Bomag BW 80AD-2 BW 90 AD AC-2 - Serwisówka [PDF]

Zitiervorschau

Service Training

BW 80 AD-2/BW 90 AD/AC-2 BW 100 ADM-2

P/N 008 099 27

March 2001

Service Training Table of Contents Foreword List of additional documentation General Maintenance

A1 A2 A3 A4

List of components

B1

Kubota diesel engine Cylinder block Cylinder head Combustion system Crankshaft Piston and pistons ring Conrod Camshaft and fuel camshaft Flywheel Rocker arms Valve control Trouble shooting Inspections and adjustments Checking the valve clearance Engine solenoid

C1 C2 C3 C4 C4 C5 C6 C6 C7 C7 C8 C9 C 12 C 13 C 15

Travel system Travel pump Control Charge pressure relief valve High pressure relief valves Drum drive motor Brake control Flushing the travel system Trouble shooting travel system Poor travel power Machine moves with travel lever in neutral

D1 D4 D4 D5 D5 D6 D7 D8 D9 D 18 D 21

Vibration Vibration pump Vibration control Vibration motor Trouble shooting vibration

E1 E2 E3 E5 E6

Steering Steering valve Trouble shooting steering system

F1 F2 F4

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 A1

Service Training Wiring diagrams Table of contents Function groups Line thicknesses Reference lines, frames Potential cross reference Releay cross-references List of components Electric system

G1 G1 G2 G3 G3 G4 G5 G5 G6

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 A2

Service Training Foreword In early 1998 tandem vibratory rollers of series BW 80 AD-2, BW90 AD/AC-2 and BW100 ADM-2 were initially launched in the market. These machines are further developments of the old machine generation BW 80/90 AD, which were already very successful in the construction equipment market. Despite this success BOMAG made the decision to develop this product range further to bring it up to the latest technical standard. The designation of the new machine types BW 80/90 AD/AC-2 is intended as a clear differentiation from the old product range. For the Service Department of BOMAG the revision of these machines was reason enough to modify the training documents accordingly and to adapt them to the latest requirements. The contents of this training should help the service engineer to apply the correct measures for adjustments and trouble shooting and to perform repair work in a professional manner. The customer should recognize that the service engineer is fully acquainted with the machine. He should see that the engineer applies the correct measures to find a possible fault on the machine and that he applies the appropriate measures in an expert way. After this training course the participant should have the necessary confidence when working on and with the machine.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 A1

Service Training List of additional documentation Operating and maintenance instructions Machine

Part-no.:

S/N

BW 80 AD-2

008 104 30

101 460 42 0101

BW 90 AD/AC-2

008 104 30

101 460 72 0101

BW 100 ADM-2

008 104 30

101 460 62 0101

Machine

Part-no.:

S/N

BW 80 AD-2

008 102 80

101 460 42 0101

BW 90 AD-2

008 102 81

101 460 72 0101

BW 100 ADM-2

008 102 82

101 460 62 0101

Spare parts catalogue

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 A2

Service Training General The machines of series BW 80 AD/ BW 90 AD-2 are tandem vibratory rollers and combination rollers for compaction work in road construction. The machines are most suitable for both the compaction of bituminous materials as well as for light compaction work in earth construction. Compaction is achieved by the vibration of both drums, or by the compaction of the drum and the static load of the rubber tires. The output power of the water cooled Kubota diesel engine is transferred to the drums or wheel set )travel and vibration system) and to the steering via hydrostatic drive systems. This kind of power transmission ensures lowest possible efficiency losses. Both drums on the BW 80/90 AD-2 are fitted with travel motors and with vibration motors. The motors for the respective drive system are arranged on one side of the machine. As it is quite beneficial for some applications (e.g. laying of asphalt) to be able to vibrate with only one drum and use the other one statically, the machine is fitted with a vibration shut-off valve for the rear drum. On the combination rollers BW 90 AC-2 the wheel set is driven by one travel motor. This roller unites the the high compaction power of the vibrating drum with the outstanding surface sealing effect of the rubber wheels in one machine. This obviously is under certain conditions far more economical than using a vibratory roller and an additional rubber tire roller. The standard equipment of the machine includes a gravity-feed water sprinkler system. A pressure sprinkler system is available as an option. Together with the scrapers the water sprinkler system keeps the drum surfaces clear of any material. On AC-machines a pressure sprinkler system keeps the rubber tires free of dirt and bitumen. In this case the rubber tires are sprinkled with an emulsion. Front and rear frames of the machine are connected by an oscillating articulated joint. The amply dimensioned oscillation angle ensures that the drums always have ground contact over their entire width. Both travel motors are equipped with integrated multi-disc brakes, which have the function of parking brakes. When the brake solenoid valve is switched to the appropriate position the increasing charge pressure will release the brakes when starting the engine. When shutting the engine down the brakes will close.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 A3

