9 [S35] Rotary switch for vibration, amplitude pre-selection
10 [S42] Rotary switch for travel speed ranges
11 [S01] Emergency stop switch
12 [S03] Push button for warning horn
13 [S120] Rotary button for engine speed
14 [S37] Rotary switch for direction indicators (optional equipment)
15 [S14] Rotary switch for hazard light system (optional equipment)
n Instrument cluster
4.5 Wiring
X5
C
H07
AS
A15
S120
OPTION
EMR
S15
S53
S118
H04
nicht benötigt
S00 not required
H124
S291
OPTION
E03
E04
E07
P03
P04
P07
P12
EXX
PXY
X1
S-582-0023
Fig. 37
1 Wiring loom, dashboard <> central electrics
S42 S01
S03
S35
Option/option
X42
X14
S06
X1
X2
S-582-0024
Fig. 38
1 Wiring loom, arm rest, right <> central electrics
Fig. 39
1 Wiring loom, engine <> central electrics
3
-
M01
1 4
F00:2
F00:1
X36
G01:-
G01:+
5
-
S-582-0040
Fig. 40
1 Wiring loom, central electrics supply
2 Wiring loom, battery <> starter motor
3 Wiring loom, frame <> diesel engine
4 Wiring loom, frame <> battery (-)
5 Wiring loom, battery (+) <> main battery fuse
Fig. 41
1 Wiring loom, rear frame <> central electrics
Fig. 42
1 Wiring loom, cabin <> central electrics
B104 X20
X17
Y15
X1 2
S-582-0009
Fig. 43
1 Wiring loom, heating / air conditioning
2 Wiring loom, air conditioning compressor
E28
E27
E25
E23
XS
X3
S-582-0010
Fig. 44
1 Wiring loom, working lights
Fig. 45
1 Wiring loom, acceleration transducer
Fig. 46
4 Wiring loom, tachometer module
Fig. 47
11 Wiring loom, lighting on railing
Fig. 48
13 Wiring loom, cabin tachograph
S-582-0008
Fig. 49
NOTICE!
A wrong connection will cause severe damage
in the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.
1. Connect the plus pole of the external battery first with the
plus pole of the vehicle battery using the first jump lead.
2. Then connect the second battery cable first to the minus pole
of the current supplying auxiliary battery and then to engine
or chassis ground, as far away from the battery as possible.
3. Start the engine.
NOTICE!
Danger of damage to the electronic system!
If no powerful consuming device is switched on,
Fig. 50
voltage peaks may occur when separating the con-
necting cables between the batteries, which could
damage electrical components.
Fig. 51
General
In all automated sequences the use of sensors as a source of
information for the electronic control is indispensable. The sensors
deliver the necessary signals about positions, end positions, filling
levels or serve as pulse transducers for counting tasks or speed
detection. In industrial applications inductive and capacitive prox-
imity switches are today indispensable. Compared with mechanical
switches they provide almost ideal prerequsites: contactless, wear-
free operation, high switching frequency and switching accuracy as
well as high protection against vibration, dust and moisture. Induc-
tive sensors detect all metals without contact, capacitive sensors
detect almost all solid and liquid media, such as metal, glass,
wood, plastic, water, oil, etc.
Working principle
The working principle is based on the principle of the dampened
LC-oscillator. The coil of the oscillation circuit forms a high-fre-
quency magnetic stray field.
This stray field leaks out from the active area of the proximity
switch. If metal or non-ferrous metal enters into the response range
energy is absorbed. The oscillator is thus dampened and the
resulting change in current consumption is evaluated.
Fig. 52
PNP circuitry
On sensors with PNP circuitry the output stage contains a PNP
transistor, which switches the load against the positive operating
voltage. The load is connected between the output and the nega-
tive operating voltage. The switch is designed with a normally open
contact, i.e. the contact closes when the initiator comes in “contact”
with metal.
Fig. 53: PNP circuitry
NPN circuitry
On sensors with NPN-circuitry the output stage contains a NPN-
transistor, which switches the load against the negative operating
voltage. The load is connected between the output and the positive
operating voltage.
Fig. 55
Fig. 57
Fig. 61
Coolant level warning lamp, new The switch contact connects the monitoring board (A15, Pin15) to
design ground. The coolant level warning lamp e flashes.
Fig. 63
Air filter warning lamp, new design The vacuum switch operates at a vacuum of > 50 mbar.
The switch contact connects the monitoring board (A15, Pin16) to
ground. The air filter warning lamp gÄ Fig. 64 lights.
Fig. 65
Fig. 67
Fig. 68
Engine oil pressure warning lamp With a too low engine oil pressure the monitoring board (A15,
Pin11) is connected to ground. The warning lamp d flashes.
Fig. 70
WARNING!
Danger of scalding!
Do not remove the cap from the compensa-
tion tank when the engine is still hot.
ENVIRONMENT!
Dispose of escaping coolant environmentally
7. Let the engine cool down and check the coolant level again,
top up if necessary.
Fig. 74
Fig. 75
Nominal values:
n Pick-up current 0.5 seconds, 4 Amp.
n Holding current, 0.5 Amp.
n Resistance, 280 Ω
Function
The throttle control switch (S120) is used to change from "MIN" idle
speed to "MAX" full throttle and vice versa.
Fig. 79
NOTICE!
With the governor rod retracted the gap
should be min. 0.1 mm and max. 0.5 mm.
If the gap is too small, the limit switch in the
solenoid may not be able to operate.
In case of a too wide gap the engine will not
reach its maximum speed.
Fig. 80
Fig. 81
Fig. 82
Charge control light, new design If the battery is not being charged, a ground signal is applied to D+
terminal 3 . Current flows from the monitoring board (A15) through
the charge control light and through (Pin10) to the D+ terminal. The
charge control lamp fÄ Fig. 83 lights up.
Engine PRM-meter Terminal "W" on the generator delivers a pulsating direct voltage,
which can be utilized to determine the rotary speed of the engine.
NOTICE!
Multiple activation of the heater control in short
term operation (low generator running time) dis-
charges the starter battery.
If the engine does not start properly in case of
automatic starting of the heating flange because
the starter does not get energized due to a fault
and does not crank the engine, the starting
process must be completely aborted (ignition key
to OFF, voltage supply to heating flange inter-
Fig. 86: Monitoring board, new
rupted). In order to avoid damage to heating flange
design, A15
or charge air hoses caused by overheating,
another start of the engine must be avoided and
trouble shooting should be performed instead.
Several successive starting attempts can cause
overheating of the heating flange .
Fig. 87
Fig. 88
1 Heating start
2 Signal lamp
3 Start
4 Switching relay
5 Status
6 Terminal 15/S
7 Terminal L
8 Terminal 50
9 Terminal R
10 Start process
Fig. 89: Heating flange function dia- 11 Ready for starting: 0 sec.
gram
Service Training
Electrics
MESX
Version 4.06
Table of contents
1 Document alteration list .....................................................................................................................3
2 Proof of software change MESX .......................................................................................................4
3 Proof of software change BOP ..........................................................................................................6
4 Known faults ......................................................................................................................................7
5 How to proceed when replacing components? .................................................................................8
5.1 How to proceed when replacing an ESX control? .....................................................................8
5.2 How to proceed when replacing a rear axle sensor?.................................................................8
5.3 Which components can be replaced without a subsequent adjustment procedure? ................8
5.4 List of machine types .................................................................................................................9
6 Possible adjustments on machines without BOP ............................................................................12
6.1 Description of the Display Module ...........................................................................................12
6.2 Input of code numbers .............................................................................................................12
6.3 Changing the machine type (only via display module) ............................................................13
6.4 Inverting the direction signal (only via display module) ...........................................................14
6.5 Changing the bit rate (only with display module) .....................................................................15
7 Adjustment/display possibilities on machines with BOP .................................................................16
7.1 Adjusting the machine type (BOP) ...........................................................................................16
7.2 Inverting the direction signal via the BOP control terminal ......................................................18
7.3 Accessing the diagnostics menu..............................................................................................20
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof)................ 22
7.3.2 Operating hours meter on machines with circular exciter (BTMplus, BTMprof) .............. 23
7.3.3 Extended diagnose BVC machines ................................................................................. 24
7.3.4 Operating hour meter BVC machines .............................................................................. 25
7.4 Simulation mode ......................................................................................................................26
7.5 Changing the printout language ...............................................................................................30
7.6 Setting the machine serial number ..........................................................................................32
7.7 Teaching distance pulses ........................................................................................................34
7.8 Activating the amplitude limitation (only BVC machines).........................................................36
7.9 Changing the display mode (metric/imperial) ..........................................................................38
7.10 Position to switch over the acceleration transducer (only BVC machines) ..........................40
7.11 Switching the GPS Receiver Voltage Supply Mode .............................................................42
8 Possible settings on the BCM05mobile...........................................................................................44
8.1 Reading the software version ..................................................................................................44
8.2 Changing the language ............................................................................................................44
8.3 Changing the unit system (metric/imperial) .............................................................................44
9 Block diagram BEM .........................................................................................................................45
10 Block diagram BTMplus / VARIOCONTROL ...............................................................................46
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile ................................................47
12 Description of the signals on the ESX-control .............................................................................48
13 Fault codes of the ESX control ....................................................................................................53
13.1 Overview...............................................................................................................................53
13.2 Description of fault reactions ................................................................................................54
13.3 Detailed description of fault codes and their possible causes ............................................55
14 Input codes for ESX control (only via BEM display module) .......................................................59
14.1 Travel system .......................................................................................................................59
14.2 Vibration ...............................................................................................................................60
14.3 Light ......................................................................................................................................60
14.4 Acceleration transducer ........................................................................................................61
14.5 Diesel engine ........................................................................................................................61
14.6 Setting the machine type ......................................................................................................62
14.7 Parameter change ................................................................................................................63
15 Terminology in connection with ESX ...........................................................................................64
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 "5.4 List of
machine types, or "7.1 Adjusting the machine type (BOP)").
• Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
• Set the machine serial number (only on machines with BOP), see: 7.6
• Set the printer language (only machines with printer), see: 7.5
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
101 583 27 1001
177 PD 101 583 43 1001 XXX XXX XX XXXX
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
101 583 32 1001
101 584 10 1001
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
101 583 31 1001
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
101 583 28 1001
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
101 583 33 1001
179 PDH 101 582 25 1001 XXX XXX XX XXXX 7512 3.03
101 583 35 1001
211 D 101 582 40 1001 XXX XXX XX XXXX 7520 1.03
101 582 41 1001
101 583 09 1001
101 583 51 1001
211 PD 101 582 45 1001 XXX XXX XX XXXX 7529 4.00
101 583 10 1001
213 D 101 582 50 1001 XXX XXX XX XXXX 7530 1.03
101 583 08 1001
213 DH 101 582 51 1001 XXX XXX XX XXXX 7531 1.03
101 583 14 1001
101 583 37 1001
101 584 11 1001
101 584 12 1001
213 PD 101 582 46 1001 XXX XXX XX XXXX 7539 4.00
101 583 13 1001
213 PDH 101 582 52 1001 XXX XXX XX XXXX 7532 3.03
101 583 15 1001
213 BVC 101 582 53 1001 XXX XXX XX XXXX 7533 1.02
101 583 16 1001
213 BVC plates 101 582 54 1001 XXX XXX XX XXXX 7534 3.00
101 583 06 1001
213 BVC DI 101 582 53 1001 XXX XXX XX XXXX 7535 1.05
101 583 16 1001
214 D 101 583 42 1001 XXX XXX XX XXXX
214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03
101 583 19 1001
214 PDH 101 582 59 1001 XXX XXX XX XXXX 7542 3.03
101 583 20 1001
216 D 101 582 62 1001 XXX XXX XX XXXX 7550 3.03
101 583 23 1001
101 584 13 1001
Machine type First serial number Last serial number Code Available from
version
219 D 101 582 72 1001 XXX XXX XX XXXX 7560 2.00
101 582 10 1001
861 582 75 1001
101 584 02 1001
219 DH 101 582 70 1001 XXX XXX XX XXXX 7561 1.05
101 582 77 1001
101 584 04 1001
219 PD 101 582 73 1001 XXX XXX XX XXXX 7569 4.00
101 582 11 1001
101 584 03 1001
219 PDH 101 582 71 1001 XXX XXX XX XXXX 7562 3.03
101 582 78 1001
101 584 05 1001
226 DH 101 582 80 1001 XXX XXX XX XXXX 7571 3.03
101 582 83 1001
101 582 88 1001
101 584 06 1001
226 PDH 101 582 81 1001 XXX XXX XX XXXX 7572 3.03
101 582 84 1001
101 582 89 1001
101 584 07 1001
226 BVC 101 582 82 1001 XXX XXX XX XXXX 7573 3.01
101 582 85 1001
101 582 86 1001
101 584 08 1001
226 BVC DI 101 582 82 1001 XXX XXX XX XXXX 7575 1.04
101 582 85 1001
101 582 86 1001
101 584 08 1001
226 BVC RC 101 582 82 1001 XXX XXX XX XXXX 7576 3.03
101 582 85 1001
101 582 86 1001
101 584 08 1001
332 DEEP IMPACT 101 583 44 1001 XXX XXX XX XXXX 7585 4.05
101 583 52 1001
101 584 09 1001
101 584 14 1001
Machine type First serial number Last serial number Code Available from
version
VARIOCONTROL 101 582 12 1001 XXX XXX XX XXXX 7537 4.00
VARIOCONTROL+ 101 582 13 1001 XXX XXX XX XXXX 7538 4.00
Machine type First serial number Last serial number Code Available from
version
177 D-40 901 582 26 1001 XXX XXX XX XXXX 7600 4.00
177 DH-40 901 582 27 1001
177 DHC-4 101 582 00 1001 XXX XXX XX XXXX 7601 4.00
101 583 29 1001
177 PDHC-4 101 582 01 1001 XXX XXX XX XXXX 7602 4.00
101 583 30 1001
177 PDH-40 901 582 28 1001 XXX XXX XX XXXX 7609 4.00
179 DHC-4 101 582 02 1001 XXX XXX XX XXXX 7611 4.00
101 583 34 1001
179 PDHC-4 101 582 03 1001 XXX XXX XX XXXX 7612 4.00
101 583 36 1001
211 D-40 101 582 42 1001 XXX XXX XX XXXX 7620 4.00
901 583 02 1001
901 583 25 1001
211 PD-40 101 582 47 1001 XXX XXX XX XXXX 7629 4.00
901 583 03 1001
901 583 26 1001
212 D-40 101 582 43 1001 XXX XXX XX XXXX 7680 4.00
101 582 48 1001
101 583 49 1001
212 PD-40 101 583 48 1001 XXX XXX XX XXXX 7689 4.00
101 583 50 1001
213 D-40 101 582 44 1001 XXX XXX XX XXXX 7630 4.00
901 582 55 1001
901 583 07 1001
213 DH-40 901 582 56 1001
213 DHC-4 101 582 04 1001 XXX XXX XX XXXX 7631 4.00
101 583 11 1001
213 PDHC-4 101 582 05 1001 XXX XXX XX XXXX 7632 4.00
101 583 12 1001
213 PD-40 101 582 49 1001 XXX XXX XX XXXX 7639 4.00
213 PDH-40 901 582 57 1001
214 DHC-4 101 582 06 1001 XXX XXX XX XXXX 7641 4.00
101 583 17 1001
214 PDHC-4 101 582 07 1001 XXX XXX XX XXXX 7642 4.00
101 583 18 1001
216 D-40 101 583 39 1001 XXX XXX XX XXXX 7650 4.04
216 DHC-4 101 582 08 1001 XXX XXX XX XXXX 7651 4.00
101 583 21 1001
216 PD-40 101 583 40 1001 XXX XXX XX XXXX 7659 4.04
216 PDHC-4 101 582 09 1001 XXX XXX XX XXXX 7652 4.00
101 583 22 1001
218 D-40 101 583 34 1001 XXX XXX XX XXXX 7670 4.04
101 583 41 1001
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!
• 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 )
• 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!
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.
Note: Parameter adjustments can only be performed when the engine is not running!
• Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.
• Enter code number 7 6 0 1 . This code number inverts the direction signal.
The display module now permanently shows the code 0 0 0 1 (signal inverted), or the code 0 0 0 0 (signal
not inverted).
In succession the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 14"Input codes for ESX control").
• 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 .
• 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 .
• 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!
• Press key "?" to open the screen page "MENU". The following screen is displayed:
• Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:
• The desired machine type can be selected by pressing the keys "F11" and "F12". (see List of
machine types under item 5.4 "List of machine types" ).
• 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 MESX are now adjusted to the new machine type.
7.2 Inverting the direction signal via the BOP control terminal
Depending on the installation position, the axle sensor used delivers a 12V output signal in forward
and reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.
Note: Parameter adjustments can only be performed when the engine is not running!
• Press key "?" to open the screen page "MENU". The following screen is displayed:
• Press key "F1" to open the screen page "Invert direction signal". The following screen is displayed:
• The direction signal can now be inverted or not inverted by pressing key "F5" ("Invert = 1" or
"Invert = 0").
• After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
Check on the printout or in the diagnostics menu whether the travel direction has been correctly
detected.
• 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".
• By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see
below).
98% Small Ampl: Triggering of solenoid valve for low amplitude in percent
MD+ Status MESX input MD+ (detection engine running) (LED on = 12V)
+01234 Distance pulses detected by the MESX (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
Vib. small ampl.: Operating hours with vibration driven with small amplitude mode
+01234 Distance pulses detected by the MESX (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
• By pressing key "B" you can display an operating hour meter (see below).
Ampl. < 1.25 mm: Operating hours with vibration driven with small amplitude mode
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!
• Press key "?" to open the screen page "MENU". The following screen is displayed:
• Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:
• Press key "A" to open the screen page "extended diagnose". The following screen is
displayed:
• Press key "A" again to open the screen page "simulation mode". The following screen is
displayed:
• The simulated travel direction can be selected with keys "F5", "F6", "F7". The detected travel
direction is displayed in the roller symbol underneath.
• 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.
• Press key "F6" to open the screen page "Printout language". The following screen is displayed:
• The desired printout language can be selected by pressing the keys "F11" and "F12".
• After selecting the desired language press key "F14" to save the adjustment. The symbol (F14)
lights green for a moment as a sign of confirmation.
• Press key "F7" to open the screen page "Serial number". The following screen is displayed:
• The desired printout language can be selected by pressing the keys "F11" and "F12".
• After the adjustment press key"F14" to save the adjustment. 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.
• Press key "?" to open the screen page "MENU". The following screen is displayed:
• Press key "F8" to open the screen page "Distance pulses". The following screen is displayed:
• Pressing the key "F5" starts the teach mode. The following symbol appears:
• Drive a distance of 10 m length in forward and press the key "F6" at the end. The following symbol
appears:
• 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!
• Press key "F3" to open the screen page "Amplitude limitation". The following screen is displayed:
• The limitation can now be activated or deactivated by pressing key "F5" ("Limit = 1" or "Limit = 0").
• After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
• Press key "F4" to open the screen page "Display mode". The following screen is displayed:
• The imperial display (mph, °F, etc.) can now be activated or deactivated by pressing key "F5"
("Imperial = 1" or "Imperial = 0").
• After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
• Press key "F9" to open the screen page "Acc Position". The following screen is displayed:
• Press key "F1" to activate the upper position or press key "F3" to activate the lower position.
• After the desired change press and hold key "F14" to save the adjustment. The symbol lights
green after a few seconds as a sign of confirmation. Then release the key again.
• Press key "F14" to open the screen page "GPS Mode". The following screen is displayed:
This function enables the GPS Receiver Power Supply to be controlled via MESX, so that the receiver
can be switched on and off in a defined way.
• The GPS Mode can now be changed over by pressing the "F5"-key:
Note: After this setting the service window must be closed to avoid unauthorized
access. Press "Close window" at the bottom right in the service window.
165
166
Service Training MESX Block diagram
X44:5 Interface RS 232 TxD, used for printer control. Measurement not possible!
X44:6
X44:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analog input / voltage input 0..8.5 V Stop bottom approx. 2.2 V
Neutral position approx. 4.25 V
Stop top approx. 6.6 V
167
168
Service Training MESX Description of signals
X44:11
X44:12
X44:13
X44:14
X44:21
X44:22
X44:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X44:34
X44:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on machine
type.
Digital input active high
169
170
Service Training MESX Description of signals
X44:40
X44:41
Electric systems – MESSX, A83
X44:42
X44:43
X44:44
X44:45
X44:49
X44:50
X44:52
X44:61
X44:62
X44:63
X44:64
171
Electric systems – MESSX, A83
13.1 Overview
Note: Errors with error reaction 1 are only warning messages and are NOT saved in the error log!
173
174
Service Training MESX Description of fault codes of the ESX control
The voltage applied to the input is above the Potentiometer not connected to ground
specified range (see signal description). Potentiometer defective
4526 Output proportional solenoid front Current path has short circuit to voltage supply X44:47 2
Valve for exciter down Current path has non-permitted connection to another current
Output current too low. path
Current path is interrupted
4527 Output proportional solenoid front Current path has short circuit to ground X44:47 2
Valve for exciter down Current path has non-permitted connection to another current
Output current too high. path
175
176
Service Training MESX Description of fault codes of the ESX control
4532 Position controller negative limit reached Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired Valves for "Exciter up" and "Exciter down" mixed up X44:37
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
Electric systems – MESSX, A83
4601 Input acceleration transducer 1 Current path has no connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is below the Current path connected to ground or
specified range (see signal description). Transducer defective X44:31
4602 Input acceleration transducer 1 Current path has connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is above the Current path not connected to ground or
specified range (see signal description). Transducer defective X44:31
4606 Input acceleration transducer 2 Current path has no connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is below the Current path connected to ground or
specified range (see signal description). Transducer defective X44:07
4607 Input acceleration transducer 2 Current path has connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is above the Current path not connected to ground or
specified range (see signal description). Transducer defective X44:07
177
178
Service Training MESX Description of input codes of the ESX control
14 Input codes for ESX control (only via BEM display module)
14.2 Vibration
14.3 Light
179
180
Service Training MESX Description of input codes of the ESX control
181
182
Service Training MESX Description of input codes of the ESX control
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
• torn (not necessarily visible from outside)
• chafed
• 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 Ω to 300 Ω; 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 = Voltage
R = Resistance
I = Current
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)
Fig. 93
BVC machines and machines with E-VIB meter are equipped with
two piezo electric acceleration transducers, which are mounted to
the drum.
During operation these transducers transmit the acceleration sig-
nals to the measuring ESX.
The function of the piezo electric acceleration transducer is based
on the self-charging effect of quartz crystals under mechanical load
(pressure, tension, torsion) in vertical direction to the polar axes,
which was discovered in 1880 by J. and P. Curie.
Mode of action
Fig. 94
Once side of the piezo disc is connected with the so-called seismic
mass, the other one with a rigid carrier. When this combination is
set to oscillate, the seismic (sluggish) mass transfers a force to the
piezo disc. According to Newton's Law the resultant force is the
product of acceleration and mass.
A small wire connects the piezo element with the sensor socket.
The piezo electric effect generates a charge (u) on the electrodes,
which is proportional to the force and thus also to the acceleration
(a).
Fig. 95
1 [S44] Rotary switch for fan
2 Rotary switch for air conditioning
3 Cabin fan (M09)
B104 Pressure switch for air conditioning
Y15 Solenoid valve of air conditioning compressor
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 special roller, there is a possibility to adapt
the module to any machine with the help of a self-teaching mode.
1. Whenever the module is switched on the system runs a self-
test by passing through the entire display range in both direc-
tions. The display self-test takes approx. 15 seconds.
2. After this the module changes to measuring mode. The fre-
quency of the travel pulses of the roller is detected and con-
verted to a proportional output voltage that triggers the dis-
play.
3. The output signal for the display is a PWM-signal.
NOTICE!
BW24RH, BW27RH, C550H and C560H = travel
18 meters.
All other machines = travel 10 meters.
The module has now learned the pulses of the speed sensor.
1. Connect the speedometer (0 to 6 Volt) to "OUT +" and "OUT
–“.
Fig. 97
1. Lift up the interlock (5).
2. Fold down the switch block (4).
3. Loosen the screw (1).
4. Lift up the interlock (2) and pull out the front element (3).
Assembly
NOTICE!
Do not crimp more than one lead per pin or per
socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
Fig. 103: Crimp connections When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Removing DT contacts
Fig. 105
1. Pull the orange wedge out with long nose pliers.
2. Slightly pull the lead and unlock the interlocking hook with a
screw driver.
3. Pull the contact out of the socket.
Installing DT contacts
Fig. 106
1. Insert the contacts through the rubber grommet until they
click into place.
2. Insert the orange wedge in direction of arrow.
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in
the housing.
Fig. 108
1. Pull the orange wedge (interlock) out with long nose pliers.
2. Slightly pull the lead and unlock the interlocking hook with a
screw driver.
3. Pull the contact out of the socket.
Fig. 109
1. Insert the contacts through the rubber grommet until they
click into place.
2. Insert the orange wedge, until it clicks into place.
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in
the housing.
Fig. 110
Assembly
1. Connect the plug with the coil connection and press it firmly
onto the connecting housing.
Fig. 111
Fig. 112
Fig. 113
Fig. 114
WARNING!
Danger of cauterisation ! Danger of explosion!
When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the battery
to avoid the accumulation of highly explosive
gases.
ENVIRONMENT!
Dispose of the old battery environmentally.
NOTICE!
Exhausted batteries (batteries with formation of
sulphate on the plates) are not covered under war-
ranty!
1. Remove the batteries Ä Fig. 117 and clean the battery com-
partment.
2. Clean the outside of the battery.
3. Clean battery poles and pole clamps and grease them with
pole grease (Vaseline).
4. Check the fastening of the battery.
5. On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
Fig. 117
5 Diesel engine
The block-type cylinder head is made of cast steel. Each of the cyl-
inders has an inlet and an outlet valve. The valve guides are
shrunk into the cylinders. The valve seat rings are made of high
quality steel and also shrunk fit.
9 1
8
7
6
5
4 2
S-582-0041
3
Fig. 119
1 Heating flange
2 Main fuel filter
3 Oil filter
4 Oil cooler
5 Oil pressure switch
6 Oil dipstick
7 Plug-in injection pumps
8 Crankcase ventilation valve
9 Engine solenoid actuator
11 12 1
10
8 3
4
7 6 5
S-582-0042
Fig. 120
1 Exhaust manifold
2 Starter motor
3 Exhaust turbo charger
4 Oil return line from turbo charger
5 Oil drain plug
6 Coolant outlet
7 Coolant inlet
8 Ribbed V-belt
9 Coolant pump
10 Fuel pump
11 Generator
12 Oil filler cap
19 Oil filter
20 Suction line
21 Crankshaft bearings
22 Conrod bearings
The oil inside the combustion engine has the function of lubricating
and cooling all drive components, removing impurities and neutral-
izing chemically effective combustion products, transferring forces
and damping vibrations.. The oil is only able to fulfil this function, if
sufficient quantities are transported to the critical points in the
engine and if its properties are adapted to the prevailing require-
ments by corresponding manufacturing processes and refining
(additives).
Figure (1) shows pressure circulation lubrication in combination
with splash and oil mist lubrication. Here oil is transported under
pressure to all bearing locations by the oil pump (16), while sliding
surfaces are splash or oil mist lubricated. After flowing through the
bearing locations and along sliding surfaces the oil is collected in
the oil sump (1) under the drive, where the oil is cooled, defoamed
by calming and stored.
The oil filter (19) removes solid foreign particles from the engine oil
(combustion residues, metal abrasion, dust) and thus maintains the
function of the lubrication oil during the maintenance intervals.
Short description
The coolant pump ("water pump") draws coolant through the hose
lines directly out of the radiator and forces it first of all through the
lubrication oil cooler, which is integrated in the engine. The coolant
then enters into the engine, flows up along the cylinders into the
cylinder head and to the thermostat at the coolant outlet. Form
their the coolant is returned through the corresponding lines to the
radiator inlet. When the engine is cold the coolant is pumped in a
short circuit through the engine, until the response temperature of
the thermostat (start of opening) is reached. The water pump
draws cold coolant out of the radiator, as required to replenish the
hot out flowing coolant.
The coolant is a mixture of water and anti-freeze agent. The anti-
freeze agent increases the boiling temperature of the mixture and
thus enables temperatures of up to 120° C at an overpressure of
up to 1.4 bar.
The coolant compensation tank enables reliable gas separation,
thus avoiding cavitation in the cooling system, which mainly occurs
in the suction side of the pump. The air volume inside the compen-
sation must be so high, that quick build-up of pressure in case of
heating and expansion of coolant is assured and any escape of
coolant during after-boiling is avoided.
The radiator (1) dissipates the waste heat generated in the engine
into the into the environment.
Part of the combustion heat is transferred to the lubrication oil. The
lubrication oil cooler (5) serves the function of cooling the lubrica-
tion oil.
Heating
WARNING!
Danger of scalding!
Do not remove the cap from the compensation
tank when the engine is still hot.
ENVIRONMENT!
Catch running out coolant and dispose of environ-
mentally.
Fig. 124
Fig. 125
11. Let the engine cool down and check the coolant level again,
Fig. 126 top up if necessary.
WARNING!
For diesel fuel the ignition temperature, i.e. the
temperature at which fuel will ignite when coming
into contact with air, is approx. 220°C, but may
deviate strongly because of impurities.
Fuel conducting components and lines therefore
are a source of danger inside the engine compart-
ment, because leaks may lead to fire resulting in
considerably damage to material and persons.
Check valve
Fig. 128
1. According to our experience, it is not always assured that
only clean fuel will be used. Fuel tanks are frequently filled
without suitable precautions against contamination or fuel fil-
ters are inappropriately serviced. Many damage analyses on
injection pumps and injection valves have revealed that most
of these components had failed due to premature wear. Wear
on injection pump plunger and injection valve needle seat is
caused by contaminated fuel. Modern exhaust optimized
diesel engines with high pressure injection systems strictly
require clean fuel to be able to work reliably over their entire
lifetime. If the throttle resistances of pre-cleaner/main filter
caused by contaminated fuel are so high that the fuel pump
is no longer able to ensure a sufficient fuel supply, the injec-
tion pumps will draw the required fuel through the leak fuiel
return line from the tank without filtration. The engine is no
longer able to provide its full power, operation of construction
equipment or other machines, however, may still be possible
to a limited extent. After short time operation under such con-
ditions the injection system components may already be pre-
damaged.
NOTICE!
Fig. 129: Observe the direction of This valve must strictly be installed into the fuel
flow return line by our customers.
Single cylinder plug-in injection Deutz diesel engines series 2012/1013 are equipped with Bosch
pumps cylinder plug-in injection pumps series PF 33.
The concept of plug-in injection pumps enables the realization of
high injection pressures, combined with short injection lines, which
is necessary to ensure a high hydraulic stiffness of the injection
system. This in turn provides the prerequisite for low exhaust emis-
sion values (soot) in combination with a low fuel consumption.
The start of injection is influenced by:
n fuel consumption
n the power
n the exhaust emission
of the engine.
The term "start of injection" refers to the start of the injection pump
delivering fuel.
The drive cams 2 Ä Fig. 130 for the single PF-injection pumps are
located on the camshaft (1) for engine valve control.
Permissible manufacturing tolerances for the components:
n Cylinder crankcase
n Camshaft
n plunger
n plug-in injection pump
Injection valves
NOTICE!
When replacing an injection pump and/or an injec-
tion valve, you must also replace the high pressure
line between pump and valve.
NOTICE!
Ensure strict cleanliness when working on the
injection system.
Fig. 132
Fig. 133
Fig. 134
Fig. 135
10. Turn the crankshaft for approx. 120° against the sense of
rotation.
Fig. 136
Fig. 137
13. Take the compensation shim carefully out with the rod
magnet.
Fig. 138
5.
Measurement "A" determines by how many
1/100 of a mm the distance between cylinder
crankcase contact surface and plunger foot is
longer than the basic measurement Lo.
Basic measurement of injection pump (Lo) =
117.5 mm.
Theor. thickness „TS„ (mm) Shim thickness „SS Theor. thickness „TS„ (mm) Shim thickness „SS
„ (mm) „ (mm)
0.95 - 1,049 1.0 2.45 - 2,549 2.5
1.05 - 1,149 1.1 2.55 - 2,649 2.6
1.15 - 1,249 1.2 2.65 - 2,749 2.7
1.25 - 1,349 1.3 2.75 - 2,849 2.8
1.35 - 1,449 1.4 2.85 - 2,949 2.9
1.45 - 1,549 1.5 2.95 - 3,049 3.0
1.55 - 1,649 1.6 3.05 - 3,149 3.1
1.65 - 1,749 1.7 3.15 - 3,249 3.2
1.75 - 1,849 1.8 3.25 - 3,349 3.3
1.85 - 1,949 1.9 3.35 - 3,449 3.4
1.95 - 2,049 2.0 3.45 - 3,549 3.5
2.05 - 2,149 2.1 3.55 - 3,649 3.6
2.15 - 2,249 2.2 3.65 - 3,749 3.7
2.25 - 2,349 2.3 3.75 - 3,849 3.8
2.35 - 2,449 2.4
Fig. 143:
Fig. 144:
Fig. 145:
4.
NOTICE!
The roller plunger for the corresponding
injection pump must be positioned on the
base circle of camshaft.
Apply some oil to the locating bore in the crankcase and the
O-rings on the injection pump.
5. Carefully insert the injection pump control lever into the gov-
ernor rod.
Fig. 146:
6.
NOTICE!
The chamfer must face towards the injection
pump body.
Fig. 147:
Fig. 148:
Fig. 149:
9. Carefully turn the injection pump with and open end spanner
in counter-clockwise direction against the noticeable stop
Fig. 150:
10.
Always start with the outer screw furthest
away from the flywheel.
Fig. 151:
Fig. 152:
14.
Cover the O-ring slightly with oil.
Fig. 153:
15. Use the shut-down lever to push the governor rod to stop
position and hold it.
16. Install the engine shut-down assy.
17. Tighten the screws with 21 Nm.
18. Plug the cable plug onto the shut-down magneto.
Fig. 154:
19.
NOTICE!
Take care that the sealing cones match
exactly when assembling the injection line.
Subsequent bending is not permitted. The
injection line must never be used twice.
Fig. 156:
NOTICE!
Ensure strict cleanliness when working on the
injection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
Removal
1. Remove pressure control valve and cylinder head cover.
2. Disconnect the cable plugs from shut-down solenoid, gov-
ernor and temperature sensor.
3. Swing the holding plate to the side.
Fig. 158
Fig. 159
Fig. 160
Assembly
1. Slide the new seal rings with some grease over the injection
valves and insert the injection valves .
2.
NOTICE!
The chamfer on the injection valves must
point away from the claws.
Fig. 161
Fig. 162
4.
NOTICE!
Take care that the sealing cones match
exactly when assembling the injection line.
Subsequent bending is not permitted. The
injection line must never be used twice.
Fig. 163
Fig. 164
Fig. 165
Fig. 166:
NOTICE!
Ensure strict cleanliness when working on the
injection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
Fig. 168
Fig. 169
5. Slowly press the lever of the nozzle tester 8008 down with
the pressure gauge connected.
Opening pressure: 220 bar
6.
The opening pressure is reached, when the
pointer stops or suddenly drops.
The pressure inside the spring chamber will
have build up again after approx. 3 - 4
strokes. In order to repeat the test the
clamping nut needs to be slackened and
Fig. 170 retightened again, as specified.
Once identical values are measured during 3
tests, the values can be considered valid.
Fig. 171
3. Clean all parts with clean diesel fuel and blow off with com-
pressed air.
Fig. 172
Sequence of individual disas-
sembly:
1 Tensioning nut
2 Injection nozzle
3 Intermediate piece
4 Pressure bolt
5 Compression spring
6 Shim
4.
NOTICE!
Nozzle needle and nozzle body have been
fitted by lapping and must never be mixed up
by mistake 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 .
5.
Fig. 173
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 fuel.
Fig. 174
Fig. 175
Fig. 176
10. Install the pressure bolt with the centring collar towards the
pressure spring.
Fig. 177
11. Insert the centring pins of the intermediate piece into the
bores of the nozzle holder.
12.
The chamfer points towards the pressure
bolt.
Fig. 178
13. Attach the centring bores of the injection nozzle to the cen-
tring pins of the intermediate piece.
14.
The nozzle needle must not drop out of the
nozzle body.
Fig. 179
Fig. 180
Fig. 181
Leak test
1. Dry nozzle and nozzle holder - blow dry with compressed air.
2. Press the hand lever of the tester slowly down, to a point
about 20 bar before the previously indicated opening pres-
sure.
Fig. 182
3.
The nozzle is leak tight, if no drop drips off
within a period of 10 seconds.
4.
NOTICE!
If a drop drips off , the injection valve must be
dismantled and the leak must be eliminated
by thorough cleaning. If this does not lead to
a success, replace the injection nozzle.
Fig. 183 Rework is not permitted!
Fig. 184
NOTICE!
A used injection valve must audibly rattle and
spray off well atomized fuel when operating the
lever 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!
Fig. 185
Fig. 186
Fig. 187
WARNING!
Danger of injury!
Support the engine hood for all maintenance and
repair work.
1. Pull the dipstick Ä Fig. 189 out, wipe it off with a lint-free,
clean cloth and reinsert it until it bottoms.
2. Pull the dipstick back out again.
3. If the oil level is below the "MAX" mark fill in oil.
4. If the oil level is above the “Max” mark determine the cause
and drain the oil off.
NOTICE!
Fig. 189
Before longer work periods you should always top
the oil up to the "MAX"-mark.
For quality and quantity of oil refer to the table of fuels and
lubricants.
WARNING!
Danger of scalding!
Fill up coolant only when the engine is cold.
NOTICE!
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.
Do not use radiator sealant to seal leaks.
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Fig. 190
WARNING!
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.
NOTICE!
Drain the oil only when the engine is warm.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
Fig. 191
Fig. 192
7. Turn the new filter cartridge on by hand, until the seal con-
tacts.
8. Tighten the filter element for another half turn.
Fig. 193
Fig. 194
NOTICE!
Danger of engine damage!
We recommend to have this work carried out by
trained personnel or our after sales service.
– Before checking the valve clearance let the
engine cool down for at least 30 minutes. The
engine oil temperature must be below 80 °C
(176 °F).
Fig. 195
Fig. 196
Fig. 197
Valve clearance:
Intake valve 0.3 mm (0.012 in)
Exhaust valve 0.5 mm (0.020 in)
2. If the gap is too narrow or too wide for the feeler gauge,
adjust the valve clearance.
Fig. 198
Fig. 199
WARNING!
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.
1. Loosen and unscrew the fuel filter cartridge Ä Fig. 200 using
an appropriate filter wrench.
2. Clean the sealing face on the filter carrier from any dirt.
Fig. 200
1. Slightly oil the rubber seal Ä Fig. 201 on the new filter car-
tridge.
2. Fill the filter cartridge with clean diesel fuel.
3. Turn the new filter cartridge on by hand, until the seal con-
tacts.
4. Tighten the filter element for another half turn.
5. Check the filter cartridge for leaks after a short test run.
Fig. 201
WARNING!
Danger of fire, health hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Do not inhale any fuel fumes.
NOTICE!
Ensure strict cleanliness! Thoroughly clean the
area around the fuel filters.
The filter cartridge must never be filled beforehand.
After work on the fuel system bleed the system,
perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is manda-
tory.
ENVIRONMENT!
Any fuel must be caught and disposed of in an
environmentally friendly manner.
Fig. 203
1. Operate the hand pump manually, until fuel flows out of the
slackened bleeding screw without air bubbles.
2. Then tighten the bleeding screw while pumping.
3. Check the filter cartridge for leaks
WARNING!
Danger of injury!
Work on the V-belt must only be performed with
the engine shut down.
Fig. 204
Fig. 205
Fig. 206
Fig. 207
WARNING!
Danger of scalding!
Change the coolant only when the engine is cold.
NOTICE!
Do not start the engine after draining off the
coolant.
In case of lubrication oil entering into the cooling
system or a suspicious turbidity caused by corro-
sion residues or other suspended matter, the
coolant must be drained off and the complete
cooling system needs to be cleaned. Lubrication oil
can damage the sealing materials used in the
engine.
When changing the coolant without any signs of
contamination, cleaning of the cooling system is
not necessary.
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Do not mix different coolants and additives, see
section "Fuelds and Lubricants - Coolant".
ENVIRONMENT!
Catch coolant and dispose of in an environmentally
friendly manner.
Fig. 208
2. Unscrew the plug, let the coolant run out and catch it.
3. Check the condition of the coolant.
NOTICE!
Thoroughly flush the cooling system if the
coolant is contaminated by corrosion resi-
dues or other suspended matter.
If lubrication oil has entered you must add a
cleansing agent in order to remove any resi-
dues from the system. Follow the instructions
Fig. 209
of the manufacturer. If in doubt consult your
local service station or the engine manufac-
turer.
5.13.7 As required
5.13.7.1 Air filter maintenance
NOTICE!
Do not start the engine after having removed the
air filter.