Service Training Maintenance Tandem and combination rollers of product range BW 80 AD-2, BW 90 AD/AC-2 and BW 100 ADM-2 are heavy duty machines, which were specially designed for the tough applications in asphalt and earth construction. To be able to meet these demands, the machine must always be ready to be loaded up to their limits. Apart from this all safety installations must always be fully functional under the partly very dangerous conditions on a construction side. Thorough maintenance of the machine is therefore mandatory. It not only guarantees a considerably higher functional safety, but also prolongs the lifetime of the machine and of important components. The time necessary for thorough maintenance can under no circumstances be compared with the faults and damage which may be caused by neglecting these maintenance instructions. The maintenance intervals are given in operating hours. It is quite obvious that with each service interval the work for shorter preceeding intervals must also be carried out. With the 2000 hour intervals you must therefore also perform the work for the maintenance intervals at 500 and 1000 operating hours. It should also be clear, that the 2500 hour service interval does includes only the work for the 10 and 500 hour intervals. For maintenance work you must only use the fuels and lubricants (oils, fuel, grease etc.) specified in the table of fuels and lubricants.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 A4

Service Training List of Components BW 80 AD-2/BW 90 AD/AC-2/ BW 100 ADM-2 Engine Manufacturer

Kubota

Type

D 722

Cooling

Water

Working cycles

4

Number of cylinders

3

Power DIN 6271 IFN/SAE at 3000 min-1

kW

11,9

Displacement

cm³

719

Fixed speed at high idle

min-1

3100

Fixed speed at low idle

min-1

1350

Valve clearance I/O

mm

0.15

Travel pump Manufacturer

Hydromatik

Type

A10 VG 18

System

Axial piston

Displacement

cm3/U

18

High pressure limitation

bar

300

Charge pressure

bar

20

Rotaray speed

min-1

2600

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 B1

Service Training BW 80 AD-2/BW 90 AD/AC-2/ BW 100 ADM-2 Travel motors (drums) Manufacturer

Danfoss

Type

OMT 500 FK

Number

2

System

Gerotor

Displacement

cm³/U

Brake

500 yes BW 90 AC-2

Travel motor (wheels) Manufacturer

Rexroth

Type

MCR 05

Number

2

System

Radial piston motor

Displacement

cm3/U

Brake

565 yes BW 80 AD-2/BW 90 AD/AC-2/ BW 100 ADM-2

Steering/charge/vibration pump Manufacturer

Bosch

Type

HY/ZFS 11/8

System

Gear pump

Displacement

cm3/U

8

Starting pressure

bar

210

Operating pressure

bar

100

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 B2

Service Training Vibration motor Manufacturer

Bosch

Type

HY/MZFS 11/5,5

System

Gear motor

Displacement

cm3/U

5,5

Frequency

Hz

60

Amplitude

mm

0.50

Steering valve Manufacturer

Danfoss

Type

OSPC 50 ON

System

Rotary valve

Filling capacities Engine oil (15W / 40)

3,9 l to max. dipstick mark

Hydraulic oil

9 l to middle dipstick mark

Coolant (water + anti-freeze)

1,9 l

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 B3

Service Training Kubota Diesel Engine Tandem vibratory rollers of product range BW 80 AD-2/90 AD-2 and BW 100 ADM-2 and combination rollers of series BW 90 AC-2 are powered by water cooled Kubota diesel engines of series D722-B. The engine is a water cooled four-stroke diesel engine of upright design. The engine works with the “E-TVCS”, the new three vortex combustion system from Kubota. The benefit of this combustion system is the higher power, lower fuel consumption and the vibration-free, smooth running. 3

4 2

5 1

Fig 1: Cross-sectional view of diesel engine 1) Fuel pump 2) Injection pump 3) Injection nozzle 4) Suction tube 5) Starter

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C1

Service Training Body of engine: Cylinder block: The engine is fitted with a sturdy, tunnel-type cylinder block. Cylinder bushes and cylinder liners provide sufficient cooling as well as a high level of stiffness and a high wear resistance. Since each of the cylinders is provided with its own chamber, the development of noise is reduced to a minimum.