If necessary, the air filter may be cleaned up to six
times. After one year at the latest it must be
replaced together with the safety element.
Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit.
Do not use gasoline or hot fluids to clean the filter
element.
After cleaning the air filter must be inspected for
damage using a torch.
Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
If the air filter is damaged, the safety element must
be replaced as well.
The safety element must not be cleaned.
Servicing of the dry air filter is necessary when the yellow piston
Ä Fig. 211 has reached the red underlaid inscription "Service", but
at the latest after one year.
Fig. 211
1. Open the engine hood Ä Fig. 212 completely and secure it.
Fig. 212
Fig. 213
1. Pull out the main filter element Ä Fig. 214 with light turning
movements.
WARNING!
Danger of injury!
Wear protective clothing (goggles, gloves).
Fig. 214
1. Blow the air filter Ä Fig. 215 out with dry compressed air
(max. 5 bar (70 psi)) from inside to outside by moving the
gun up and down inside the element, until it if free of dust.
Fig. 215
1. Examine the air filter with a torch for cracks and holes in the
paper bellows Ä Fig. 216.
2. In case of damage replace the air filter and the safety ele-
ment.
Fig. 216
1. Slide the air filter carefully into the housing Ä Fig. 217.
NOTICE!
The dust discharge valve must point vertically
downwards.
Make sure that the cover locks engage correctly.
Fig. 217
1. Remove the housing cover and pull the air filter off.
2. Pull the safety element Ä Fig. 218 out by turning it lightly.
3. Push in a new safety filter element.
4. Insert the air filter and reassemble the housing cover.
Fig. 218
WARNING!
Danger of injury!
Support the engine hood for all maintenance and
repair work.
ENVIRONMENT!
Catch running out fuel and dispose of environmen-
tally.
1. Slacken the drain plug Ä Fig. 219 for a few turns and catch
running out fuel / water.
2. Tighten the drain plug again and check for leaks, if necessary
replace the seal ring.
Fig. 219
6 Hydraulic system
4 Y07
MB
Y08
5
M3 B
3 MA 6
2
1 M1
B
M2
L1
M3
D
S
E
M2
L1
M1
A
S
L2
MA
MB
S-582-0038
Fig. 220
1 Travel pump
2 Multi-function valve, travel pump
3 Multi-function valve, travel pump
4 Solenoid valve vibration (Y07), high amplitude
5 Solenoid valve vibration (Y08), low amplitude
6 Vibration pump
M3 Charge pressure, 26+ 3 bar
1/MA Travel pressure against block, forward travel, MA 420 bar
1/MB Travel pressure against block, backward travel, MA 420 bar
6/MA Vibration pressure, MA 420 bar
6/MB Vibration pressure, MB 420 bar
Vibration pump
High amplitude Low amplitude
Current on coil C1 C2
Plugs Y07 Y08
Pressure on port A B
Fig. 221
1 Pressure test port M2 system pressure, B
2 Leak oil connection L1
3 Pressure test port M4 control pressure
4 Pressure test port M5 control pressure
5 Leak oil connection L2
6 Pressure test port M1 system pressure, A
7 System pressure, port A
8 Suction port S
9 System pressure, port B
10 Speed transducer (optional equipment)
11 Charge pressure port
12 Charge pressure test port, M3
Closed circuit
NOTICE!
Components may get damaged!
– The aggregate must always be filled with
hydraulic oil and purged before start-up and
during operation.
– This must also be considered for longer
periods of rest, because the aggregate may
run empty through the hydraulic lines.
Fig. 224
1 Actuating lever
2 Drive shaft
3 Bearing for swashing cradle
4 Pistons with slipper pads
5 Cylinder block
6 Valve plate
7 Control piston
Fig. 225
1 Drive shaft
2 Drive shaft bearing
3 Swash plate
4 Pistons with slipper pads
5 Cylinder block
6 Multi-function valves
7 Charge pump (optional)
8 Valve plate
MDC control, mechanical displace- The mechanical displacement control converts a mechanical input
ment control signal into a position controlling output signal by means of a spring
centred 4-way servo valve. This valve opens the hydraulic pres-
sure to one side of the control cylinder. The control piston inside
the control cylinders moves the swash plate within a swashing
angle range of ±17° and thereby changes the displacement of the
pump from maximum displacement to the one direction to the max-
imum displacement to the opposite direction.
The mechanical displacement control has no adjustment elements.
The control is held in neutral position by resetting springs and
washers at both ends of the control piston. Since there are no fur-
ther resetting springs on the input shaft of the control, the shaft will
automatically be correctly positioned when it is mounted to the
pump.
Fig. 226
1 to the control
2 Multi-function valves
3 Charge pump
4 Charge pressure relief valve
5 Control pressure relief valve
6 Drive shaft
7 to the control piston
8 to the control piston
9 Servo control
A Connection A
B Connection B
With the servo control (9) the swashing angle can be infinitely
adjusted from neutral position to the maximum displacement posi-
tion.
When altering the swash plate position through the neutral posi-
tion, the oil flow will be reversed and the machine will drive to the
opposite direction.
Since the control is spring centred, the swash plate will automati-
cally return to neutral position under the following conditions,
thereby interrupting the oil flow and braking the machine:
n when shutting the engine down
n if the external control cable comes loose
n if the pressure in the charge circuit drops below a certain value.
Multi-function valves Pumps of series 90 are equipped with multi-function valves, which
activate a pressure override valve and a high pressure limitation,
one after the other.
The multi-function valve consists of:
n No-stroke pressure controller
n High pressure relief valve
n Boost check valve
n Bypass function
No-stroke pressure controller
The multi-function valve contains a no-stroke pressure controller
and a high pressure relief valve. When the pre-adjusted pressure
value is reached, the no-stroke pressure controller will return the
pump very quickly back towards neutral, thereby limiting the
system pressure. In case of a unusually sudden pressure increase
the high pressure relief valve will immediately limit the system
pressure by opening the system flow to the low pressure side of
the hydraulic circuit. The no-stroke pressure controller serves as
pre-control unit for the piston of the high pressure relief valve. The
high pressure relief valve is designed for responding to pressures
approx. 35 bar above the nominal value of the no-stroke pressure.
Bypass function
The bypass function is also integrated in the multi-function valves
and can be manually operated.when the vehicle (or the mechanical
function) is to be moved, without the pump running.
Opening the by-pass function
NOTICE!
When working on the bypass valves switch off the
drive and keep the high pressure circuit pressure-
less. The bypass valves must be open on both
multi-function valves to be able to achieve the
bypass function.
Charge pressure relief valve Pumps of series 90 are equipped with a charge pressure relief
valve that can be adjusted from the outside. Charge pressure is
adjusted by loosening the counter nut and turning the setscrew
accordingly with a large screwdriver or a 1/2" open end spanner.
Turning the setscrew clockwise increases the value, turning anti-
clockwise reduces the value (by approx. 3.9 per revolution). Tight-
ening torque for counter nut: 52 Nm!
Fig. 229
The charge pressure relief valve has the function of maintaining
the charge pressure at a specified value. A cone valve reduces the
charge pressure if this value is exceeded. This nominal value is
measured against case pressure and adjusted at 1500 rpm. This
nominal setting assumes that the pump is running in idle position
(zero flow); the charge pressure is slightly lower in forward or
reverse.
Fig. 230
1 Pressure test port M2 system pressure, B
2 Leak oil connection L1
3 Pressure test port M4 control pressure
4 Pressure test port M5 control pressure
5 Leak oil connection L2
6 Pressure test port M1 system pressure, A
7 System pressure, port A
8 Suction port S
9 System pressure, port B
10 Speed transducer (optional equipment)
11 Charge pressure port
12 Charge pressure test port, M3
13 Control pressure port, X3
14 Adjustment screw, mechanical neutral position
15 Multi-function valves
NOTICE!
Components may get damaged!
– The aggregate must always be filled with
hydraulic oil and purged before start-up and
during operation.
– This must also be considered for longer
periods of rest, because the aggregate may
run empty through the hydraulic lines.
Fig. 231
1 Control unit
2 Servo piston
3 Bearing for swashing cradle
4 Attachment plate
5 Spool valve
6 Charge pump, optional
7 Drive shaft
8 Pistons with sliding blocks
9 Swash plate
10 Valve plate
11 Control lever, not used with EDC-control
Hydraulic diagram
5 6
7
1
2
3
4
S-HYD-583883
Fig. 232
1 From the charge pump
2 Closed circuit
3 High pressure relief valve with integrated boost check valve
4 4/3 way valve
5 Pump drive
6 Charge pump
7 High pressure limitation
8 Charge pressure relief valve, blocked
High pressure relief valves Pressure peaks occurring during very fast swashing processes, as
well as the maximum pressures are safeguarded by superordinate
high pressure relief valves, which open when the adjusted value is
exceeded and release oil into the low pressure side. The fluid
quantity always remains constant in the closed hydraulic circuit.
Leakages in pump and motor are compensated by the charge
pump.
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 quanti-
ties.
Charge pump The charge pump is needed to supply the system with cool
hydraulic fluid, to maintain a positive pressure in the working cir-
cuit, to ensure a certain pressure level, to operate the control
system and to compensate internal leakages.
The charge pump is a fixed displacement Gerotor-type pump, inte-
grated in the variable displacement pump and driven by the pump
shaft.
Fig. 233
The swash plate pump is a positive displacement machine with oil
displacing pistons arranged axially to the drive shaft. The pistons
are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or
variable displacement can be used as hydraulic pumps or hydraulic
motors. In pump mode the mechanical energy is converted to
hydrostatic energy, when used in motor mode the hydrostatic
energy is converted to mechanical energy. When used as a pump,
the flow volume is proportional to the drive speed and the
swashing angle. The available (pump) torque increases with the
pressure drop between high and low pressure side.
Variable displacement pumps and motors can be change their dis-
placement, i.e. the pump delivery rate or motor throughput, by
simply changing the angle of the swash plate.
Description of function
Fig. 234
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
Driven by the engine, the drive shaft rotates and drives the cylinder
via a splined connection. The cylinder rotates with the drive shaft
and drives the 9 pistons. The pistons rest with their slipper pads on
the sliding face of the swashing cradle and perform an axial move-
ment. The slipper pads are held on the sliding face and are posi-
tively guided by a retaining device. During a complete rotation of
the cylinder block each piston moves through the bottom and top
dead centre back to its initial position. From dead centre to dead
centre is performs a full piston stroke. During this process the flow
volume determined by the stroke is drawn in through the control
slots in the valve plate or pumped out. During the suction stroke
the hydraulic fluid is drawn into the increasing piston chamber, i.e.
it is actually pressed in. On the opposite side the oil is pressed out
of the piston bores into the hydraulic system during the compres-
sion stroke.
2 3
6 5 4 S-HYD-583885
Function
Piston position (1) The hydraulic oil is delivered to the distributor under Pressure. The
distributor guides the hydraulic oil through ring channels and bores
to the cylinders on the descending flanks of the cam race so that
the oil presses against the working pistons.
Due to the pressure on the back of the piston the roller will move
along the cam, thereby causing a rotary movement of the cylinder
block.
Piston position (2) At this point of the piston stroke the opening cross-sections of
bores and ring channels in the distributor to the working piston
have their biggest size. As the cylinder block continues to rotate,
the opening cross-sections become smaller towards the valley
between the cams.
Piston position (3) At the deepest point of the cam race (dead centre) the hydraulic oil
flow through the distributor to the working piston is interrupted, the
bores and ring channels block one another.
Other working pistons are driven by the hydraulic oil flowing
through the distributor (see piston positions 1 to 3), so that the
working piston is moved out of this top dead centre position.
Piston position (4) The distributor now connects the cylinder with the low pressure
side. The working pistons moving along the ascending flank of the
cam race (9) away from the bottom dead centre pump the
hydraulic oil through the bores and ring channels in the distributor
back to the travel pump.
At this point of the piston stroke the opening cross-sections of
bores and ring channels in the distributor for the hydraulic oil flow
have their biggest size.
Piston position (5) As the cylinder block continues to rotate, the opening cross-sec-
tions become smaller towards the peak of the cam. At the highest
point of the cam race (dead centre) the hydraulic oil flow through
the distributor back to the travel pump is interrupted and a new
working cycle is started (see piston positions 1 to 5).
Fig. 237
Product description A plug-in fixed displacement motor converts the hydrostatic volu-
metric flow into mechanical rotary motion. It has mainly been
designed for installation into mechanical gear drives.
Function The hydraulic oil flows under high pressure through the corre-
sponding port to the back of the working pistons. Since the working
pistons are arranged under an angle to the output shaft, the pres-
surized pistons will perform an axial stroke, thereby causing a
rotary motion 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 rota-
tion 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.
Flushing valve In a closed circuit the same pressure fluid keeps permanently cir-
culating between pump and motor. This can cause overheating of
the pressure fluid.
The flushing valve has the function to support cooling of the oil cir-
cuit by flushing the motor and thus to prolong the service life of the
motor. If the hydraulic motor is operated under load, the flushing
valve opens during clockwise and anti-clockwise rotation, whereby
a defined flushing quantity is discharged through an orifice from the
low pressure side of the circuit. This flushed out amount of oil then
flows through the case drain back to the tank, normally through a
cooler. Any pressure fluid removed from the closed circuit must be
replaced by cool oil from the charge pump. The flushing valve
thereby ensures permanent renewal and cooling of the pressure
fluid. The flushing pressure relief valve has a fixed setting of 16 bar
and has the function of securing the minimum charge pressure.
Fig. 238
1 Control piston
2 4-way valve
3 Proportional valve
4 Minimum swashing angle setting
5 Valve segment
6 Bearing plate
7 Tapered roller bearing
8 SAE-flange
9 Synchronizing joint
10 Speed sensor
11 Piston
12 Flushing pressure relief valve
NOTICE!
Components may get damaged!
– The aggregate must always be filled with
hydraulic oil and purged before start-up and
during operation.
– This must also be considered for longer
periods of rest, because the aggregate may
run empty through the hydraulic lines.
8 Swash plate
S1 Hydraulic diagram with flushing valve
S2 Speed detection
The output speed of the motor depends on the oil quantity supplied
by the vibration pump. The output torque raises with increasing
pressure difference between low and high pressure side in the
closed circuit. Changing the flow direction of the oil will also
change the sense of rotation of the motor.
When switching the vibration on the hydraulic motor must first start
to move the resting exciter shaft. This resistance causes a
hydraulic starting pressure, which is limited by the pressure over-
ride (vibration pump). Once the exciter shaft has reached its final
speed, the pressure will drop to operating pressure. The value of
the operating pressure mainly depends on the condition of the
ground (degree of compaction, material etc.).
Flushing valve The vibration motor is equipped with an integrated flushing valve.
In the closed hydraulic circuit the flushing and charge pressure
relief valve is used to avoid excessive temperatures and to secure
the minimum charge pressure. The valve is integrated in the con-
necting plate. A certain amount of pressure fluid, which is deter-
mined by the size of an orifice, is taken out of the corresponding
low pressure side and discharged into the motor housing. This fluid
is returned to the tank, together with the leak oil. The pressure fluid
taken out of the circuit is then replaced by cooled oil from the
charge pump.
Speed detection In this case the rotating, geared drive generates a signal propor-
tionate to the speed, which is then detected by a sensor and for-
warded for evaluation.
Fig. 240
Description of function
Fig. 241
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
The motor function is a reversal of the pump function. In this case
the hydraulic fluid the hydraulic system directs the oil flow to the
hydraulic motor. The medium flows through control slots in the
valve plate to the cylinder bores. 4 or 5 cylinder bores are opposed
to the kidney shaped control slots in the pressure side. The other
control slot is in this case connected with the rest of the cylinder
bores, which in turn are connected with the return flow side or are
partly covered by the connecting web between the kidney shaped
control slots. By loading the piston it slides down the slanted swash
plate and drives the cylinder that guides it. The cylinder with the 9
pistons rotates with the drive shaft, whereby the piston perform a
stroke-like movement. The hydraulic pressure generates the torque
on the cylinder and thus the rotation of the drive shaft. The sup-
plied fluid quantity determines the output speed.
Function
Fig. 243
The increasing volume caused by a tooth exiting a tooth gap
results in a vacuum in the suction chamber. The pressure fluid is
transported into the pressure chamber. There the meshing of teeth
and tooth gaps displaces the pressure fluid into the upper supply
line.
Fig. 244
Multiple gear pumps Gear pumps are most suitable for multiple pump arrangements,
whereby the drive shaft of pump 1 is extended to drive a second or
3. pump. The shafts are connected by drivers in between. The indi-
vidual pump stages are sealed to each other, i.e. the suction ports
are separated from each other.
Fig. 245
Fig. 246
T
P 4
3
5
2
ML M3 M3
E
D
1
B21
6
S
P
8
Y04
7 S-582-0044
Fig. 247
1 Hydraulic oil tank
2 Steering/charge pump
3 Steering valve
4 Silencer optional equipment for cabin with heating; it is always subjected to hydraulic oil flow
5 Vibration pump with integrated charge pump
6 Charge circuit filter
7 Brake valve
8 Travel pump
B21 Differential pressure switch on charge circuit filter
M3 Pressure test ports for charge pressure, 26+ 3 bar
ML Steering pressure test port
The charge circuit provides the hydraulic oil for the charge system
and the control functions in the closed circuits for travel and vibra-
tion drive, as well as to release the parking brake.
The steering/charge pump is a gear pump with constant displace-
ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.
Another charge pump is integrated in the vibration pump.
M3
B
L1
10 S
E
L1
A
L2
2
1
MB
MA
M3
L1
L1
9 E
B
S
A
L2 3
Y04 P
8 A1.1
55-70°C H
K B
D T
L
G
C L1 B
B
Y31
R A
7
T1
L
1 5 4
6
S-582-0043
Fig. 248
1 Travel pump
2 Vibration pump
3 Brake valve
Return flows All return flows pass through the return flow manifold block with
thermostat. This thermostat guides the oil flow directly back to the
hydraulic oil tank, until the operating temperature is reached. At an
oil temperature of 55 °C the valve starts to switch over and at
70 °C the total amount of oil will flow through the hydraulic oil
cooler.
Service brake During operation the closed hydrostatic travel circuit has the func-
tion of a service brake. When the travel lever is returned towards
neutral position, the displacement of the travel motor is adjusted
towards zero accordingly and the machine is hydraulically braked.
Parking brake To avoid creeping movements of the machine, the machine is addi-
tionally equipped with a multi-disc parking brake in the drive axle. It
closes in neutral position of the travel lever and when the engine is
stopped.
Fig. 249
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel motor
5 Drum shell
6 Rubber buffer
7 Rectangular rubber buffers
8 Travel bearings
Y07
MB B
Y08 2
1 MA
L1
S
E
L1
L1
L1
A
T
M3
E
7
6 F
H T
A
B A
K
B
L 55-70°C
5
4
S-582-0045
Fig. 250
1 Radiator
2 Vibration pump with integrated charge pump
3 Travel pump
4 Vibration motor
5 Return flow filter optional equipment
6 Return flow manifold with thermal element
7 Hydraulic oil tank
MA Vibration pressure, MA 420 bar
MB Vibration pressure, MB 420 bar
Vibration pump
High amplitude Low amplitude
Current on coil C1 C2
Plugs Y07 Y08
Pressure on port A B
Fig. 251
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 ampli-
tude.
The eccentric weights on the vibrator shaft are fitted with additional
change-over weights. Depending on the sense of rotation of the
exciter shaft these change-over weights add to or subtract from the
basic weights.
n Basic weight plus change-over weight = high amplitude
n Basic weight minus change-over weight = low amplitude
Fig. 252
1 Basic weight
2 Changeover weight
3 Exciter shafts
When switching the vibration on the motor must first start to move
the resting exciter shaft. This resistance causes a hydraulic starting
pressure, which is limited by the pressure override. Once the
exciter shaft has reached its final speed, the pressure will drop to
operating pressure. The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction,
material etc.).
Fig. 255
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel motor
5 Drum shell
6 Rubber buffer
7 Rectangular rubber buffers
8 Travel bearings
The vibration motor output shaft is joined with the exciter shaft in
the drum via a Bowex coupling. The rotation of the exciter shaft
with the bolted on eccentric weights causes the vibration of the
elastically suspended drums.
Return flows All return flows pass through the return flow manifold with tempera-
ture controlled valve (thermostat). This thermostat guides the oil
flow directly back to the hydraulic oil tank, until the operating tem-
perature is reached. At an oil temperature of 55 °C the valve starts
to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.
Vibration motor with flushing valve The vibration motor is equipped with an integrated flushing valve.
In the closed hydraulic circuit the flushing and charge pressure
relief valve is used to avoid excessive temperatures and to secure
the minimum charge pressure. The valve is integrated in the con-
necting plate.
A certain amount of pressure fluid, which is determined by the size
of an orifice, is taken out of the corresponding low pressure side
and discharged into the motor housing. This fluid is returned to the
tank, together with the leak oil. The pressure fluid taken out of the
circuit is then replaced by cooled oil from the charge pump.
Fig. 256
1 High pressure port, high amplitude
2 High pressure port, low amplitude
3 Leak oil and flushing port
4 Flushing spool
5 Flushing valve
2 T
1 L
R
3
ML
B21
5 4
S-582-0046
Fig. 257
1 Hydraulic oil tank
2 Steering valve
3 Silencer optional equipment for cabin with heating; it is always subjected to hydraulic oil flow
4 Charge circuit filter
5 Steering cylinder
6 Steering/charge pump
ML Pressure test port for steering
2 T
1 L
R
3
ML
B21
S-582-0018
Fig. 258
1 Hydraulic oil tank
2 Steering valve
3 Silencer optional equipment for cabin with heating; it is always subjected to hydraulic oil flow
4 Charge circuit filter
5 Steering cylinder
6 Steering/charge pump
ML Pressure test port for steering
The steering/charge pump is a gear pump with constant displace-
ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.
Fig. 259
1 Drum
2 Front frame
3 Oscillating articulated joint with two steering cylinders
4 Oscillating articulated joint with one steering cylinder
5 Steering cylinder
6 Rear frame
7 Drive axle
8 Single drum roller with one steering cylinder
9 Single drum roller with two steering cylinders
Front and rear frames of the single drum rollers are connected by
an oscillating articulated joint.
The front console of the joint is fastened with screws to the rear
cross-member of the front frame. The rear console is tightly bolted
to the rear frame.
The use of rocker bearings between front and rear frame ensures
that both frames can oscillate to each other for +/- 12°. This ena-
bles good ground contact of drum and wheels, even under severe
soil conditions.
When turning the steering wheel, the steering cylinders will extend
or retract and swivel the front console around the vertical bolt. This
articulates the machine and results in a steering movement.
4 Y07
MB
Y08
5
M3 B
3 MA 6
2
1 M1
B
M2
L1
M3
D
S
E
M2
L1
M1
A
S
L2
MA
MB
S-582-0038
Fig. 260
1 Travel pump
2 Multi-function valve, travel pump
3 Multi-function valve, travel pump
4 Solenoid valve vibration (Y07), high amplitude
5 Solenoid valve vibration (Y08), low amplitude
6 Vibration pump
M3 Charge pressure, 26+ 3 bar
1/MA Travel pressure against block, forward travel, MA 420 bar
1/MB Travel pressure against block, backward travel, MA 420 bar
6/MA Vibration pressure, MA 420 bar
6/MB Vibration pressure, MB 420 bar
Vibration pump
High amplitude Low amplitude
Current on coil C1 C2
Plugs Y07 Y08
Pressure on port A B
Fig. 261
1 Pressure test port M2 system pressure, B
2 Leak oil connection L1
3 Pressure test port M4 control pressure
4 Pressure test port M5 control pressure
5 Leak oil connection L2
6 Pressure test port M1 system pressure, A
7 System pressure, port A
8 Suction port S
9 System pressure, port B
10 Speed transducer (optional equipment)
11 Charge pressure port
12 Charge pressure test port, M3
Special tools
Hydraulic test case
NOTICE!
Perform measurements at operating temperature
of the hydraulic oil (50 °C).
Fig. 262
Fig. 263
3. Pull the plug Ä Fig. 264 off the brake solenoid valve to close
the brake.
Fig. 264
Fig. 265
Fig. 266
Evaluation of measurement
1. If pressure builds up on one side, adjust the mechanical neu-
tral position, until the pressures on both pressure gauges are
identical.
Fig. 268
Special tools
Hydraulic test case
NOTICE!
Perform measurements at operating temperature
of the hydraulic oil (50 °C).
Fig. 269
2. Pull the plug Ä Fig. 270 off the brake solenoid valve to close
the brake.
Fig. 270
Evaluation of test
If the nominal value is not reached, check
the steering/charge pump.
Fig. 272
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 individually.
Special tools
Vibration reed frequency meter
NOTICE!
Perform measurements at operating temperature
of the hydraulic oil (50 °C).
Fig. 273
Fig. 275
Special tools
Hydraulic test case
NOTICE!
Perform measurements at operating temperature
of the hydraulic oil (50 °C).
1. Drive the machine with the drum onto an elastic base (rubber
tyres) Ä Fig. 276.
2. Block the wheels with suitable chocks.
3. Apply the brake.
Fig. 276
Evaluation of test
If the charge pressure drops, check the
components individually.
If the starting pressure is not reached,
check the vibration pump.
If the starting pressure is only reached for
one frequency, check the high pressure
relief valves.
NOTICE!
Perform measurements at operating temperature
of the hydraulic oil (50 °C).
1. Drive the machine with the drum onto an elastic base (rubber
tyres) Ä Fig. 278 and block the wheels additionally with suit-
able chocks.
2. Apply the brake.
Fig. 278
Fig. 279
Fig. 280
Evaluation of test
If the permissible leak oil rate is
exceeded, replace the vibration motor.
WARNING!
Danger of crushing, do not access the articulation
area of the machine!
NOTICE!
Perform measurements at operating temperature
of the hydraulic oil (approx. 50 °C).
Special tools
Hydraulic test case, gear pump testing equipment
Measurement 1
1. Connect a 600 bar pressure gauge to the steering pressure
test port Ä Fig. 281.
2. Start the diesel engine and run it at idle speed.
3. Turn the steering against an end stop.
4. Read the pressure gauge.
ð
Nominal value
see technical data, max. steering pres-
sure of steering/charge pump.
Fig. 281
Evaluation of measurement 1
n If the nominal value is not reached, check the steering cylinder.
Measurement 2
Evaluation of measurement 2
n If the nominal value is reached, replace the steering cylinder.
n If the nominal value is not reached, check the steering/charge
pump.
Measurement 3
1. Reconnect the hydraulic hoses to the steering cylinders.
2. Actuate the emergency stop switch.
Fig. 284
3. Close the pump outlet port Ä Fig. 285 with the gear pump
test equipment.
4. Crank the diesel engine only with the starter motor.
ð
Nominal value
see technical data for steering/charge
pump.
Fig. 285
Evaluation of measurement 3
n If the nominal value is reached, replace the steering valve.
n If the nominal value is not reached, replace the steering/charge
pump.
Fig. 286
Effect of contamination
n Coarse particles (> 15 µm)
– Sudden failure of components.
n Fine particle contamination (5 – 15 µm)
– Wear of components, internal leaks, inaccurate controlling
behaviour, blockage of valves.
n Extra fine particle contamination (< 2 – 5 µm)
– Silting of oil, accelerated aging of oil, corrosion.
n Water in oil
– Increased wear, accelerated aging of oil.
n Chips (abrasion) in the oil
– Open and clean all components in the oil circuit, replace if
necessary.
– Clean all high pressure hoses in the oil circuit, replace if
necessary.
– If abrasion is found in the travel circuit you should also
flush the vibration circuit.
– If abrasion is found in the vibration circuit you should also
flush the travel circuit.
Before flushing
1. Change the filter element
Fig. 287
2.
NOTICE!
Clean the hydraulic tank
Change the oil in case of excessive contami-
nation, 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 an oil container.
3. Mark all hoses and disconnect them from the hydraulic oil
Fig. 288 tank.
4. Clean the oil tank thoroughly from inside, remove the tank
cover, if necessary.
5. Reconnect all hoses.
6. Fill the hydraulic oil tank again with the filling and filtering
unit.
Bleeding
1. Always bleed closed hydraulic circuits if lines had been
removed or connected.
Fig. 289
Fig. 290
Fig. 291
1 Elbow union (tool)
2 Connecting union (tool)
3 Drum drive motor
4 Axle motor
5 Screw socket R1 - 25S (tool)
6 not used
7 not used
8 Flushing filter with filter element 1µ (tool)
9 not used
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (drum drive motor reverse)
13 High pressure hose (drum drive motor forward)
14 High pressure hose (B, axle motor reverse)
15 High pressure hose (A, axle motor forward)
16 High pressure port (B, axle motor reverse)
17 not used
18 Flushing hose 25S - 20S (tool)
19 Flushing hose 25S - 20S (tool)
Fig. 292
1 Elbow union (tool)
2 Connecting union (tool)
3 Drum drive motor
4 Axle motor
NOTICE!
Before the installation of the filters check hoses
and connections for cleanliness.
The flushing filter must be installed in the low pres-
sure side in the return flow to the pump, so that
only cleaned oil will enter the travel pump in for-
ward travel.
With the connection shown in the illustration the
travel pump must therefore be actuated to forward
Fig. 293 direction.
1. Disconnect the high pressure hose (14) from the travel pump
(port B) and connect it with the flushing hose (19) (flushing
filter inlet “IN”).
2. Connect the flushing hose (18) (flushing filter outlet “OUT”) to
the high pressure port (B) on the travel pump.
Fig. 294
Fig. 295
Fig. 296
Fig. 297
3.
NOTICE!
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
Start the engine and shift the travel lever to travel direction
forward.
4. Perform the flushing process at various engine speeds for
approx. 10 minutes.
5. Shut down the engine.
Fig. 298 6. Reconnect the high pressure hoses (12 and 13) to the drum
drive motor.
1. Jack up the front of the machine, so that the drum can rotate
freely.
2. Secure the rear wheels with chocks.
3. Pre-select the slow speed range.
Fig. 299
4. Keep circulating the complete tank content with the filling and
filtering unit throughout the entire flushing process.
Fig. 300
5.
NOTICE!
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
6. Run the flushing procedure for approx. 10 minutes. During
this process, keep changing the pump flow by shifting the
travel lever several times between full and half forward travel.
7. Shut down the engine.
Fig. 301
Fig. 302
4. Keep circulating the complete tank content with the filling and
filtering unit throughout the entire flushing process.
Fig. 303
5.
NOTICE!
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
6. Run the flushing procedure for approx. 10 minutes. During
this process, keep changing the pump flow by shifting the
travel lever several times between full and half forward travel.
7. Shut down the engine.
Fig. 304
8. Remove the flushing filter and reconnect the high pressure
hoses.
Fig. 305
Fig. 306
Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Check all connections for leaks with the engine running
(visual inspection).
3. Perform a test drive, load the travel system in forward and
reverse, e.g. by driving uphill or starting on a gradient.
4. Check all ports and connections once again for leak tightness
(visual inspection).
Fig. 307
B A 1
9
2
10 A
3
8
OUT
5 4 A
IN
B
5
7
6 S-582-0031
Fig. 308
1 Vibration pump
2 High pressure hose, A <> A
3 High pressure hose, B <> B
4 Elbow union (tool)
5 Connecting union (tool)
6 Vibration motor
7 Flushing filter with filter element 1µ (tool)
8 Screw socket R1 - 25S (tool)
9 Flushing hose 25S - 20S (tool)
10 Flushing hose 25S - 20S (tool)
NOTICE!
Before the installation of the filters check hoses
and connections for cleanliness.
The flushing filter must be installed in the low pres-
sure side in the return flow to the pump, so that
only cleaned oil will enter the vibration pump in
high frequency.
D, DH and PDH machines: For the connection
schematic shown here the vibration must always
Fig. 309 be filtered with “high frequency / low amplitude”.
Fig. 310
Fig. 311
Fig. 312
2. Keep circulating the complete tank content with the filling and
filtering unit throughout the entire flushing process.
Fig. 313
3.
NOTICE!
D, DH and PDH machines: Use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
Flushing the vibration motor 1. Reconnect the hoses (3 and 9) to the vibration motor.
2. Unscrew the fastening screws for the vibration motor and pull
the motor out of the coupling.
Fig. 315
3. Keep circulating the complete tank content with the filling and
filtering unit throughout the entire flushing process.
Fig. 316
4.
NOTICE!
D, DH and PDH machines: Use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
Removing the flushing filter and 1. Remove the flushing filter, install the vibration motor and
reinstalling the vibration motor reconnect the high pressure hoses (2 & 3).
Fig. 318
Fig. 319
Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Perform a test drive.
3. Check all ports and connections once again for leak tightness
(visual inspection).
Fig. 320
WARNING!
The engine must not start.
Fig. 321
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Operate the starter motor for approx. 30 seconds. Wait one
minute and repeat this procedure, until oil starts to run out of
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 322
Fig. 323
Fig. 324
10.
NOTICE!
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
WARNING!
Run the engine with idle speed.
Fig. 325
Start the diesel engine.
11. Shift the travel lever approx. 1/3 to forward direction.
12. After approx. 1 to 2 minutes shut down the diesel engine for
a minute.
ð
This waiting time is necessary to allow air
bubbles to escape through the leak oil
return line.
WARNING!
The engine must not start.
Fig. 326
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Crank the diesel engine approx. 10 seconds with the starter
motor. Wait one minute and repeat this procedure, until oil
starts to run out of the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 327
Fig. 328
Fig. 329
10.
NOTICE!
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.
NOTICE!
In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.
Normal level
approx. 3 cm below the top edge of the inspection glass.
Minimum level
Middle of inspection glass.
For quality and quantity of oil refer to the table of fuels and
lubricants.
WARNING!
Danger of scalding!
Danger of scalding by hot oil when unscrewing the
oil filter.
NOTICE!
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed after
the oil change and after the test run.
Replace the filter element at the latest after one
year
ENVIRONMENT!
Dispose of the old filter element environmentally.
1. Open the engine hood Ä Fig. 332 completely and secure it.
Fig. 332
1. Unscrew the fastening screws Ä Fig. 333 and take off the
cover.
2. Replace the filter element, attach the cover and fasten it with
the screw.
Fig. 333
WARNING!
Danger of scalding!
When draining off hot hydraulic oil!
NOTICE!
The hydraulic oil must also be changed after major
repairs in the hydraulic system.
Perform the oil change when the hydraulic oil is
warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Change the filter only after the hydraulic oil change
and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
When changing from mineral oil based hydraulic oil
to an ester based biologically degradable oil, you
should consult the lubrication oil service of the oil
manufacturer for details.
ENVIRONMENT!
Catch running out hydraulic oil and dispose of
environmentally.
Fig. 334
Nominal value:
approx. 3 cm below the upper edge of the inspection glass
WARNING!
Danger of scalding!
Danger of scalding by hot oil when unscrewing the
oil filter.
NOTICE!
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed after
the oil change and after the test run.
Do not use the oil in the filter bowl again.
ENVIRONMENT!
Catch running out oil, dispose of oil and filter ele-
ment environmentally.
1. Unscrew the cap nut 4 Ä Fig. 336 and take the filter bowl (5)
with the filter element (3) off.
2. Examine the sealing face on the filter element thoroughly for
any visible dirt.
NOTICE!
Visible dirt may be an early sign for the failure of
system components and indicate the possible
Fig. 336 failure of components. In this case determine the
cause and replace or repair the defective compo-
nents, if necessary. Negligence may cause
destruction to the entire hydraulic system.
Do not clean or reuse the filter element.
1. Take the old filter element (3) out and clean the filter bowl
and the thread.
2. Reinstall the filter bowl with the new filter element, check the
condition of the O-rings (1) and (2), replace if necessary.
3. After a test run check the filter for leaks.
7 Air conditioning
7.1 Overview
Fig. 337
1 Compressor
2 Condenser
3 Drier / collector
4 HKL module
Fig. 338
A - heat absorption
B- Heat dissipation
Heat always flows from the warmer to the colder matter. Any
matter consists of a mass of moving molecules. The rapidly moving
molecules or a warmer matter dissipate part of their energy to the
slower moving molecules with less heat. The movement of the mol-
ecules in the warmer matter becomes slower and the molecules in
the cooler matter are accelerated. This process continued, until all
molecules in the two matters move with identical speed. The mat-
ters have then reached an identical temperature and the transfer of
heat stops.
Fig. 339
Pressure and boiling point The boiling point is the temperature at which fluid changes to gas-
eous state.
Changing the pressure above a fluid also changes the boiling
point. It is a well known fact, that e.g. the lower the pressure
applied to water, the lower the boiling point.
When looking at water, the following values do apply:
n Atmospheric pressure, boiling point 100°C
n Overpressure 0.4 bar, boiling point 126°C
n Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants must have a
low boiling point, so that they can absorb and dissipate heat
quickly.
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Solidification point:
-101.6 °C
Critical temperature:
100,6 °C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pressure) means that
above this point there is no separating interface between liquid and
gas. Above its critical point any substance is gaseous. At tempera-
tures below the critical point all refrigerant types in pressure con-
tainers have a liquid and a gaseous phase, i.e. a gas cushion is
above the liquid. As long as gas is in the container, besides the
liquid, the pressure depends on the ambient temperature.
Colour:
Steam pressure:
In an incompletely filled, closed container, vaporous refrigerant will
volatilize from the surface in the same quantity that will turn liquid
in combination with steam particles. This state of equilibrium
occurs under pressure and is frequently referred to as steam pres-
sure. The steam pressure is independent from the temperature.
Water content:
In liquid refrigerant water can only be dissolved in very low quanti-
ties. In contrast to this refrigerant steam mixes with water steam at
any ratio. If the dryer in the liquid container has absorbed approx. 8
gr. of water, the refrigerant circuit transports possibly existing water
in form of droplets. This water flows to the nozzle of the expansion
valve and turns to ice. The air conditioning system stops cooling.
Water destroys the air conditioning system, because under high
pressures and temperatures and in connection with other contami-
nants it forms acids.
Inflammability:
Refrigerant is not inflammable. On the contrary, it has fire inhibiting
or fire extinguishing properties. Refrigerant is decomposed by
flames or glowing surfaces. Ultraviolet light also cracks refrigerant
(caused by electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the mucous mem-
branes is an early and in-time warning.
Filling factor:
Properties of compressor oil / The most important properties are high solvency in connection with
refrigeration oil refrigerants, good lubrication characteristics, that they are free of
acids and their low water content. For this purpose only certain oils
can be used. PAG-oils suitable for use with refrigerant R134a 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 moisture and acids, becomes dark, viscous and aggres-
sive against metals.
ENVIRONMENT!
Used compressor oil / refrigeration oil must be dis-
posed of as hazardous waste.
NOTICE!
Compressor replacement
New compressors are delivered with an approx.
250 gr.compressor oil filling. To avoid excessive oil
in the A/C-system and thus a poor cooling effect,
the oil level in the A/C-system must be adjusted
accordingly.
The quantity depends on the amount of oil that
may have been lost in connection with the possible
replacement of other components.
The compressor oil quantity must be 10% of the
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system
requires a compressor oil / refrigerant oil filling of
110 gr.
Procedure
Monitoring chain
1 Switches
2 Fuse
3 Thermostat
4 Low pressure switch contact
5 High pressure switch contact
6 Relays
7 Connection for magnetic clutch
8 Pressure switch
WARNING!
Danger of injury caused by exploding compo-
nent!
– Do not clean the condenser in the air condi-
tioning system with a hot water jet.
Fig. 344
The fins must be free of dirt and damage.
NOTICE!
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by
exchanging the components, must be replaced
with fresh oil.
NOTICE!
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because mois-
ture will enter in such a case.
This requires emptying the air conditioning system!
Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
Fig. 346
Inspection glass
During operation the refrigerant must flow through the inspection
glass without air bubbles. In most cases the presence of air bub-
bles is a sign for a too low refrigerant level in the system. Apart
from this, the refrigerant may not sufficiently condense as a result
of a soiled evaporator or a defective condenser fan and the fluid
level in the refrigerant container may drop down to a level, at which
gaseous refrigerant could flow through the rising tube to the
inspection glass. This results in abnormally high temperatures in
and on the fluid lines (between refrigerant container and expansion
valve), as well as very high pressures in the pressure side.
However, incorrect evacuation or filling may also be the reason for
Fig. 347 air entering into the system and since air cannot be condensed,
one will not be able to get rid of these bubbles by topping up refrig-
erant. In this case the air conditioning system needs to be evacu-
ated and refilled.
WARNING!
In case of mechanical damage or corrosion on this
pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Expansion valve
Evaporator
NOTICE!
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by
exchanging the components, must be replaced
with fresh oil.
Thermostat
Fig. 350
Adjustable thermostat
With adjustable temperature regulators the switching point can be
changed so that the compressor is already shut down at higher
temperatures. This enables regulation of the air temperature.
Pressure switch
Pipes and hoses in air conditioning systems must meet very high
requirements with respect to resistance against heat and pressure.
The requirements concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through the hose
material, are very high. Pipes and hoses to be used must therefore
be specially made for air conditioning purposes. For this reason the
hoses have an inside lining of butyl rubber and an outside coating
of EDPM rubber. Hose sections exposed to heat are provided with
a special heat insulation.