Fig. 2

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C2

Service Training Cylinder head: The inlet and outlet channels in cross-flow design are arranged at both sides of the cylinder head. This cross-flow concept avoids heating up of the intake air and an expansion caused by the hot exhaust gases. The cool and therefore highly dense intake air contributes to the enhancement of the engine power. Apart from that, it limits the risk of a deformation of the cylinder head caused by hot exhaust gases, because the intake openings are arranged alternately with the exhaust openings. The intake air swirls in and is thoroughly mixed with the fuel, which enhances the combustion and reduces the fuel consumption. Both the injection nozzle with the protective cap and the screened and fast heating glow plug are integrated in the vortex chamber. This glow plug contributes to an even quicker starting of the engine, even at -15° C.

Fig. 3: 1) Vortex chamber 2) Intake channel 3) Exhaust channel 4) Nozzles

5) Glow plug 6) Cylinder head 7) Shot channel

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C3

Service Training Combustion system This engine uses the „E-TVCS“ (Three Vortex Combustion System) to achieve an optimal combustion and for maximum power. The E-TVCS-combustion system is based on a unique shape in the air intake section (9) of the combustion chamber. During compression it generates three air flows (1) inside the vortex chamber (8), which results in an ideal air-fuel mixture. Apart from that, the bottom of the piston (7) is provided with a fan shaped channel (shot channel), which allows for an excellent discharge of exhaust gases in combination with a most effective combustion.

Fig 4: Crankshaft The crankshaft is made of a tough stainless steel alloy and friction bearing seats, crank journals and oil seal sliding sections are induction hardened, in order to enhance the wear resistance. The V-belt pulley (1st cylinder) is fitted with a fixed bearing bush, the intermediate friction bearing seats are fitted with split bearing bushes and the friction bearing seat at the flywheel end carries a split bearing bush with the thrust bearing. Sealing to the flywheel end and to the V-belt pulley side is accomplished by radial seals running on replaceable wear rings. Wear ring flywheel end

split thrust bnearing Split bearing bush Fig. 5:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C4

Service Training Piston and piston rings The piston is made of an aluminium alloy. The top end of the piston is provided with two recesses for the valves. A fan shaped recess is also present on the top side of the piston. This allows for a uniform discharge of combustion gases. The piston pin is slightly out of the centre of the piston. With this design it is possible to reduce the piston impact at top and bottom dead centres, which in turn results in a lower noise level. In cold condition the piston has a slightly oval shape (accounting for the heat expansion) and an arched crown. The three piston rings sit in their respective grooves in the piston. The top ring is a trapezoidal ring, designed for high loads. The drum shaped clamping face of the ring adapts perfectly to the wall of the cylinder. The second ring (2) is a ring with an undercut, which avoids passing of oil in a most effective way. The oil scraper ring (3) has diagonally slanted contact faces and is equipped with an expansion ring, which increases the contact pressure of the oil scraper ring against the cylinder wall. The grooves are arranged at the top section of the piston, in order to avoid heat and abrasion.

Fig. 6: 1) Top ring 2) Second ring 3) Oil scraper ring 4) Fan shaped recess 5) Valve recess

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C5

Service Training Conrod The conrod (2) connects the piston to the crankshaft. The conrod foot carries a (split) conrod bearing cup (3) and the conrod head is fitted with a fixed bearing bush (1).

Fig. 7: 1) Conrod bush 2) Conrod 3) Conrod bearing cup

Camshaft and fuel camshaft The camshaft (3) is made of special cast iron. Journals and cam sections are hardened and provide a higher wear resistance. All journals are pressure lubricated. The fuel camshaft (5) is the control. It is fitted with a steel ball to control the governor. The fuel camshaft is made of carbon steel. The cam sections are annealed for higher wear resistance.

Fig. 8: 1) Cam drive 4) Injection pump

2) Camshaft limiter 5) Fuel camshaft

3) Camshaft

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C6

Service Training Flywheel The flywheel stores the rotary force of the combustion cycle in form of inertia of masses and reduces the rotation fluctuations of the crankshaft. This results in a uniform rotation of the engine. The outer face of the flywheel carries the adjustment marks for the top dead centre (TDC). The gearing of the outer flywheel ring meshes with the compensation bevel gear of the starter motor.

Fig. 9: 1) Crankshaft

2) Flywheel

3) Flywheel screws

Rocker arms The rocker arm arrangement consists of the rocker arms (1), the rocker arm blocks (4) and the rocker arm axle (5). It converts the up and down movement of the push rods into an open/close movement of the intake and exhaust valves. The lubrication oil is forced through the block to the rocker arm axle, which serves as a point of rotation, so that the rocker arms and the entire system are sufficiently lubricated.

Fig. 10: 1) Rocker arm 4) Rocker arm block

2) Counter nut 5) Rocker arm axle

3) Adjustment screw

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C7

Service Training Trouble shooting Fault

Possible cause

Remedy

The engine does not start

• No fuel • Air in fuel system • Water in fuel system

Fill in fuel Bleed Replace the fuel and repair or renew the fuel system

• Fuel line clogged • Fuel filter clogged • Too high fuel viscosity or use of incorrect engine oil for the ambient temperature • Fuel with too low Cetan-number • Loss of fuel because of loosened locking nut on the injection line • Incorrect setting of injection • Fuel camshaft worn • Injection nozzle clogged • Faulty function of the fuel lift pump • Crankshaft, camshaft, piston or bearings seized • Loss of compression on cylinder

• Incorrect valve seat alignment, valve spring broken, valve jammed • Insufficient valve control • Piston ring worn • Excessive valve clearance • Battery discharged

Clean Replace Use the specified fuel Use specified fuel Tighten the nut Adjust Replace Clean Repair or replace Repair or replace Replace the cylinder head gasket. Tighten cylinder head screws, glow plug and nozzle holder Repair or replace Adjust Replace Adjust Recharge

Starter does not work

•Faulty function of starter • Faulty function of ignition switch • Wiring loose

Repair or replace Repair or replace Connect

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C8

Service Training Fault

Possible cause

Remedy

The engine does not turn evenly

• Fuel filter cloged or dirty • Air filter clogged • Loss of fuel due to loosened locking nut on injection line • Faulty function of the injection pump • Incorrect opening pressure of the injection nozzle • Injection nozzle defective or clogged • Fuel leakage line clogged • Faulty governor function • Engine oil level too high

Replace Clean or replace Tighten the nut

Blue or white exhaust smoke

• Piston rings worn or stretched • Incorrect injection timing • Insufficient compression Black or dark grey exhaust smoke

Insufficient power

• Cylinder head gasket defective • Overload • Poor fuel quality • Fuel pre-cleaner clogged • Air filter clogged • Incorrect engine timing • Moving engine may probably be seized • Uneven injection of fuel • Insufficient nozzle injection • Loss of compression

Excessive lubricant consumption

Fuel mixed with lubrication oil Water mixed in lubrication oil Lubrication oil mixed in coolant

• Oil scraper ring worn or stretched • Piston ring groove worn • Valve shaft and guide worn • Crankshaft bearings and crankshaft journal bearings worn. • Plunger in fuel pump worn

Repair or replace Adjust Repair or replace Clean Repair Reduce to the specified level Replace Adjust Check the compression pressure Replace Reduce the load Use only specified fuel quality Replace Clean or replace Adjust Repair or replace Repair or replace the injection pump Repair or replace the nozzle Replace the cylinder head gasket, tighten cylinder head screws, glow plug and nozzle holder Replace Replace the piston Replace Replace