O-rings are made of a special type of chloroprene rubber (neo-
prene). Before assembly of the air conditioning system these O-
rings must be lubricated with compressor oil / refrigeration oil. The
O-rings must always be replaced when assembling A/C-compo-
nents.
Recommended tightening torques for O-ring sealed fittings
7.8 Compressor
Structure
Magnetic clutch The belt pulley (2) runs on a bearing on the refrigerant compressor
housing. It is driven by the ribbed V-belt and rotates on the ball
bearing (5) around the magnetic coil (6), which is mounted to the
refrigerant compressor housing. The pressure plate (7) is con-
nected to the shaft of the refrigerant compressor (4) by means of a
splined connection. It consists of 2 rings, which are connected by a
resilient plate.
The magnetic coil (6) is energized to start up the refrigerant com-
pressor (1). The magnetic force pulls the outer ring of the pressure
plate (7) against the belt pulley (2) and holds it in position. This
causes a positive connection between pressure plate (7) and belt
pulley (2).
Once the magnetic coil (6) is de-energized, spring force will return
the outer ring of the pressure plate (7) back to its rest position and
the flow of force is interrupted. This ensures switching off of the
refrigerant compressor in case of a mechanical defect.
Delivery process Once the magnetic coupling of the refrigerant compressor (1) has
caused the frictional connection, the shaft of the refrigerant com-
pressor (4) will drive the swash plate (9) via the driver disc (8). The
revolving slanted swash plate (9) causes a stroke movement of the
7 pistons (10), which are evenly distributed along the circumfer-
ence.
The pistons (10) are thereby actuated by slipper pads (11).
During the suction stroke gaseous refrigerant flows through the
suction valve (A) into the corresponding cylinder. When the stroke
of the piston (10) is reversed, it compresses the gaseous refrig-
erant, until the pressure inside the cylinder becomes so high, that
the pressure valve (B) opens and allows the refrigerant to flow
through the compressor outlet and thus into the refrigerant circuit.
The refrigerant compressor (1) has integrated chambers both on
the suction and on the pressure side, which have the function to
dampen resonances, which are generated by suction and com-
pression.
Displacement control The refrigerant compressor (1) is designed in such a way, that
already has sufficient flow rate to keep up the refrigerant circuit,
even at a slow vehicle speed and low engine speed.
Since the flow rate of the refrigerant compressor (1) rises with
increasing engine and travel speed, the flow rate needs to be
reduced or regulated.
This is to avoid that the refrigerant compressor (1) unnecessarily
uses engine power.
The flow rate is controlled by switching the magnetic coupling on
and off.
Safety contgrol of the refrigerant To prevent the ribbed V-belt jumping off in case of a mechanical
compressor (1) defect of the refrigerant compressor (1), the magnetic coupling will
disengage automatically.
In case of a mechanical defect the refrigerant compressor (1) will
be harder to turn or may even block completely. The heat created
on the friction surface of the V-belt (2) blows a meting fuse (3) in
the magnetic coil (6). This interrupts the power supply to the mag-
netic coil (6) and releases the frictional connection.
Service valves The service valves are installed directly on the compressor. These
are used to e.g. evacuate and fill the system.
ENVIRONMENT!
Contaminated refrigerant must be disposed of
environmentally
Releasing refrigerant into the atmosphere is pro-
hibited (see restrictive injunction concerning CFC,
day of enforcement 01. 08. 1991, § 8)
WARNING!
For draining refrigeration systems you should not
simply use any delivery containers, but only appro-
priate pressure bottles, which must be specially
marked and should comply with the pressure gas
directive.
When transferring refrigerant you must make sure
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suffi-
cient gas space for expansion (filling factor: 0,7).
NOTICE!
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 addi-
tional 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 refrigerant con-
tainer should be about 1/3 filled with liquid refrigerant, the evapo-
rator should be maximally filled at the calculated evaporation tem-
perature, i.e. the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the pressure gauge.
Fig. 354
Filling instructions
1 Connect the service adapter with the blue hand wheel in the
suction side.
2 Connect the service adapter with the red hand wheel in the
pressure side (the hand wheels on the service adapters must
be fully backed out - left hand stop)
3 Connect the blue suction hose below the blue hand wheel on
the pressure gauge bar to the blue service adapter.
4 Connect the red pressure hose below the red hand wheel on
the pressure gauge bar to the red service adapter.
5 Connect the yellow hose below the yellow hand wheel on the
manometer bar to the 2-stage vacuum pump.
6 Connect the last hose below the black hand wheel on the
nitrogen bottle via the pressure reducing valve.
7 Check on the pressure gauge bar that all hand wheels are
closed.
8 Turn the hand wheels on both service adapter clockwise. This
opens the valves (right hand stop).
9 Open the valve on the nitrogen bottle (only via pressure
reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pressure gauge
bar and fill nitrogen into the system, until a pressure of approx.
3.5 to 5.0 bar is indicated on the suction side.
11 Then open the blue hand wheel and raise the pressure in the
suction side (max. 10 bar). Check for leaks with a leak detec-
tion 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 pressure gauges
show -1, close all hand wheels on the pressure gauge bar.
16 Switch off the vacuum pump, watch the pressure gauges to
see whether the vacuum is maintained.
17 Open the valve on the refrigerant bottle and open the black and
red hand wheels on the pressure gauge bar. Fill refrigerant into
the system, until a pressure equilibrium between suction and
pressure side is reached (reading of pressure gauges).
18 Close the red hand wheel.
19 Perform a leak test with the electronic leak detector.
20 Start the engine and switch on the system.
WARNING!
Danger of injury!
Work on the belt drive must only be performed with
the engine shut down.
NOTICE!
Replace a damaged or cracked V-belt.
Fig. 355
Fig. 356
NOTICE!
Fig. 357 Check the V-belt tension after a running time of 30
minutes.
NOTICE!
A soiled condenser results in a considerable
reduction of air conditioning power.
Under extremely dusty conditions it may be neces-
sary to clean the condenser several times per day.
If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.
Fig. 358
Fig. 359
Fig. 360
Fig. 361
Fig. 362
Fig. 363
NOTICE!
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.
WARNING!
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.
Fig. 364
7.13.4 As required
7.13.4.1 Checking the compressor oil level / refrigeration oil level
NOTICE!
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil /
refrigeration oil PAG SP-20 (H14-003-404).
Fig. 365
1 Housing
2 Seal ring
3 Cover
4 Rocker bearing
5 Bolt
6 Shim/supporting disc
7 Belleville springs
8 Rocker bearing
9 Console
10 Belleville springs
11 Shim/supporting disc
12 Cover
13 Cover
14 Intermediate ring
15 Rocker bearing
16 Intermediate ring
17 Rocker bearing
18 Carrier
19 Friction bearing
20 V-ring
21 Seal ring
9 Drum
Fig. 366
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel motor
5 Drum shell
6 Rubber buffer
7 Rectangular rubber buffers
8 Travel bearings
NOTICE!
Notes on repair
– 1
Install the O-ring with some grease.
– 2
Fitting and contact surface of the connection
must be absolutely dry and free of grease, oil,
paint and conserving agent.
– 3
Grease radial seals + running surface on shaft
before assembling.
– 4
Install the dowel pins with the grooves offset by
180° to each other, but in line with the axis of
the shaft.
– 5
The thread must be free of grease, oil, paint
and conserving agents.
– 6
Wet the elastomer part + bore in flanged hub
with spirit (no oil) to ease assembly of the
mechanical seal.
– Clean the sliding surfaces on the seal and
apply a thin film of oil.
– During assembly fill the cavity up to 1/3 with
grease.
– 7
Fill the bearing completely with grease.
– Bearing space to 1/3 filled with grease.
– 8
Ventilation bore in cover pointing down.
– 9
Check the end float of the shaft: Nominal
value 0.6 to 1.8 mm.
NOTICE!
Components may get damaged!
– Use only gear oil of the permitted specification
Ä Chapter 1.3.1.6 „Gear oil SAE
75W-90“ on page 34.
Fig. 368
5. Clean the area around the filler plug and unscrew the filler
plug.
6. Fill in oil through the filler bore, until it starts to run out
through the level inspection bore.
Fig. 369
NOTICE!
Components may get damaged!
– Drain gear oil only at operating temperature.
– Use only gear oil of the permitted specification
Ä Chapter 1.3.1.6 „Gear oil SAE
75W-90“ on page 34.
– Filling quantity: Ä Chapter 1.4 „List of fuels and
lubricants“ on page 35.
WARNING!
Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
Fig. 370 – Avoid touching hot components.
5. Unscrew the drain plug and catch any oil running out.
6. Turn the drain plug tightly back in.
Fig. 371
9. Unscrew the oil filler plug and fill in new oil through the oil
filler bore, until oil starts to drip out through the inspection
bore.
10. Retighten the filler and level inspection plugs.
11. Change the oil on both sides.
12. Dispose of oil in an environmentally friendly way.
Fig. 372
9.2.4 As required
9.2.4.1 Retightening the padfoot shell
After the installation of the padfoot shell, all fastening screws must
be retightened.
1. Run an approx. two minute test drive with vibration.
2. Park the machine in secured condition Ä Chapter 1.2.5
„Parking the machine in secured condition“ on page 23.
3. Retighten all fastening screws.
4. After approx. 60 minutes work retighten all fastening screws
again.
Fig. 373
Fig. 374
Fig. 375
10 Drive axle
WARNING!
Danger of being injured by bursting tyres!
– Wear your personal protective equipment
(safety shoes, gloves, goggles, hard hat).
– When checking the tyre pressure stand in the
extended path of the tyre track.
– Use an air hose with a length of min. 6 meters.
– Never exceed the permitted maximum pres-
sure.
1. Move the machine until the tire inflation valve (1) is in top
position.
2. Park the machine in secured condition Ä Chapter 1.2.5
„Parking the machine in secured condition“ on page 23.
3. Check the tyres for cuts, bulges, damaged rims, missing
wheel studs or nuts.
4. Have damaged wheels or tyres replaced immediately.
5. Unscrew the valve caps and check the front and rear tire
pressure, correct if necessary.
Fig. 376 Ensure equal pressure in all tires.
NOTICE!
Components may get damaged!
– Use only gear oil of the permitted specification
Ä Chapter 1.3.1.5 „Gear oil SAE
80W-140“ on page 33.
3. If necessary clean the area around the filler plug (2) and
unscrew the filler plug.
Fig. 377
4. Fill in oil through the filler bore, until it starts to run out
through the level inspection bore.
5. After filling in oil wait until the oil has evenly distributed inside
the axle.
6. Retighten level inspection and filler plugs.
NOTICE!
Components may get damaged!
– Use only gear oil of the permitted specification
Ä Chapter 1.3.1.5 „Gear oil SAE
80W-140“ on page 33.
NOTICE!
Components may get damaged!
– Drain gear oil only at operating temperature.
– Use only gear oil of the permitted specification
Ä Chapter 1.3.1.5 „Gear oil SAE
80W-140“ on page 33.
– Filling quantity: Ä Chapter 1.4 „List of fuels and
lubricants“ on page 35.
WARNING!
Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Avoid touching hot components.
3. Unscrew the drain plug and catch any oil running out.
Fig. 379 4. Turn the drain plug tightly back in.
5. Clean the area around the filler plug (2) and the level inspec-
tion plug (1).
6. Unscrew the oil level inspection plug.
NOTICE!
Components may get damaged!
– Drain gear oil only at operating temperature.
– Use only gear oil of the permitted specification
Ä Chapter 1.3.1.5 „Gear oil SAE
80W-140“ on page 33.
– Filling quantity: Ä Chapter 1.4 „List of fuels and
lubricants“ on page 35.
WARNING!
Danger of burning on hot components!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
Fig. 381
– Avoid touching hot components.
4. Unscrew the level inspection plug and catch any oil running
out.
5. Move the drive wheel, until the oil level inspection plug is in
horizontal position.
6. Fill in oil through the inspection bore, until it starts to run out
through the level inspection bore.
7. Turn the level inspection plug tightly back in.
8. Change the oil in both wheel hubs.
9. Dispose of oil in an environmentally friendly way.
Fig. 382
Fig. 383
Fig. 384
10.5 As required
10.5.1 Adjust the parking brake
NOTICE!
Have adjustment work on the brakes only carried
out by a specialist! Always adjust both sides.
1. Disengage the travel lever Ä Fig. 385 to the left, but do not
move to position "I" or "II".
Fig. 385
Fig. 386
Fig. 387
11 Troubleshooting
Fig. 388
Fig. 389
WARNING!
Danger of accident! Danger of injury!
Apply appropriate measures (e.g. with metal wheel
chocks, to be provided by the operating company)
to secure the machine against rolling away before
releasing the parking brake.
When using towing ropes tow the machine only
uphill.
When towing downhill you must use a tow bar.
The machine cannot be steered.
Use a towing vehicle with sufficient traction and
braking power for the unbraked towed load.
Do not touch hot engine parts.
NOTICE!
Tow the machine only after having released the
parking brake.
Towing speed 1 km/h, max. towing distance 500 m.
Fig. 390
Travel pump
4.
NOTICE!
Do not turn the valves out completely!
Fig. 391
Drive axle
5. To release the brake turn counter nuts (1) approx. 8 mm
back.
6.
NOTICE!
From this stop turn the screw in for maximum
another turn to release the brake!
Turn the screws in evenly on both sides.
After towing
NOTICE!
Apply appropriate measures (e.g. with metal wheel
chocks) to secure the machine against rolling away
before disconnecting the tow bar.
1. Turn the high pressure relief valve cartridges tightly back in.
2. Turn all brake releasing screws of the axle evenly back out,
until they are light moving again.
3. Turn the brake releasing screws back in again, until they abut
against the brake piston.
Fig. 393
4. Unscrew the brake releasing screws for two turns and tighten
the counter nuts.
5. Repeat this adjustment procedure on the opposite wheel
side.
Switches, plugs, wiring looms Over the years corrosion and contamination can create high con-
tact resistances in plugs and switches, wiring looms affected by
“copper worm” (corrosion) are poor conductors. In extreme inci-
dents such a component will be absolutely dead, while minor
damage more or less reduces the performance of the affected con-
sumers to a noticeable extent.
In many cases it is enough to examine the components visually:
Green male connectors of plugs, neglected switch contacts must
be mechanically cleaned and reassembled with some contact
spray. Cables core showing green discolouration must be replaced.
A resistance measurement provides exact information about the
conductivity.
Leakage currents The machine has not been driven for a few days, and the battery is
almost empty? This may be caused by a “surreptitious consumer”
in the electrical network of the machine, of a leakage current
simply “draws” your battery empty. Such a leakage current can be
caused by e.g. the ignition lock, a defect switch, a relay or a
clamped or chafed cable.
Measuring fault Whenever the electrical system of the vehicle behaves in an unex-
pected way, one should first consider that there may be a ground
problem! The older the electrical system and the lower the voltage,
the more likely this will be the cause.
If the battery is empty If the battery is empty, the fault is normally quite quickly identified.
Necessary if:
n the battery is permanently discharged
n the battery has boiled over and acid has escaped
n the headlights light considerably brighter when accelerating
n light bulbs burn out frequently at irregular intervals
NOTICE!
A wrong connection will cause severe damage
in the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.
1. Connect the plus pole of the external battery first with the
plus pole of the vehicle battery using the first jump lead.
2. Then connect the second battery cable first to the minus pole
of the current supplying auxiliary battery and then to engine
or chassis ground, as far away from the battery as possible.
3. Start the engine.
NOTICE!
Danger of damage to the electronic system!
If no powerful consuming device is switched on,
Fig. 395
voltage peaks may occur when separating the con-
necting cables between the batteries, which could
damage electrical components.
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings
and do not bridge fuses.
WARNING!
Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
Fig. 397
Fig. 398
Fig. 399
Cover sheet
Table of contents
Sheets with representations of n The main reading direction is sheet by sheet, from top to
functions bottom and from left to right.
n All sheets are successively numbered.
n BOMAG used the resolved type of representation. In this case
parts and components with different functions, which belong to
the same components (e.g. relay coil and relay contact), can
be represented on different sheets. Cross-references, which
refer to the sheet and current path, serve as linkage between
these partial components.
List of components
Overview of plugs
Overview of pins
Representation of electric devices Electronic devices and components are increasingly used in the
construction equipment industry. Controls with software, control
elements (e.g. joystics and man / machine interfaces, such as e.g.
screens, LC-Displays) are frequently used to represent and control
machine functions. The internal construction of such components
is in most cases protected or just too complex to be illustrated in
the wiring diagram within the context of the actual machine func-
tion. There are two different ways to simplify the representation of
such devices in the diagram.
Black-Box representation
Fig. 413
F Direction
n For normally open contacts the contact symbols _3/_4 are
used.
n For normally closed contacts the contact symbols _1/_2 are
used.
In combination with the contact block numbering described above
each individual connection is clearly defined.
Example:
The contact block marked with 4 is called 43/44, if it is a normally
open contact and 41/42, if it is a normally closed contact.
The contact block marked with 2 is called 23/24, if it is a normally
open contact and 21/22 , if it is a normally closed contact.
The contact block marked with 1 is called 13/14, if it is a normally
open contact and 11/12, if it is a normally closed contact.
The contact block marked with 5 is called 53/54, if it is a normally
open contact and 51/52, if it is a normally closed contact.
NOTICE!
This type of tester must not be used for testing on
electronic components. The high power consump-
tion of the test lamp may destroy electronic compo-
nents in the control units.
Multimeter
This tester is a multimeter and can be used to measure e.g. cur-
rent, voltage and resistance. Furthermore, depending on the
design you must carry out transistor and frequency tests.
In order to avoid damage:
n the range selector switch must be correctly set for the corre-
sponding measurement.
n the test cable must be plugged into the correct socket.
n the voltage type (AC/DC) must be set.
n In case of direct voltage the correct polarity must be assured.
n the measuring range should be chosen higher at the beginning
Fig. 416: Multimeter of the test.
n In order to avoid any influence on the circuitry to be measured,
the internal resistance of the voltage tester should be as high
as possible.
Fig. 417
Fig. 418
Advice
If the electric circuit is difficult to access and the internal resistance
of the consumer is known, the voltage may also be measured at
the consumer.
The current value can then be calculated with the help of Ohm's
law.
Fig. 424
Magnet tester
The magnet tester is used to test solenoid valves and magnetic
coils.
The test lamp responds to the magnetic fields of A.C-voltage, D.C.-
voltage and permanent magnets.
n The component to be tested does not need to be removed.
n The magnetic coil can also be tested under a protective cap.
Power measurement
The electric power of a module within a circuit can be indirectly
determined (calculated) by separate measuring of current and
voltage.
However, there are also pure power meters with 4 connections
available. The power meter has a electro-dynamic measuring
mechanism. The current circuit must be opened for measuring.
Take care when performing power measurements: Voltage or cur-
rent path may already be overloaded during the measurement,
even though the end stop in the meter has not yet been reached.
Fig. 426
NOTICE!
A wrong connection will cause severe damage
in the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.
1. Connect the plus pole of the external battery first with the
plus pole of the vehicle battery using the first jump lead.
2. Then connect the second battery cable first to the minus pole
of the current supplying auxiliary battery and then to engine
or chassis ground, as far away from the battery as possible.
3. Start the engine.
NOTICE!
Danger of damage to the electronic system!
If no powerful consuming device is switched on,
Fig. 427
voltage peaks may occur when separating the con-
necting cables between the batteries, which could
damage electrical components.
Blue engine Engine oil level too high Check, drain off if necessary
exhaust smoke
White engine Temperature below starting limit Check
exhaust smoke
The fuel quality does not meet the Change the fuel
requirements
Incorrect valve clearance Check, adjust if necessary
Injection valve defective Check, replace if necessary
Black engine Air filter clogged / exhaust turbocharger Check, replace if necessary
exhaust smoke defective
Charge air pipe leaking Check, replace if necessary
Radiator dirty Check, clean if necessary
Incorrect valve clearance Check, adjust if necessary
Injection valve defective Check, replace if necessary
NOTICE!
Fasten the starter to make sure that it will not come
loose during the test.
Fig. 428
Fig. 429
Fig. 430
Measuring the charge current n All plug-and-socket connectors must be free of corrosion and
intermittent contact.
n The generator ground connection must be OK.
n During the measurement switch on as many consumers as
possible.
Fig. 432
Fig. 434
Checking the regulator voltage with The battery and generator tester comes with an 8-line LC display
the generator tester with background illumination and is able to print out test results via
an (optional) thermal printer.