• Cylinder head gasket defective • Cracks in cylinder head or crankcase

Replace pumps elements or pump Replace Replace

Cylinder head gasket defective

Replace

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C9

Service Training Fault

Possible cause

Remedy

Oil pressure too low

• Engine oil level too low • Oil screen clogged • Oil filter cartridge clogged • Pressure relief valve blocked with dust • Pressure relief valve spring exhausted or broken • Excessive oil clearance of the crankshaft bearing • Excessive oil clearance of the rocker arm shaft • Oil passage clogged • Different type of oil

Fill Clean Replace Clean Replace

Oil pressure too high

Engine overheating

Rapid discharging of battery

• Oil pump defective • Different type of oil • Pressure relief valve defective • Oil level too low • Blower V-belt broken or not correctly tensioned • Coolant level too low • Radiator and radiator fins clogged by dust • Radiator corroded on inside • Coolant piping corroded • Radiator cap defective • Water pipe damaged • Thermostat defective • Water pump defective • Overloaded • Battery fluid level too low • V-belt slipping • Cables loose • Regulator defective • Generator defective • Battery defective

Replace Replace Clean Use the specified oil quality Repair or replace Use specified oil quality Replace Fill Replace or adjust Fill Clean Clean or replace Clean or replace Replace Replace Replace Replace Reduce the load Top up distilled water and recharge Adjust the tension or replace the V-belt Connect Connect Connect Connect

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C 10

Service Training Inspections and adjustments

Fig 11: Compression pressure: 1. Run the engine warm and shut it down. Remove the nozzle holders. 2. Attach a compression measuring instrument to the nozzle holder opening on the engine. 3. Make sure that the throttle lever is in top position (no injection) and crank the engine with the starter. 4. Read the maximum pressure. Repeat this measurement at least two times. 5. If the measurement is below the permissible limit, check cylinder, piston, valve and cylinder head.

Adjustment values: Compression pressure

Factory data Permissible limit value

28,4-32,4 bar 22,6 bar

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C 11

Service Training Checking the valve clearance 333 1

Fig. 12: IMPORTANT: The valve clearance must only be checked and adjusted when the engine is cold. 1. Remove the cylinder head cover. (The rubber gasket may be used again.) 2. Crank cylinder 1 (V-belt pulley side) to overlapping position (charging change TDC). 3. In this position adjust the intake valve of cylinder 2 and the exhaust valve of cylinder 3. Intake and exhaust valves are in line with the respective intake or exhaust channels. The valve clearance marked „1“ must be measured with a feeler gauge of respective thickness. 4. If the valve clearance is not within the limits of the factory setting, correct it by turning the adjustment screw accordingly. Valve clearance (cold)

Factory setting

0,15 mm

(These values apply for intake and exhaust valves) 5. After adjusting the valve clearance retighten the locking nut on the adjustment screw. Make sure not to turn the adjustment screw. Check the valve clearance once again. 6. Bring cylinder 2 to overlapping position. Adjust intake valve on cylinder 3 and exhaust valve on cylinder 1 in the same way as described above. 7. Bring cylinder 3 to overlapping position. Adjust intake valve on cylinder 1 and exhaust valve on cylinder 2 in the same way.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C 12

Service Training Engine solenoid: The engine is equipped with a shut-down solenoid which works according to the „ENERGIZED TO RUN“ principle. The advantage of this solenoid is the fact, that the engine will be shut down immediately, if there is a fault in the electric system (safety function). The disadvantage is the quite extensive design of the solenoid with two coils. Nominal currents of the coils: Pick-up coil (AW)

51 A

Holding coil (HW)

1,1 A

Fig. 13 Function of the engine solenoid: The pick-up coil (AW) is directly energized by the starter. Once the engine oil pressure is reached, the holding coil is supplied with voltage. Once the engine has started, the voltage to the pick-up coil is interrupted and only the holding coil is supplied with voltage. Monitoring functions on the engine: Engine oil pressure monitoring: The engine is shut down if the oil pressure drops below 0.5 bar.

Fig. 14 Monitoring of the coolant temperature: If the coolant temperature exceeds the coolant temperature limit (120 °C), the warning buzzer will emit an audible warning and the coolant warning light will light up.

Fig. 15 ________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 C 13

Service Training Travel system: The travel system of the tandem vibratory rollers BW80/90 AD-2 and BW 100 ADM-2 is a closed hydraulic circuit.

vom Lenkventil über Hydraulikölfilter

Vom Bremsventil

-2 Travel-SystemBW BW 80/90 80/90 AD-2 100 100 ADM-2 Fahrantrieb AD-2/BW / BW ADM-3

2

7

300 bar

5

6

1

5

4

300 bar

20 bar

3

1 2 3 4

1 Drive Fahrpumpe Pump 2 Drive Fahrmotor motorhinten rear 3 Drive Fahrmotor motorvorne front 4 Diesel Dieselmotor Engine

5 5 Hochdruckbegrenzungsventile High pressure relief valve 6 6 Speisedruckbegrenzungsventil Charge pressure relief valve 7 7 Hydraulikölkühler mit Bypass-Valve By-pass-Ventil Hydraulic-oil with

BW80_Fahr.eps

Fig. 16:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D1

Service Training The hydraulic circuit consists mainly of: •

the hydraulic oil tank

•

the travel pump (axial piston pump in swash plate design with variable displacement),

•

the travel motors (gerotor motors with fixed displacement (radial piston motor on AC/ADS-machines)

•

the charge pump (gear pump with fixed displacement),

•

the hydraulic oil cooler,

•

the fine filter and

•

the pressure resistant hydraulic hoses.

on AD-machines)

The travel pump is an axial piston pump with infinitely variable displacement. It is connected to the engine and driven by a V-belt. The oil quantity supplied by the travel pump is determined by the travel pump displacement and the speed of the diesel engine. The charge pump, which works also as steering and vibration pump is connected with the travel pump to a tandem unit. The hydraulic oil flowing out of the steering valve flows through the charge oil filter into the travel pump. The charge circuit has the function to replace leakages in the closed circuit and to protect the machine against thermal overloads. Cool and filtered hydraulic oil flows through the boost check valves inside the high pressure relief valve cartridges into the closed hydraulic travel circuit. The travel pump is fitted with all control and safety elements, which are needed for closed circuit operation. These are: • High pressure relief valves (300 bar) • Boost check valves • Charge pressure relief valve (20 bar) The drums are each driven by a travel motor. The travel motors are arranged on one side of the machine and hydraulically connected in series.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D2

Service Training On the AC-machines the rubber tires are driven by either one or two motors. This wheel drive motor is hydraulically connected in series to the drum drive motor. An anti-cavitation valve between both travel motors compensates variations in the oil flow. All motors are fitted with integrated multi-disc brakes, which have the function of parking brakes. The travel speed of the machine is controlled via the travel lever. The travel cable between travel lever and pump control lever transmits the travel lever movements to the pump control lever and operates the pump. When adjusting the travel lever through the neutral position to the opposite direction the flow direction of the pump flow as well as the sense of rotation of the travel motors will also be reversed.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D3

Service Training Travel pump The travel pump is an axial piston pump in swash plate design. The flow volume of the oil flow is proportional to the drive speed and the displacement. It can be infinitely adjusted. The flow volume increases from 0 to max. flow as the swashing angle of the swash plate increases. A belt drive connects the pump to the engine. This turns the drive shaft and the spines on the drive shaft drive the cylinder block. The cylinder block rotates and carries the pistons. The pistons rest with their slipper pads against the swash plate and perform a stroking movement in axial direction. A retention device holds the slipper pads on the sliding surface of the swash plate. During one revolution each of the pistons moves through its top and bottom dead centre back to its initial position. Between the two dead centres (the stroke reversing points) each of the pistons performs a full stroke. During such a stroke the amount of oil corresponding with the piston area and the length of the stroke is drawn in and pressed out again through the control slots in the valve plate. During the suction stroke the hydraulic oil is pressed by the charge pressure into the enlarging piston room. On the opposite side the oil is forced by the piston out of the cylinder bore into the hydraulic system.