The generator test assesses the regulator voltage and the ripple
factor of the generator voltage.
n All plug-and-socket connectors must be free of corrosion and
intermittent contact.
n The generator ground connection must be OK.
n The battery should be in good condition – the idle voltage of
the battery should be at least 12.6 Volt.
n If possible switch off all consumers.
n Perform the measurement at raised engine speed.
Fig. 435
Fig. 436
Checking the regulator in disas- On a Bosch generator unscrew two fastening screws for the regu-
sembled state lator and lift the regulator off. For this work the generator does not
need to be removed.
The Delco-Remy generator needs to be removed and partly dis-
mantled, if the regulator needs to be disassembled. Unscrew the
housing screws to do so. Pull rotor with drive bearing and V-belt
pulley out of the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the collector
ring bearing. Disassemble exciter diodes and brush holders and
remove also the regulator.
Fig. 437
Fig. 439
The illustrations Ä Fig. 439 and Ä Fig. 440 show two different
regulator types.
Fig. 440
Fig. 442
10 Pressure resistance plugs
1. Connect pressure gauges (6) for high pressure and charge
pressure.
2. Disconnect hydraulic motor / ´hydraulic motors (3) and close
the ports with pressure resistant plugs (10).
NOTICE!
Do not run the test over a longer period of time
(danger of overheating).
Drive elements
Malfunction Possible cause
n Mechanical parts on the drive side defective (coupling seat, alignment
Abnormal noises
faults, etc.)
No or insufficient volumetric n Speed transfer of distance transfer defective
flow
No or insufficient pressure n Torque transfer defective
Fluctuation of pressure / flow n Drive elements defective
volume
Flow valves
Malfunction Possible cause
n Trapped air
Abnormal noises n Pressure differential too small
n vibrations
No or insufficient volumetric n Control orifice blocked
flow n One-way restrictor deadjusted
n Trapped air
Fluctuation of pressure / flow n Pressure differential too small
volume n Flow valve contaminated
n Check valve defective
n Wear
n Gap losses
Pressure fluid too hot
Way valves
Malfunction Possible cause
n Control defective
Abnormal noises n Design fault (nominal width)
n Restrictions
n Incorrect or inaccurate spool position
n negative overlap
No or insufficient volumetric
n Pilot pressure too low - does not switch
flow
n Incorrect position
n mechanically jammed
No or insufficient pressure n Resetting spring broken
n leaking
n Dummy plug loosened
n Flow forces influence the spool action and the opening distances
Fluctuation of pressure / flow n Positioning fault
volume n unstable position
n Pilot pressure fluctuation
n Incorrect position
n Throttle losses
Pressure fluid too hot n too small dimensioned
n Cross-section too small
n Wear
Pressure accumulator
Malfunction Possible cause
n Accumulator bladder defective
n Nitrogen filling enters into hydraulic circuit
n defective seals
n
Abnormal noises
Inflow and outflow velocity too high
Note: Accumulators in connection with throttle losses can form resonant
systems
No or insufficient volumetric n Nitrogen filling level too low
flow
n Nitrogen filling pressure too low or too high _ Stored power is not
No or insufficient pressure
enough
Fluctuation of pressure / flow n Resonant system between hydraulic accumulator, pressure and flow
volume valves and pump
Filter
Malfunction Possible cause
n Insufficient fastening
n mechanical oscillations
Abnormal noises
Pressure fluid too hot n Opening pressure of bypass valves too high
Radiator
Malfunction Possible cause
n Air-oil radiator fan noises
n mechanical oscillations
Abnormal noises
Pressure lines
Malfunction Possible cause
n Inappropriate operation
Abnormal noises n Structure borne noise
n Pipe cross-section too small
n Screw fittings leaking
n Cross section too small
No or insufficient volumetric
n Throttle actuator pressure increase
flow
n Cable breakage
No or insufficient pressure n Screw fittings leaking
n Display or measuring equipment defective
n Not correctly ventilated
n Display or measuring equipment defective
Fluctuation of pressure / flow
n Display fault
volume
Engine
Malfunction Possible cause
n Incorrect sense of rotation
n Too high speed
n
Abnormal noises
Bearing play
n Bearing damage
No or insufficient volumetric n Speed too low
flow
n Incorrect sense of rotation
n Poor drive power
No or insufficient pressure
Clutch
Malfunction Possible cause
n Coupling seat defective
Abnormal noises n Alignment fault
n elastic elements defective
No or insufficient volumetric n Rotary speed transfer defective
flow
No or insufficient pressure n Torque transfer defective
Pump
Malfunction Possible cause
n Too high speed
n Air intake
n
Abnormal noises
Cavitation
n mechanical damage
No or insufficient volumetric n Internal leakage
flow n Wear caused by dirt
n Internal leakage
No or insufficient pressure n Wear caused by dirt
n Drive damage
Pump
Malfunction Possible cause
n Air intake
n Internal leakage
n Wear caused by dirt
Fluctuation of pressure / flow n Drive damage
volume n With engine under load or temporary overloading disturbed control
behaviour caused by contamination
n Engine overload caused by power take-up on auxiliary drive
n Regulator oscillates
n Internal leakage
n Wear damage
Pressure fluid too hot
Leakage line
Malfunction Possible cause
Abnormal noises n insufficient fastening
n High temperatures caused by high leakage indicate an expected
Pressure fluid too hot
failure of a component
Suction conditions
Malfunction Possible cause
n Insufficient suction cross-section
n too high suction height
n direction changes
n cross-sectional constrictions
n
Abnormal noises
leaking suction line
n Air bubbles
n Tank shut-off valve not opened
n Resistance on filter
n Suction behaviour disturbed
n insufficient suction cross-section
No or insufficient volumetric n too high suction height
flow n direction changes
n cross-sectional constrictions
n leaking suction line
Suction conditions
Malfunction Possible cause
n Suction behaviour disturbed
n insufficient suction cross-section
n too high suction height
No or insufficient pressure n direction changes
n cross-sectional constrictions
n leaking suction line
n Trapped air
n Suction behaviour disturbed
n insufficient suction cross-section
n too high suction height
n
Fluctuation of pressure / flow
direction changes
n
volume
cross-sectional constrictions
n leaking suction line
n Trapped air
n Incorrect viscosity
n Oil filling too low
n In case of extreme local heating up the lubricity, pressure loading
Pressure fluid too hot ability and ageing resistance of the pressure fluid is impaired
n Wear of components
n Gap losses
n Heating up
Technical equipment Pressure gauge and thermometer are the most important auxiliary
means for trouble shooting. The refrigerant states, such as over-
heating and undercooling, provide important information when per-
forming trouble shooting. Even your own senses should not be
underrated in trouble shooting. Bubbles in the inspection glass,
contamination and white frost are visible indicators. If the com-
pressor draws in wet steam, this is visible in the suction line and
may also be audibly perceptible. An overloaded compressor can
even be smelled.
The following tools and auxiliary means should be available for
trouble shooting:
n Service station
n Pressure gauge
n Thermometer
n dry nitrogen
n Refrigerant bottle for new refrigerant
n Container for old oil
n Vacuum pump
n Hoses
n Scales
n Suction station
n Leak detector
The measuring equipment must be checked at regular intervals.
Calibration can only be made by an approved testing authority.
Pressure gauge Most pressure gauges used in practice are (for cost reasons) over-
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 pres-
sure is needed for the calculation and determination of material
data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = Overpressure (pressure gauge reading)
Example:
A totally empty air conditioning system holds an atmospheric pres-
sure of approx. Pambp = 1 bar.
Filling the system with refrigerant causes an overpressure of Pe = 3
bar.
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
Evacuating the system down to Pe = -0.6 bar, creates a "vacuum"
(negative overpressure).
Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
Overheating
Common overheating values The optimal overheating value is approx. 5 - 8 Kelvin. With this
overheating the maximum system power is reached. However, the
thermostatic expansion valve is unable to regulate this value
exactly. Depending on design and operating conditions overheating
fluctuates within a range between 4 and 12 Kelvin. The influence of
the ambient air on the suction line causes an additional over-
heating effect.
Supercooling
For this reason one shifts the condition "Expansion Valve Inlet"
away from the boiling curve into the fluid area and refers to this
condition as Supercooling. This supercooling ensures a fluid
supply in front of the expansion valve.
Common supercooling values In systems with fluid container the supercooling at the fluid con-
tainer outlet is approx. Zero "0" Kelvin (assumed that the system is
filled with the correct refrigerant quantity). In this case the fluid con-
tainer provides the required fluid supply.
Visual inspection With the appropriate experience some faults can be visually
detected or felt. Frequently occurring condenser soiling or forma-
tion of steam bubbles in the inspection glass can be quickly
detected.
In case of unusual formation of hoarfrost on the evaporator the
hoarfrost pattern provides useful information. Hoarfrost only occur-
ring 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 indicates 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 com-
pressor.
The oil level in the compressor sight glass provides information
about the oil quantity and the oil recirculation in the system. How-
ever, the oil level may also be considerably influenced by con-
densing refrigerant. Discoloration informs about the state of the oil.
Water in the system can simply be detected through the inspection
glass with moisture indicator.
Typical faults and possible causes Most of the faults in the refrigerant side can be assigned with the
help of the checklist. In many cases faults have a quite similar
appearance, but totally different causes. White frost on an evapo-
rator, for instance, may be quite normal. However, in this case the
expansion valve may be defective or there may be oil return prob-
lems.
The following list contains pressure values in a system, that can be
expected at various ambient temperatures (measured at medium
speeds).
Values effecting the operating pres- Since the pressures occurring in a refrigeration system are highly
sures dependent on environmental conditions, it is mandatory to know
these dependencies. The following table contains some of these
dependencies.
Fig. 448
Fig. 449
Fig. 450
Fig. 451
Other faults
Noise in system
Inspection glass
Monitoring devices
NOTICE!
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and
rubber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Small leaks with only very low amounts of refrigerant escaping can
be detected, e.g. with an electronic leak tester. Such equipment is
able to detect leaks of less than 5 gr. per year.
The leak tester used must be specially designed for the refrigerant
composition in the air conditioning system. For example, leak
detectors for refrigerant R12 are not suitable for R134a, because
the refrigerant R134a is free of chlorine atoms, meaning that this
leak detector will not respond.
Fig. 452
Fig. 454
12 Disposal
WARNING!
Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
tion regulations when handling fuels and lubri-
cants must be followed Ä Chapter 1.2.4 „Han-
dling fuels and lubricants“ on page 17.
13 Special tools
n Equipment kit
n BOMAG part-no.: 079 950 06
Fig. 457
Fig. 459
Fig. 460
Fig. 461
n Pressure gauge
n 60 bar BOMAG part-no.: 059 721 07
n 600 bar BOMAG part-no.: 059 721 04
Fig. 462
Fig. 463
Fig. 464
Fig. 465
Fig. 466
Fig. 467
Fig. 468
Fig. 469
Fig. 470
Fig. 471
n Guide pin
Fig. 472
n Clamping device
Fig. 473
n Disassembly device
Fig. 474
Fig. 475
Fig. 476
Fig. 477
Fig. 478
Fig. 479
Fig. 480
Fig. 481
14 Index
B
Betriebsmittel
A83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
F
Fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
H
Hydraulic units
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
L
List of fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
M
Maintenance
Fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
List of fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Maintenance intervals
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
O
Operating means
A02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 73
A05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 73, 93, 203
A06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
A12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 89
A13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 86, 116
A15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 79, 81, 84
A16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 89, 95
A51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 89, 95
A66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
A67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
A68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 73
A83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 73, 92
A87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
A93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 67
A108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 79, 190
A124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 73
A138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
B03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 86, 104
B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 83, 86
B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 88
B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 98
B14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 98
B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 88, 101, 302, 313, 314
B30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 83, 86, 108, 116
B51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 86, 103
B60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 88, 93
B62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 92, 188
B104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 90, 190, 374
B105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358, 369
B112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
B113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 86, 116
B124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 82, 88, 105, 106
E03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 84
E04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 84
E07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 84
E08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89, 91, 94
E25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89, 91, 94
E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89, 91, 94
E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89, 91, 94
E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 78, 89
E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
E32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89
E70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 78, 89
E71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89
E72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
EXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 84
F00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 87
F03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 76, 89, 427
F39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 76, 89, 427
F42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 76, 95, 427
F43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 76, 89, 427
F44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 76, 89, 427
F48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 76, 89, 95, 427
F143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 76, 89, 427
F144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 76, 89, 427
F145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 87
G02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
G03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
H04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
H06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
H07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 84
H14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 88
H124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
K04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73, 191, 199
K05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 86, 116
K14.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 89
K35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
K48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
K61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
K69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
K114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
K141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 89
K150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 86, 87
M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 89
M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 89
M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
M09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 84
P04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 84
P05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P
Plugs
X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 84, 85, 86, 88, 90, 92, 93, 96
X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 85, 96
X3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 89, 91, 94, 96
X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 89
X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 96
X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 96
X18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 96
X21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 96
X22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 87, 96
X37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 96
X38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 86, 96
X42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 96
X44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 92, 96
X46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92, 96
X49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92, 96
X53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 96
X58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
XS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91, 94
T
Table of operating means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Trouble shooting
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
Axial piston motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Axial piston pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Fault table hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Appendix
A Circuit diagrams
A Circuit diagrams
A.1 Hydraulic diagram 581 202 10 (58215, 58243, 58244, 58248, 58249)
Industriegebiet Hellerwald
D-56154 Boppard
521
522
Table of contents
Inhaltsverzeichnis
Page Higher-level function Function
Blatt Anlage Funktion Description Beschreibung
Circuit diagrams
F159:2 / 5.0
X37 A
2 2 2 2 30
S120:23 / 8.0
X1 79 X37 B
X1 4 X1 3
Fuse, heating-flange
Sicherung Heizflansch
Sicherung Glühkerze 1
Sicherung Glühkerze 2
K05
1 /8.5 87 87a
Hauptsicherung Zentralelektrik
Relais Startstrom
2
X1 8 7
86 1 30 15/54 / 5.0
R10 K61 X1 53
82 Ω /4.4 87 87a K05:87a / 5.0
K61 85 2
Relay, charge control
12V
Relais Ladekontrolle
Relais Ladekontrolle
Only at D-40 USA version and BW 219 D-4, otherwise option winterpackage
Nur bei D-40 USA Version und BW 219 D-4, sonst Option Winterpacket
D+ / 11.0
X1 65 M01
1
S30 B+ D+ -
BK W / 12.0 X1 168 55 55
70mm²
Ground Central Electric
Masse Zentralelektrik
31 31 31 31
Generator Relay, brake control Relay, potential 30 on 15 Solenoid valve, start boost fuel Starter
Generator Relais Bremskontrolle Relais Potential 30 auf 15 Magnetventil Startmehrmenge Starter
Relay, air conditioner Solenoid valve, boost fuel
Relais Klimaanlage Magnetventil Minusangleichung
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 4 von 47
Erstellt 25.08.2010 Supply, Starting unit Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Versorgung, Starten Einbauort + EPE / 000 / 00
Circuit diagrams
523
524
4.2 / F159:2
F124:2 / 7.0
4.2 / F158:2
4.8 / K05:87a
4.6 / 15/54
X1
52
Circuit diagrams
4.2 / F48:2
A13
/5.5
Glow control unit
Glühzeitsteuergerät
2 7 5
A13 15 TK 50 30
/5.1
3 1 30
K14 R26
/5.3 4 220 kΩ H
Glühzeitsteuergerät
Relais Vorglühen
Relay, glow plug system
L 31 R H
3 4 6 1
3
K14.1
/5.6 4
Relay, glow plug system
Relais Vorglühen
X1 217
Only at BW 177 D/PD-4
Nur bei BW 177 D/PD-4
Option Winterpackage
Option Winterpaket
X1 75 X67 1
1 1 86 86 1 1 1
Only at D-40 USA version and BW 219 D-4, otherwise option winterpackage
Nur bei D-40 USA Version und BW 219 D-4, sonst Option Winterpacket
167A 2 2 12V 12V 50A 2 50A 2 200W 2
85 85
X67 2
X1 57 64 57 218
Ground Engine
Masse Motor
31 31 31
3 4 /5.1 3 4 /5.7
Heating-flange Relay, glow plug system Relay, glow plug system Glow plug 1 Glow plug 2 Fuel-pre-heater
Heizflansch Relais Vorglühen Relais Vorglühen Glühstiftkerze 1 Glühstiftkerze 2 Kraftstoffvorheizung
Sensor, coolant temperature
Sensor Kühlmitteltemperatur
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 5 von 47
Erstellt 25.08.2010 Pre-heating, Fuel-pre-heating Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Vorglühen, Kraftstoffvorwärmung Einbauort + EPE / 000 / 00
525 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40
Erstellt
Geprüft
Created
Checked
0
4.9 / 30
M. Vogt
25.08.2010
25.08.2010
M. Werner
15A
F22
Relais Arbeisscheinwerfer
Relay, working lights
/17.3
K06
X1
X1
21E
21A
X1
2
30
87a
15A
F19
1
X1
X1
22A
X1
X1
X1
X1
146
145
34E
34A
BW 177-219 D-4/D-40
2
15A
F146
X1
X1
35A
X2
X2
80E
80A
2,5mm²
X1
9
4
X1
10
X1:2 / 17.0
4.7 / F13:2
30A
F13
X1
X1
15A
Absicherung Potential 30
Only at option electronical burglary protection
X1
X1
16A
6
20A
F105
X1
X1
17A
Only at StvZO-illumination
Nur bei StvZO-Beleuchtung
15A
F11
X1
X1
7
18E
18A
15A
F07
X1
X1
Anlage
Fuse, hazard light
Function
Funktion
Einbauort
Sicherung Warnblinker
2
1
19E
19A
Mounting location
Higher-level function
8
+
=
==
Blatt
Page
6
F22:2 / 18.0
F19:2 / 18.0
F84:2 / 13.0
X1:10 / 19.0
F11:2 / 17.0
F07:2 / 17.0
F105:2 / 8.0
F146:2 / 13.0
F150:2 / 16.0
F68:2.1 / 24.0
9
von
from
47
EPE / 000 / 00
Circuit diagrams
526
4.9 / K11:30
30
K11
/4.6 87
Relay, potential 30 on 15
Relais Potential 30 auf 15
Circuit diagrams
X1 37E X1 25E X1 26E X1 27E X1 28E X1 29E X1 30E X1 31E X1 32E X1 33E
1 1 1 1 1 1 1 1 1 1
F124 F08 F18 F14 F23 F25 F39 F24 F03 F148
25A 2 15A 2 10A 2 15A 2 10A 2 10A 2 15A 2 10A 2 15A 2 10A 2
X1 37A X1 25A X1 26A X1 27A X1 28A X1 29A X1 30A X1 31A X1 32A X1 33A
Fuse, vibration
Fuse, indicators
Fuse, main cabin
Sicherung Blinker
Fuse, signal horns
Sicherung Vibration
Fuse, fuel-pre-heating
Hauptsicherung Kabine
Sicherung Signalhörner
Sicherung Kraftstoffvorheizung
Vorsicherung Arbeitsscheinwerfer
Only without seat contact
Nur ohne Sitzkontakt
Only at StvZO-illumination
Nur bei StvZO-Beleuchtung
F03:2 / 9.0
F24:2 / 11.0
F39:2 / 18.0
F25:2 / 8.0
F23:2.1 / 10.0
F18:2 / 17.0
F08:2 / 17.0
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 7 von 47
Erstellt 25.08.2010 Fuse protection potential 15 Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Absicherung Potential 15 Einbauort + EPE / 000 / 00
7.8 / F25:2
6.8 / F105:2
X12 1 3 X13 3 1
BN BU BU BN
30 30 B13 B14
+ - - +
K35 K114 Proximity switch, travel lever "0" position Proximity switch, travel lever forw. and "0" position
/8.2 87a 87 /8.1 87 87a Initiator Fahrhebel "0" Initiator Fahrhebel vorwärts u. "0"
Relay, holding contact Relay, engine rpm Opened in break position BK Closed in forward and "0" position BK
Relais Selbsthaltung Relais Motordrehzahl geöffnet in Bremsposition geschlossen in vorwärts und "0" position
30
X12 2 K48 X13 2
/8.4 87a 87
Relay, travel lever 0-position
X1 80
Fwd Relais Fahrhebel 0-Stellung
11 23 86 148 30 30
X1
S120 K35 K36 K26
Switch, engine speed 12 24 12V /4.5 87a 87 /8.7 87a 87
85
Schalter Motordrehzahl Relay, holding contact Relay, brake control Relay, backup-alarm
Relais Selbsthaltung Relais Bremskontrolle Relais
Rückfahrwarnsummer
K26:87a / 9.4
X1 113 X9 1
AW/HW
86 AUX + 2 86 86 1 86 +
K114 Y120 V47 K48 K05 Y04 K26 H14
2,41A
12V 70A/1A - 1 12V 12V 2 12V 300mA -
85 85 85 85
X9 2
87 87 87 87 87
87a 30 /8.2 87a 30 /8.1 87a 30 /8.5 87a 30 /4.7 87a 30 /8.9
Relay, engine rpm Solenoid valve, rpm engine high Relay, travel lever 0-position Solenoid valve, brake Relay, backup-alarm Back-up alarm Buzzer
Relais Motordrehzahl Magnetventil Motordrehzahl hoch Relais Fahrhebel 0-Stellung Magnetventil Bremse Relais Rückfahrwarnsummer Rückfahrwarnsummer
Relay, starting current
Relais Startstrom
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 8 von 47
Erstellt 25.08.2010 Engine speed, Brake, Back-up alarm Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Motordrehzahl, Bremse, Rückfahrwarneinrichtung Einbauort + EPE / 000 / 00
Circuit diagrams
527
528
7.8 / F03:2
4.4 / A68:14
7.8 / F14:2.1
A68
Module, seat contact 12 14 13
Circuit diagrams
Modul Sitzkontakt
Fahren
Driving
D+ Alternator
D+ Generator
Motoröldruck
Only without seat contact
Nur ohne Sitzkontakt
ohne Sitzkontakt
without seat contact
without seat contact
Only at BW 177 D/PD-4
ohne Sitzkontakt
Nur bei BW 177 D/PD-4
/8.6
/6.2
Relay, engine shut off
152 Relais Motorabschaltung 13 23
low
0
high
X1
S35
Switch, vibration low/high 14 24
Vibrationsschalter klein/groß
30 X1 158 157 X1 160 161
K22 GA TAC/ 21.7
/11.3 87a 87
KA TAC/ 21.7
87
87a 30 /9.2
Shut off solenoid, engine Relay, engine shut off Switch, seat contact Solenoid valve, vibration front low
Hubmagnet Motorabschaltung Relais Motorabschaltung Schalter Sitzkontakt Magnetventil Vibration vorne klein
Switch, vibration travel lever right Solenoid valve, vibration front high
Schalter Vibration Fahrhebel rechts Magnetventil Vibration vorne gross
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 9 von 47
Erstellt 25.08.2010 Seat contact, Vibration Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Sitzkontakt, Vibration Einbauort + EPE / 000 / 00
7.8 / F23:2.1
8.8 / F25:2
only D-40, BW 177 D/PD-4 Standard D-machines, D/PD-40 USA, 216+218 D/PD-40
nur D-40, BW 177 D/PD-4 Standard D-Maschinen, D/PD-40 USA, 216+218 D/PD-40 X1 155
13 1234 2 13 23
S42 S42 S03
Switch, speed range selector 14 Switch, speed range selector 1 5 7 3 Pushbutton, warning horn 14 24
Schalter Fahrstufen Schalter Fahrstufen Taster Signalhorn
V02 V03
2 1 1 2
1 1 1 1 2 + + 2
Y31 Y30 Y30 Y31 V21 B11 B11 V22
1,23A
1,23A 2 1,23A 2 2 1,23A 2 1 4,2A - 4,2A - 1
Solenoid valve, speed range selection axle Solenoid valve, speed range selection drum Solenoid valve, speed range selection axle Warning horn Warning horn
Magnetventil Fahrstufe Achse Magnetventil Fahrstufe Bandage Magnetventil Fahrstufe Achse Signalhorn Signalhorn
Solenoid valve, speed range selection drum
Magnetventil Fahrstufe Bandage
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 10 von 47
Erstellt 25.08.2010 Speed range selection, Warning horns Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Fahrstufen, Warnhörner Einbauort + EPE / 000 / 00
Circuit diagrams
529
530
7.8 / F24:2 F24:2 / 12.0 A15
Monitoring-module
Überwachungsmodul
X1 86 Armature carrier
Armaturenträger
X1:86 / 12.0 14 X5 Hazard light
Warnblinklicht HAZ / 17.7
14
+ Ub X5 26
+ Ub 12 X5 Indicator right X1
26
Circuit diagrams
Blinker rechts 96
IND-R / 17.8
12
X1 Glowing X5 3
5.5 / Glow 13
78 Glühen 3 X5 Indicator left X1
Blinker links 91
IND-L / 17.8
13
X1 Charge control X5 10
4.4 / D+ 5
69 Ladekontrolle 10 X5 Night dimout
Nachtabdunklung ILL / 17.0
5
X1 Brake X5 4
8.5 / K48:87a 22
87 Bremse 4 X5 Water trap
Shutoff 2 min. 22 Wasserabscheider
X1 Seat X5 9
9.5 / A68:6 21
88 Sitz 9 X5 Water trap
Shutoff 2 min. 21 Wasserabscheider
23 25 24 1 17 16 8 11 15
Shutoff 2 min. Shutoff 2 min. Shutoff 10 sec. Shutoff 10 sec.