Control The inclination angle of the swash plate is adjusted mechanically a rotary shaft. The swash plate/swashing cradle runs smoothly in roller bearings and the neutral position is spring centred. When enlarging the swashing angle the displacement volume and the torque will increase whereas a reduction of the swashing angle will reduce these values accordingly. If the swashing angle is zero, the displacement is also zero.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D4

Service Training Charge pressure relief valve The charge pressure relief valve is part of the group of safety elements in a closed hydraulic circuit. It makes sure, that the pressure in the charge circuit will not exceed the pressure adjusted on the valve. The charge pressure depends on the setting of the valve, the charge oil quantity and the engine speed. At different engine speeds the actually measured charge pressure may vary slightly from the values stated in the technical data. The adjusted charge pressure is a pressure differential (with respect to the case pressure). It applies normally when the travel pump is in neutral position. When actuating the pump the charge pressure will slightly drop, because leaks and flushing quantities in the closed circuit must now be replaced by oil from the charge circuit. Apart from this the charge circuit has also the function to control the travel pump and to release the parking brakes in the travel motors. After starting the engine charge pressure will build up immediately. As long as the travel drive is not operated, this pressure is applied to both boost check valves in the closed circuit. With the travel pump in neutral the pressure in both sides of the closed circuit is therefore always identical with the charge pressure. When actuating the pump, high pressure will build up in one of the two sides of the closed circuit. This pressure keeps the boost check valve on the respective side closed. Cool and filtered oil will only be fed in at the opposite side (i.e. the low pressure side).

High pressure relief valves The high pressure relief valves with the integrated boost check valves also belong to the group of safety elements in the closed hydraulic circuit. They limit the maximum pressure in the travel system to the pressure relief value set by a spring. This value is 300 bar. This pressure is also a pressure differential, i.e. at a charge pressure of 20 bar and a high pressure relief valve setting of 300 bar the absolute high pressure will be 320 bar (pressure gauge reading on the high pressure test port).

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D5

Service Training Drum drive motor: Both drums are driven by Danfoss travel motors, which work according to the orbital principle. The displacement section of the motor consists of a internally geared outer ring with seven ”teeth”, which is part of the housing, and an externally geared rotor with six teeth.

Fig. 17:

The teeth are formed in such a way, that they provide sufficient sealing between outer ring and rotor. One half of the tooth chamber forming between outer ring and rotor is connected with the pressure side, whereas the other half is connected with the outlet side. The motor is controlled by a rotating disc valve. The illustration shows universal shafts protruding from the rotor to both sides. The valve shaft (5) drives the disc valve (3), which thereby rotates synchronously with the rotor and which is pressed against the channel plate (6) by the pressure springs (4) and the pressure fluid. The channel plate has seven bores which are arranged in such a way, that they always lead to one of the valleys in the internally geared outer ring. By rotation of the disc valve over these bores, the pressure fluid is guided into the enlarging tooth chambers and at the same time it is pressed out of the decreasing tooth chambers. This causes the rotation of the rotor according to the orbital principle described above. The universal shaft (15) transfers the rotary movement of the rotor to the shaft (16). The drive flange for the drum is bolted to this shaft. On the one side this shaft is running in the ball bearing (17) and on the other side in the needle bearing (14). At the same time the driver (13) is driven by the shaft via a spline section. This driver drives the inner discs of the multi disc brake (11) via a second spline section. Theses inner discs are assembled alternately with the outer discs (12). These engage into the internal gearing in the brake housing (7). The pressure springs (8) press the piston (9) against the pack of brake discs. This brakes the motor mechanically. By pressing hydraulic oil from the charge circuit into the chamber between ring (10) ad piston the brake is hydraulically released. The hydraulic pressure displaces the piston and unloads the brake discs. The minimum opening pressure is approx. 12 bar

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D6

Service Training Brake control The travel circuit is fitted with multi disc brakes in the travel motors. These brakes serve as parking brakes for parking the machine (to hold the machine when parking with the machine running or to park the machine with the engine shut down) and as emergency brake. The brake control is accomplished via a 3/2 way valve, which is installed in the front of the engine compartment. If the solenoid valve is provided with current while starting the engine, the valve will change over and guide charge pressure into the brake housings. This opens the brakes. If the voltage supply to the solenoid valve is interrupted while the engine is running (e.g. by operating the emergency stop switch), the oil pressure in the brake housings is relieved into the tank and the brakes are closed by spring pressure.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D7