X5 23 25 24 1 17 16 8 11 15
GND
GND
Luftfilter
Air cleaner
Fuel gauge
1
Tankanzeige
Coolant level
Motoröldruck
Out Motor-Stop
Hydraulikölfilter
Out Warnsummer
2
Kühlmittelfüllstand
B30:2 / 12.3
X1 105 106 67 74 61 73 68 107 108
X10 2 X21 1 X8 1 2
+ 86 1 3 (1) 3 (1) 1 2 1 3
Θ 1
H07 K22 R03 B21 P B03 P B30 B06 P B55 B124
70mA - 12V 65,4 Ω 4 (2) 4 (2) 2 4 2
85 2
X10 3 X21 2
31 31 31 31 31 31
87 not at D-40
87a 30 /9.1 nicht bei D-40
Warning buzzer, breakdown Sender, level gauge Vacuum switch, air cleaner Pressure switch, engine oil Water trap
Warnsummer Betriebsstörung Geber Tankanzeige Luftfilterwartungsschalter Druckschalter Motoröl Wasserabscheider
Relay, shut off solenoid engine Pressure diff. switch, hydr. oil filter Temperature switch, engine oil Floating switch, Coolant expansion tank
Relais Hubmagnet Abschaltung Motor Differenzdruckschalter Hydr.-Ölfilter Temperaturschalter Motoröl Schwimmerschalter Kühlmittelausgleichsbehälter
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 11 von 47
Erstellt 25.08.2010 Monitoring, Failure indicators Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Überwachung, Störmeldungen Einbauort + EPE / 000 / 00
11.1 / F24:2
11.1 / X1:86
X1 225 187
BN
X22 1
BN
G + +
- X22 BK
- -
Frequenzanzeige
Frequency meter
E03 EXX EXX EXX
/17.2 BK /17.1
X1 188 192
Aufnehmer Vibrationsfreq.vorne
Aufnehmer Achsgeschwindigkeit
Voltmeter
Voltmeter
RPM meter
X1 93
Drehzahlmesser
at BW177 and BW219 BU
Anzeige Kühlmitteltemperatur
IN 15/54 OUT+ OUT- IN 15/54 OUT+ OUT-
Temperaturanzeige Hydrauliköl
Temperature gauge, hydraulic oil
BU
X1 227
Electronic, speedometer
X1 223
GND 1 3 4 GND 1 3 4
2
Θ
R04
1
BW 177-179 D-4/40 ----
BW 177-179 DHC-4 / DH-40 ----
Sensor Hydrauliköltemperatur
Sensor, hydraulic oil temperature
BW 211-216 D-4/40 PIN 1 - GND
BW 213-214 DHC-4 / DH-40 PIN 1 - GND
BW 216 DHC-4 PIN 3 - 15/54
X1 82 224 228 190 174
BW 219 D-4 PIN 3 - 15/54
only at option
measurement-equipment,
Option Option frequency meter speedometer and tachograph Option speedometer
Option Option Frequenzanzeige Nur bei Option Messtechnik, Option Geschwindigkeitsanzeige
Geschwindigkeitsanzeige, Tachograph
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 12 von 47
Erstellt 25.08.2010 Indicators, Speedsensor Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Anzeigen, Geschwindigkeitsaufnehmer Einbauort + EPE / 000 / 00
Circuit diagrams
531
532
6.8 / F146:2
Ground housing Ground Electronic Ground Baby-Board 1 Ground Baby-Board 1 Ground Baby-Board 2 Ground Baby-Board 2
Masse Gehäuse Masse Elektronik Masse Baby-Board 1 Masse Baby-Board 1 Masse Baby-Board 2 Masse Baby-Board 2
Circuit diagrams
X44 55 65 66 67 68
X44 54 28 56 57 58 59 60
Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller
ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2
Ignition Power Supply (Electronic) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs)
Zündung Spannungsvers. (Elektronik) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge)
A83
Measurement controller
Messtechnik Steuerung
X2 49 52 63 66
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 13 von 47
Erstellt 25.08.2010 Supply Measurement controller Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Versorgung Messtechniksteuerung Einbauort + EPE / 000 / 00
7.8 / F148:2 F148:2 / 16.0
13.2 / A83:28
X2 53 57 X2 47 48 49
X42 1 2 3
X2 56 60 71 66 70
X4 C D E X46 B A E
X48 1 2 X49 1 2
X74 3 5 4
P16 P33
BK GNYE BK GNYE P11 15 GND GY(GR) RD(RT) WH(WS)
+ +
- -
Opus 21
Opus 21
B62 B62
15g 15g
Printer
Drucker
20g 20g
BN BU BN BU
Transducer acceleration
Transducer acceleration
Diagnose Variomatic
Beschleunigungsaufnehmer
Beschleunigungsaufnehmer
Diagnostics, variomatic
X48 4 3 X49 4 3
X46 D F
X4 A B X42 4 5
R01
X2 55 54 59 58 68 64 65 50 51
2 1
60 Ω
X44 31 X44 29 X44 7 X44 30 X44 1 X44 4 X44 5 X44 27 X44 26
Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller
ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2
Transducer Acceleration front 20g Transducer Acceleration front 15g Transducer Acceleration rear 20g Transducer Acceleration rear 15g AGND RxD TxD CAN 1 + CAN 1 -
Beschleunigungsaufn. vorne 20g Beschleunigungsaufn. vorne 15g Beschleunigungsaufn. hinten 20g Beschleunigungsaufn. hinten 15g Analogmasse RxD TxD CAN 1 + CAN 1 -
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 14 von 47
Erstellt 25.08.2010 Option Measurement equipment Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Option Messtechnik Einbauort + EPE / 000 / 00
Circuit diagrams
533
534
9.8 /KA MESX ILL MESX/ 17.2
Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller
ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2
D+ Alternator Brake Driving direction Driving speed Vibration high amplitude Vibration low amplitude Illumination
D+ Generator Bremse Fahrtrichtung Fahrgeschwindigkeit Vibration große Amplitude Vibration kleine Amplitude Beleuchtung
Evib-Meter
Evib-Meter
ESX2
Measurement controller
A83
DO(2,5A)/4
X44 3
X44 3
X1 85
P07
0-6V
Evib-Meter -
Evib-Meter
Only at BEM
Nur bei BEM
E07
/17.1
X1 82
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 15 von 47
Erstellt 25.08.2010 Option Measurement equipment Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Option Messtechnik Einbauort + EPE / 000 / 00
6.8 / F150:2 Power supply GPS
Spannungsversorgung GPS
ESX2
14.9 / F148:2
Measurement controller
A83
DO(2,5A)/3
CAN 3 + CAN 3 -
CAN 3 + CAN 3 - X44 25
ESX2 ESX2
X44 25
Measurement controller Measurement controller
X2 79
A83 A83
+Wire2 -Wire2
X2 43 X2 44
X44 53 X44 33
X44 53 X44 33 X4 G X4 H X4 J
R25
2 1
X2 61 60 Ω 62 X73 A X73 B
X4 N M
X72 A X72 B
X75 7 2
A93
A87 GPS Receiver StarFire
USB-CAN Interface BCM GPS Empfänger StarFire
USB-CAN Schnittstelle BCM X71
12
X78
X71 1
6
X78
X71 2
5
USB
X78
USB X71 3
8
X78
4
X71 3 10 7
USB
P15
BCM05 USB X76
Vcc
BCM05 1
X72 D E C
X70
RxD
2
X70
TxD
3
X73 C
X70
AGND
5
X4 F
31
Ground Central Electric
Masse Zentralelektrik
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 16 von 47
Erstellt 25.08.2010 BOMAG Compaction Management BCM, GPS Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
BOMAG Verdichtungsmanagement BCM, GPS Einbauort + EPE / 000 / 00
Circuit diagrams
535
536
6.8 / F07:2
7.8 / F08:2
6.8 / F11:2
7.8 / F18:2
6.4 / X1:2 X1
X1 301 83
13 23 L 0R 13 23
S14 S37
012 31 11 23 Switch, hazard light 14 24 Switch, indicator 14 24
S15 Connection working head lights Warnblinkschalter Schalter Blinker
without StvZO
Switch, lighting StVZO 32 12 24 Anschluß Arbeitsscheinwerfer
Schalter Beleuchtung StVZO ohne StvZO 30 11.9 / HAZ 306 307
X1
K16
X1 302 303 /17.6 87a 87
Relay, head lights front X1 Wb LE RE 30
Relais Scheinwerfer vorne
H06
X2 A02
Flasher
11.9 / ILL
Blinkgeber
31 LA RA
Connection illumination /
15.9 ILL MESX STVZO
instruments without StvZO
Anschluß Beleuchtung
Instrumente ohne StvZO
Beleuchtung Evibmeter
Illumination, evib meter
Illumination, speedometer
15.9 /ILL MESX
Beleuchtung Drehzahlmesser
Beleuchtung Zusatzinstrument
Connection Illumination
MESX without StvZO
Beleuchtung Geschwindigkeitsanzeige
MESX ohne StvZO
86 1 1 1 1 86 1 1 1 1 1 1
K06 E13 E12 E14 E15 K16 E16 E17 E08 E09 E10 E11
12V 85 5W 2 5W 2 5W 2 5W 2 12V 85 55W 2 55W 2 21W 2 21W 2 21W 2 21W 2
87 87
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 17 von 47
Erstellt 25.08.2010 Option StvZO illumination Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Option StvZO Beleuchtung Einbauort + EPE / 000 / 00
7.8 / F39:2 F39:2 / 22.0
6.8 / F19:2
6.8 / F22:2
X3 4 5 3
Accession at Cabin
Anschluß bei Kabine
K32:86 / 19.0
Wl rear-Cab / 20.0
Wl front-Cab/ 20.0
Accession at Rops
Anschluß bei Rops
X3 1
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 18 von 47
Erstellt 25.08.2010 Rops - Lighting, Socket Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Rops - Beleuchtung, Steckdose Einbauort + EPE / 000 / 00
Circuit diagrams
537
538
6.8 / X1:10
18.3 / K32:86
RD RD RD
4mm² 4mm² 4mm²
X3 6 7 8
Circuit diagrams
RD RD RD
4mm² 4mm² 4mm²
RD
6mm²
30
K32
/19.2 87
Relay, cabin
WH
Relais Kabine 6mm²
WH
6mm²
F44:B / 22.0
A C E G
Option
86
K32
BN BN 12V 85
6mm² 1,5mm² B D F H
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 19 von 47
Erstellt 25.08.2010 Cabin - Supply, Fuse protection Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Kabine - Versorgung, Absicherung Einbauort + EPE / 000 / 00
19.8 / F42:8 F42:8 / 21.0
19.6 / F144:6
19.6 / F41:5-1
18.3 / Wl rear-Cab
5 1 1 1 1
S38 E29 E70 E72
Switch, Rotary beacon 1 21W 2 5W 2 24V 2 1 2
Schalter Rundumkennleuchte Inside light, cabin Night lamp
Innenleuchte Kabine Nachtleuchte
2
illum. Switches
Beleuchtung Bedienschalter
+ 3
S45 S158
TK - 4
Option
Rotary beacon Cabin socket Switch, cabin inside light Switch, cabin night lamp
Rundumkennleuchte Kabinensteckdose Schalter Kabineninnenleuchte Schalter Nachtbeleuchtung
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 20 von 47
Erstellt 25.08.2010 Cabin - Lighting, Socket Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Kabine - Beleuchtung, Steckdose Einbauort + EPE / 000 / 00
Circuit diagrams
539
540
20.9 / F42:8
20.9 / F130:3
19.8 / F143:7
17
Circuit diagrams
19.4 / F44:2 X3
19.4 / F43:1
Electronic system A1
tachograph
Elektronik
P09
Tachograph A2+A3
A16 B3
1
7 2 7 2
5 6
01 01 B4
S163 2
1 B51 30 15 B51 4
Switch, rear
S21 5 4 S20 5 4 C3
screen heating + + 3 A = white
unit
- - B = yellow
Schalter A5+A6
31 8 C = red
5
7
/21.4
30
K141 Only at option Radio
Nur bei Option Radio
87 87a
A51
Circuit board,frequenzy meter 4 1
Platine Frequenzanzeige
87a 30 /21.3
Windscreen wiper motor, rear Windscreen wiper motor, front Heater rear screen Relay, heating rear screen
Scheibenwischermotor hinten Scheibenwischermotor vorne Heckscheibenheizung Relais Heckscheibenheizung
Windscreen washer motor, rear Windscreen washer motor, front
Scheibenwaschermotor hinten Scheibenwaschermotor vorne
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 21 von 47
Erstellt 25.08.2010 Cabin - Cabin equipment, Radio, Tachograph Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Kabine - Kabinenausrüstung, Radio, Tachograph Einbauort + EPE / 000 / 00
19.5 / F44:B
X3 9 10
163 1 A B
X1
F97 F40 F15
3A 2 20A 1 5A 2
A108 Inline-Fuse Fuse, heating unit cab Fuse, heating unit
X17 1
Heating climatic unit Inlinesicherung Sicherung Kabinenheizung Sicherung Heizgerät
Heiz-Klima-Einheit Fuse, blower fresh air BOX2 BOX2
Supply
Sicherung Frischluftlüfter BOX2 BOX2
RD
11 2 3 1 12 13 14 16
Switch, cabin heating
5 7 11 3 10 1 Schalter Kabinenheizung
BK/GN BK S28
Out Gnd
E30
X17 4 2 Heating unit
Heizgerät
max. 8,3A
X1 166 219
2
X79 1
30 2 6 8 9 4 12
1 5 9 15 10 6 8 7 4
K09
/4.5 87 87a
Relay, air conditioner
Relais Klimaanlage
3
S29
X1 167 Switch, suspension seat 4
Schalter Luftfedersitz
X20 1 3
sw br
B104 P
LP HP MP
sw/ge br/sw
1
X20 2 4 X69 1 X77 1
Druckschalter Klimaanlage
M10
M
12V / < 9A rt
Option Air conditioner Option suspension seat Option activated charcoal filter Option Additional heater
Option Klimaanlage Option Luftfedersitz Option Aktivkohlefilter Option Zusatzheizung
Magnetic clutch, air conditioning compressor Compressor, suspension operators seat Additional blower Fuel pump, heating unit
Magnetkupplung Klimakompressor Kompressor Luftfedersitz Zusatzlüfter Kraftstoffpumpe Heizgerät
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 22 von 47
Erstellt 25.08.2010 Cabin - Heating, Air conditioning, Additional Heater Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Kabine - Heizung, Klimaanlage, Zusatzheizung Einbauort + EPE / 000 / 00
Circuit diagrams
541
542
A67
Keyboard
Tastatur
Circuit diagrams
A66
Electronic control unit
Elektronik Steuereinheit
X68
1-9
A138
Antenna, bomag telematics
Antenne Bomag Telematik
GPS GSM
CAN_L
CAN_H
Pot. 30
Pot. 15
IN0
IN1
GND
GSM
GPS
4 3 12 2 8 11 1
6.8 / F68:2.1
4.4 /D+ TM
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 24 von 47
Erstellt 25.08.2010 Bomag telematics Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Bomag Telematik Einbauort + EPE / 000 / 00
Circuit diagrams
543
544
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
Circuit diagrams
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 25 von 47
Erstellt 25.08.2010 Device tag list Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Betriebsmittelliste Einbauort + EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 26 von 47
Erstellt 25.08.2010 Device tag list Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Betriebsmittelliste Einbauort + EPE / 000 / 00
Circuit diagrams
545
546
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
Circuit diagrams
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 27 von 47
Erstellt 25.08.2010 Device tag list Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Betriebsmittelliste Einbauort + EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 28 von 47
Erstellt 25.08.2010 Device tag list Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Betriebsmittelliste Einbauort + EPE / 000 / 00
Circuit diagrams
547
548
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
Circuit diagrams
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 29 von 47
Erstellt 25.08.2010 Device tag list Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Betriebsmittelliste Einbauort + EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
Y31 10 6 Solenoid valve, speed range selection axle Magnetventil Fahrstufe Achse 1,23A
Y120 8 2 Solenoid valve, rpm engine high Magnetventil Motordrehzahl hoch 70A/1A
Y139 4 8 Solenoid valve, boost fuel Magnetventil Minusangleichung
549
550
Terminal strip overview
Klemmleistenübersicht
Terminal strip central electric
X1 Klemmleiste Zentralelektrik
Mounting location Electrobox
Circuit diagrams
Einbauort Elektrokasten
Device tag Page Path Device tag Page Path Device tag Page Path Device tag Page Path Device tag Page Path Device tag Page Path
BMK Blatt Pfad BMK Blatt Pfad BMK Blatt Pfad BMK Blatt Pfad BMK Blatt Pfad BMK Blatt Pfad
X1:1 4 4 X1:30A 7 5 X1:68 11 7 X1:103 10 7 X1:146 6 2 X1:191 12 6
X1:2 6 1 X1:30E 7 5 X1:69 11 1 X1:104 8 7 X1:147 8 6 X1:192 12 6
X1:3 4 6 X1:31A 7 5 X1:70 12 0 X1:104 10 9 X1:148 8 4 X1:217 5 8
X1:4 4 5 X1:31E 7 5 X1:71 11 5 X1:105 11 3 X1:149 8 8 X1:218 5 8
X1:7 4 7 X1:32A 7 6 X1:72 11 7 X1:106 11 4 X1:149 9 3 X1:219 22 3
X1:8 4 7 X1:32E 7 6 X1:73 11 7 X1:107 11 9 X1:149 9 5 X1:220 22 3
X1:9 6 4 X1:33A 7 7 X1:74 11 6 X1:108 11 9 X1:149 9 9 X1:223 12 2
X1:10 6 4 X1:33E 7 7 X1:75 5 4 X1:109 11 3 X1:150 8 6 X1:224 12 2
X1:15A 6 5 X1:34A 6 2 X1:76 11 7 X1:110 11 4 X1:151 9 1 X1:225 12 2
X1:15E 6 5 X1:34E 6 2 X1:77 11 6 X1:111 11 9 X1:152 9 1 X1:226 12 3
X1:16A 6 5 X1:35A 6 2 X1:78 11 1 X1:112 11 9 X1:153 8 7 X1:227 12 2
X1:16E 6 5 X1:35E 6 2 X1:79 4 6 X1:113 8 6 X1:154 9 4 X1:228 12 2
X1:17A 6 6 X1:37A 7 1 X1:80 8 1 X1:114 8 9 X1:155 10 8 X1:301 17 4
X1:17E 6 6 X1:37E 7 1 X1:81 8 1 X1:115 9 7 X1:156 8 4 X1:302 17 4
X1:18A 6 7 X1:52 5 0 X1:82 11 2 X1:116 9 8 X1:157 9 5 X1:303 17 4
X1:18E 6 7 X1:53 4 7 X1:82 12 1 X1:117 8 5 X1:158 9 4 X1:304 17 7
X1:19A 6 8 X1:54 9 1 X1:82 15 3 X1:117 8 6 X1:159 9 7 X1:305 17 9
X1:19E 6 8 X1:55 4 6 X1:82 17 0 X1:117 8 9 X1:160 9 7 X1:306 17 8
X1:21A 6 0 X1:55 4 7 X1:83 17 4 X1:117 11 3 X1:161 9 8 X1:307 17 9
X1:21E 6 0 X1:55 9 1 X1:84 17 3 X1:117 11 3 X1:162 10 5 X1:308 17 7
X1:22A 6 1 X1:56 8 3 X1:85 15 3 X1:117 11 4 X1:163 22 1 X1:309 17 6
X1:22E 6 1 X1:56 11 7 X1:86 11 0 X1:117 17 3 X1:164 22 2 X1:310 17 7
X1:23A 17 4 X1:57 5 2 X1:87 11 1 X1:118 8 1 X1:166 22 1 X1:311 17 4
X1:23E 17 4 X1:57 5 5 X1:88 11 1 X1:118 8 4 X1:167 22 1 X1:312 17 5
X1:24A 17 5 X1:57 11 5 X1:89 11 0 X1:118 9 7 X1:168 4 5 X1:313 17 8
X1:24E 17 5 X1:58 8 2 X1:90 11 3 X1:124 10 1 X1:168 22 1 X1:314 17 9
X1:25A 7 1 X1:59 8 2 X1:91 11 9 X1:124 10 5 X1:171 12 7 X1:315 17 4
X1:25E 7 1 X1:60 8 2 X1:92 12 9 X1:137 10 3 X1:172 12 7 X1:315 17 6
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 32 von 47
Erstellt 25.08.2010 Terminal strip overview X2 Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Klemmleistenübersicht X2 Einbauort + EPE / 000 / 00
Circuit diagrams
551
552
Plug overview
Steckerübersicht
Designation Mounting location Function text Designation Mounting location Function text
Bezeichnung Einbauort Funktionstext Bezeichnung Einbauort Funktionstext
Electrobox Plug, supply cabin, rops, sun-roof Armature carrier Plug, monitoring module
X3 Stecker Versorgung Kabine, Rops, Sonnendach X5 Stecker Überwachungsmodul
Circuit diagrams
Elektrokasten Armaturenträger
Contact Page Path Type Contact Page Path Type
Kontakt Blatt Pfad Typ HDP-26-24-18 Kontakt Blatt Pfad Typ AMP Superseal 26 pole
1 18 2 15 11 7
1 19 0 16 11 5
2 19 1 17 11 4
3 18 3 21 11 8
4 18 1 22 11 8
5 18 2 23 11 2
6 19 4 24 11 3
7 19 4 25 11 2
8 19 4 26 11 1
9 22 1 Rear frame Plug, Solenoid valve vibration front high
10 22 1
X6 Hinterrahmen Specker Magnetventil Vibraiton vorne groß
Contact Page Path Type
15 21 7 Kontakt Blatt Pfad Typ AMP JPT / DT 2 pole
16 21 7 1 9 8
17 21 7 2 9 8
Electrobox Plug, connection measurement equipment cabin Rear frame Plug, Solenoid valve vibration front low
X4 Elektrokasten Stecker Messtechnik Kabine X7 Hinterrahmen Specker Magnetventil Vibraiton vorne klein
Contact Page Path Type Contact Page Path Type
Kontakt Blatt Pfad Typ HDP-24-18-14 Kontakt Blatt Pfad Typ AMP JPT / DT 2 pole
A 14 5 1 9 7
B 14 6 2 9 7
C 14 5 Rear frame Plug, WaterInFuel Sensor
D 14 6 X8 Hinterrahmen Stecker Sensor "Wasser im Kraftstoff"
Contact Page Path Type
E 14 6 Kontakt Blatt Pfad Typ DT 2 pole
F 16 7 1 11 9
G 16 4 2 11 9
H 16 8 Rear frame Plug, backup alarm buzzer
J 16 8 X9 Hinterrahmen Stecker Rückfahrwarnsummer
M 16 2 Contact Page Path Type
Kontakt Blatt Pfad Typ DT 2 pole
N 16 2
Armature carrier Plug, monitoring module 1 8 9
X5 Armaturenträger Stecker Überwachungsmodul 2 8 9
Contact Page Path Type Rear frame Plug, sender level gauge
Kontakt Blatt Pfad Typ AMP Superseal 26 pole X10 Hinterrahmen Stecker Tauchrohrgeber
1 11 3 Contact Page Path Type
Kontakt Blatt Pfad Typ AMP Superseal 3 pole
3 11 1
4 11 1 2 11 3
3 11 3
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 33 von 47
Erstellt 25.08.2010 Plug overview Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Steckerübersicht Einbauort + EPE / 000 / 00
Plug overview
Steckerübersicht
Designation Mounting location Function text Designation Mounting location Function text
Bezeichnung Einbauort Funktionstext Bezeichnung Einbauort Funktionstext
Console right, seat Plug, proximity switch travel lever "0" position Electrobox Plug, supply central electric
X12 Konsole Sitz rechts Stecker Initiator Fahrhebel "0" X36 Elektrokasten Stecker Versorgung Zentralelektrik
Contact Page Path Type Contact Page Path Type
Kontakt Blatt Pfad Typ DTM 3 pole Kontakt Blatt Pfad Typ MTA 2 pole
1 8 4 A 4 3
2 8 4 B 4 3
3 8 4 Electrobox Plug, supply ignition switch
Console right, seat Plug, proximity switch travel lever forward and "0" position
X37 Elektrokasten Stecker Versorgung Startschalter
X13 Konsole Sitz rechts Stecker Initiator Fahrhebel vorwärts u. "0" Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ MTA 2 pole
Kontakt Blatt Pfad Typ DTM 3 pole A 4 6
1 8 7 B 4 7
2 8 7 Electrobox Plug, supply starter
3 8 7
X38 Elektrokasten Stecker Versorgung Starter
Contact Page Path Type
Seat Plug, switch seat-contact
X14 Kontakt Blatt Pfad Typ MTA 2 pole
Sitz Stecker Sitzkontaktschalter
Contact Page Path Type A 4 9
Kontakt Blatt Pfad Typ DT 3 pole Console right, seat Plug, connection adapter BOP
A 9 4
X42 Konsole Sitz rechts Stecker Anschluß Adapter BOP
Contact Page Path Type
B 9 4 Kontakt Blatt Pfad Typ DTM 6 pole
Cabin Plug, heating climatic unit
X17 Kabine Stecker Heiz-Klima-Einheit
1 14 8
Contact Page Path Type 2 14 9
Kontakt Blatt Pfad Typ DTP 4 pole 3 14 9
1 22 1 4 14 8
2 22 2 5 14 9
4 22 1 Electrobox Plug, measurement controller
Rear frame Plug, pressure switch air conditioning
X44 Elektrokasten Stecker Messtechniksteuerung
X20 Hinterrahmen Stecker Druckschalter Klimaanlage Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ AMP 64 pole
Kontakt Blatt Pfad Typ DT 4 pole 1 14 4
1 22 1 3 15 3
2 22 1 4 14 5
3 22 1 5 14 6
4 22 1 7 14 2
Rear frame Plug, Floating switch Coolant expansion tank 14 15 4
X21 Hinterrahmen Stecker Schwimmerschalter Kühlmittelausgleichsbehälter
15 15 6
Contact Page Path Type
Kontakt Blatt Pfad Typ DTM 2 pole 25 16 8
1 11 7 26 14 8
2 11 7 27 14 7
Front frame Plug, transducer vibration frequency front 28 13 1
X22 Vorderrahmen Stecker Aufnehmer Vibrationsfrequenz vorne 29 14 1
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 34 von 47
Erstellt 25.08.2010 Plug overview Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Steckerübersicht Einbauort + EPE / 000 / 00
Circuit diagrams
553
554
Plug overview
Steckerübersicht
Designation Mounting location Function text Designation Mounting location Function text
Bezeichnung Einbauort Funktionstext Bezeichnung Einbauort Funktionstext
Electrobox Plug, measurement controller Cabin Plug, windscreen wiper motor front
X44 Stecker Messtechniksteuerung X56 Stecker Scheibenwischermotor vorne
Circuit diagrams
Elektrokasten Kabine
Contact Page Path Type Contact Page Path Type
Kontakt Blatt Pfad Typ AMP 64 pole Kontakt Blatt Pfad Typ P4NAT
53 16 2 1 21 2
54 13 0 2 21 2
55 13 5 3 21 3
56 13 2 4 21 2
57 13 3 Cabin/Rops Plug, headlight front left
58 13 4
X58 Kabine/Rops Stecker Scheinwerfer vorne links
Contact Page Path Type
59 13 5 Kontakt Blatt Pfad Typ DT 6 pole
60 13 6 2 17 8
65 13 6 3 17 4
66 13 7 5 17 6
67 13 8 6 17 4
68 13 9 Cabin/Rops Plug, headlight front right
Console right, seat Plug, bomag operation panel (BOP) X59 Kabine/Rops Stecker Scheinwerfer vorne rechts
X46 Konsole Sitz rechts Stecker Bomag Operation Panel (BOP) Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ DT 6 pole
Kontakt Blatt Pfad Typ Burndy 12 pole 2 17 9
A 14 9 3 17 5
B 14 8 5 17 7
D 14 8 6 17 5
E 14 9 Rear frame Plug, tail light rear left
F 14 9 X60 Hinterrahmen Stecker Rückleuchte links
Front frame Plug, transducer acceleration front Contact Page Path Type
X48 Vorderrahmen Stecker Beschleunigungsaufnehmer vorne Kontakt Blatt Pfad Typ DT 4 pole
Contact Page Path Type 1 17 8
Kontakt Blatt Pfad Typ DT 4 pole 2 17 8
1 14 0 3 17 4
2 14 1 4 17 4
3 14 1 Rear frame Plug, tail light rear right
4 14 0 X61 Hinterrahmen Stecker Rückleuchte rechts
Front frame Plug, transducer acceleration rear Contact Page Path Type
X49 Vorderrahmen Stecker Beschleunigungsaufnehmer hinten Kontakt Blatt Pfad Typ DT 4 pole
Contact Page Path Type 1 17 9
Kontakt Blatt Pfad Typ DT 4 pole 2 17 9
1 14 2 3 17 5
2 14 3 4 17 5
3 14 3 Electrobox Plug, electronical burglary protection
4 14 2 X65 Elektrokasten Stecker Elektronische Diebstahlsicherung
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 35 von 47
Erstellt 25.08.2010 Plug overview Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Steckerübersicht Einbauort + EPE / 000 / 00
Plug overview
Steckerübersicht
Designation Mounting location Function text Designation Mounting location Function text
Bezeichnung Einbauort Funktionstext Bezeichnung Einbauort Funktionstext
Electrobox Plug, electronical burglary protection Cabin Plug, access GPS-Receiver
X65 Elektrokasten Stecker Elektronische Diebstahlsicherung X72 Kabine Stecker Anschluß GPS-Antenne
Contact Page Path Type Contact Page Path Type
Kontakt Blatt Pfad Typ DT 12 pole Kontakt Blatt Pfad Typ Burndy 12 pole
9 23 2 E 16 6
10 23 2 Cabin Plug, supply GPS System
11 23 2
X73 Kabine Stecker Spannungsversorgung GPS System
Contact Page Path Type
12 23 2 Kontakt Blatt Pfad Typ DT 3 pole
Rear frame Plug, fuel pre heater
X67 Hinterrahmen Stecker Kraftstoffvorheizung
A 16 8
Contact Page Path Type B 16 8
Kontakt Blatt Pfad Typ DTP 2 pole C 16 7
1 5 8 Cabin Plug, printer
2 5 8
X74 Kabine Stecker Drucker
Contact Page Path Type
Plug, keyboard electronical burglary protection
X68 Kontakt Blatt Pfad Typ AMP Mate´n´loc 6pole
Stecker Tastatur Elektronische Diebstahlsicherung
Contact Page Path Type 1 14 5
Kontakt Blatt Pfad Typ SUBD 9 pole 2 14 6
1-9 23 6 3 14 5
Cabin Plug, additional blower 4 14 6
X69 Kabine Stecker Zusatzlüfter
5 14 6
Contact Page Path Type
Cabin Plug, CAN BCM Dongle
Kontakt Blatt Pfad Typ DTM 2 pole X75 Kabine Stecker CAN BCM Dongle
1 22 4 Contact Page Path Type
2 22 4 Kontakt Blatt Pfad Typ SUBD 9 pole
Cabin Plug, Access GPS - BCM 2 16 2
X70 Kabine Stecker Anschluß GPS - BCM
7 16 2
Contact Page Path Type
Cabin Plug, supply BCM
Kontakt Blatt Pfad Typ SUBD 9 pole X76 Kabine Stecker Versorgung BCM
2 16 4 Contact Page Path Type
3 16 4 Kontakt Blatt Pfad Typ DT 2 pole
5 16 4 1 16 4
GPS Receiver StarFire Plug, GPS-Receiver StarFire 2 16 4
X71 GPS Empfänger StarFire Stecker GPS-Antenne StarFire Rear frame Plug, fuel pump additional heater
Contact Page Path Type X77 Hinterrahmen Stecker Kraftstoffpumpe Zusatzheizung
Kontakt Blatt Pfad Typ DT 12 pole Contact Page Path Type
3 16 6 Kontakt Blatt Pfad Typ DTM 2 pole
5 16 7 1 22 5
6 16 7 2 22 5
7 16 7 GPS Receiver StarFire Plug, additional options GPS-Receiver
8 16 7
X78 GPS Empfänger StarFire Stecker Zusatzoptionen GPS-Antenne
Contact Page Path Type
10 16 6 Kontakt Blatt Pfad Typ DT 4 pole
12 16 7
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 36 von 47
Erstellt 25.08.2010 Plug overview Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Steckerübersicht Einbauort + EPE / 000 / 00
Circuit diagrams
555
556
Plug overview
Steckerübersicht
Designation Mounting location Function text Designation Mounting location Function text
Bezeichnung Einbauort Funktionstext Bezeichnung Einbauort Funktionstext
Cabin/Rops Plug, suspension seat
X79 Stecker Luftfedersitz
Circuit diagrams
Kabine/Rops
Contact Page Path Type
Kontakt Blatt Pfad Typ P2NAT
2 22 3
557
558
Pin overview
Pin Übersicht
Measurement controller
A83 Messtechnik Steuerung
Pin Page Path Description
Circuit diagrams
Signal Signal
Kontakt Blatt Pfad Beschreibung
: box 13 4 Ground Housing Ground housing Masse Gehäuse
X44 : 1 14 4 AGND AGND Analogmasse
X44 : 3 15 3 DO(2,5A)/4 Evib-Meter Evib-Meter
X44 : 4 14 5 RxD RxD RxD
X44 : 5 14 6 TxD TxD TxD
X44 : 7 14 2 AI/3 Transducer Acceleration rear 20g Beschleunigungsaufn. hinten 20g
X44 : 14 15 4 DI(D)/6 Driving direction Fahrtrichtung
X44 : 15 15 6 DI(D)/8 Vibration low amplitude Vibration kleine Amplitude
X44 : 25 16 8 DO(2,5A)/3 Power supply GPS Spannungsversorgung GPS
X44 : 26 14 8 -Wire1 CAN 1 - CAN 1 -
X44 : 27 14 7 +Wire1 CAN 1 + CAN 1 +
X44 : 28 13 1 D+ Power Supply (Electronic) Spannungsvers. (Elektronik)
X44 : 29 14 1 AI/2 Transducer Acceleration front 15g Beschleunigungsaufn. vorne 15g
X44 : 30 14 3 AI/4 Transducer Acceleration rear 15g Beschleunigungsaufn. hinten 15g
X44 : 31 14 0 AI/6 Transducer Acceleration front 20g Beschleunigungsaufn. vorne 20g
X44 : 33 16 2 -Wire2 CAN 3 - CAN 3 -
X44 : 35 15 5 DI(D)/3 Driving speed Fahrgeschwindigkeit
X44 : 36 15 3 DI(D)/5 Brake Bremse
X44 : 37 15 2 DI(D)/7 D+ Alternator D+ Generator
X44 : 38 15 6 DI(D)/9 Vibration high amplitude Vibration große Amplitude
X44 : 41 15 7 DI(D)/15 Illumination Beleuchtung
X44 : 53 16 2 +Wire2 CAN 3 + CAN 3 +
X44 : 54 13 0 UE Ignition Zündung
X44 : 55 13 5 GND Ground Electronic Masse Elektronik
X44 : 56 13 2 UB Power Supply (Outputs) Spannungsvers. (Ausgänge)
X44 : 57 13 3 UB Power Supply (Outputs) Spannungsvers. (Ausgänge)
X44 : 58 13 4 UB Power Supply (Outputs) Spannungsvers. (Ausgänge)
X44 : 59 13 5 UB Power Supply (Outputs) Spannungsvers. (Ausgänge)
X44 : 60 13 6 UB Power Supply (Outputs) Spannungsvers. (Ausgänge)
X44 : 65 13 6 XGND1 Ground Baby-Board 1 Masse Baby-Board 1
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 39 von 47
Erstellt 25.08.2010 Pin overview A83 Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Pin Übersicht A83 Einbauort + EPE / 000 / 00
BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 40 von 47
Erstellt 25.08.2010 Overview Central Electric Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Übersicht Zentralelektrik Einbauort + EPE / 000 / 00
Circuit diagrams
559
560
Circuit diagrams
561
562
Circuit diagrams
563
564
Circuit diagrams
565
566
Circuit diagrams
BOMAG Maschinenhandelsgesellschaft m.b.H. BOMAG MARINI EQUIPAMENTOS LTDA BOMAG (CANADA), INC.
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