Service Training Flushing the travel system After each replacement of a component the closed travel circuit must be thoroughly flushed. If this work is not performed with the necessary care, the new components may be already damaged again after a short time by solid particles, which are still floating in the system. In case of excessive oil contamination after a severe damage in the hydraulic system (excessive abrasion and chips) the following work must be performed before flushing the system: > all other components must be opened and sealed, > replace the hydraulic hoses, > replace the hydraulic oil filter. If a components is replaced only because of an excessive leakage rate or too low power, the following measures before flushing should normally be sufficient: > change the hydraulic oil filter, > clean the hydraulic oil tank Filter the hydraulic oil with the filling and filtering unit from BOMAG. Note: Use only the filling and filtering unit from BOMAG to filter the oil. Pump the oil through a 6µ fine filter into an oil bag or into any other suitable vessel. In case of extreme oil contamination, discoloration of the oil or if the oil change interval is almost reached, the hydraulic oil needs to be changed. When working in the hydraulic system catch all hydraulic oil and dispose of environmentally.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D8

Service Training Trouble shooting travel system The machine does not move If the machine does not move after actuating the travel lever, you should first check the power supply for the brake solenoid valve. ¾ Switch the ignition on. ¾ Release the parking brake (the seat must be occupied for this purpose, because the seat contact switch must be actuated to release the brake). ¾ Check the voltage supply for the brake solenoid valve. If the voltage supply is not in order, perform trouble shooting in the electric system of the machine.

Fig. 18 If the voltage supply works correctly, check the current draw of the valve . For this purpose connect an ampere meter in line with the valve. The current draw of the solenoid valve is 2,75 A. If no current draw is measured, even though the voltage of approx. 12 V is present, change the magnetic coil.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D9

Service Training If the magnetic coil is in good working order, check the solenoid valve. ¾ Install a 60 bar pressure gauge to the brake line. ¾ Start the engine and move the travel lever out of neutral position. ¾ Read the pressure gauge. Nominal value:

approx. charge pressure (18 - 20 bar)

If the nominal value is not reached, replace the solenoid valve.

Install a 60 bar pressure gauge in this line.

Fig. 19:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 10

Service Training If the charge pressure is not reached, check the steering/charge/vibration pump. ¾ Connect a 600 bar pressure gauge to the charge/vibration pressure test port M2. ¾ Run the engine in high idle speed. ¾ Turn the steering against the end stop and read the pressure gauge. Nominal value: approx. 130-150 bar (incl. charge pressure and line resistance) If the steering pressure is not reached, replace the steering/charge pump.

Test port M2

Fig. 20:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 11

Service Training If the steering pressure is correct, check the charge pressure relief valve. ¾ Unscrew the plug. ¾ Take the valve insert out. ¾ Examine the valve visually. Replace the valve immediately if it is damaged.

Fig. 21:

The charge pressure relief valve is arranged on the underside of the travel pump. The valve can be unscrewed from the pump after opening the front cover plate. The valve can then be reached through the opening behind the cover plate.

Place of installation of the charge pressure relief valve

Fig. 22: If the valve is in good working order, check the brakes. ________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 12

Service Training ¾ Disconnect the brake lines from front and rear travel motor, one after the other and close them with suitable plugs. ¾ Check the charge pressure again with the brakes closed. If the charge pressure is now reached, seal the respective brake or replace the respective travel motor.

Close the brake lines

Fig. 23:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 13

Service Training If the charge pressure is not reached, check the high pressure. For this purpose you should first examine the high pressure relief valves visually.

Fig. 25:

High pressure relief valves

Fig. 26: The two high pressure relief valves are arranged on the right and left hand side of the travel pump.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 14

Service Training If the charge pressure is correct, perform a high pressure test of the travel pump. Attention ! The following test must not exceed a duration of 5 seconds! ¾ Close the high pressure outlets A and B. ¾ Connect 600 bar pressure gauges to the high pressure test ports. ¾ Run the engine with idle speed and actuate the travel pump quickly to both directions. ¾ Read the pressure gauges. Nominal value: 300 - 340 bar

Close the high pressure outlets

High pressure test ports

Fig. 24

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 15

Service Training If high pressure is reached, check both travel motors individually. ¾ Connect 600 bar pressure gauges to the pressure test ports MA and MB. ¾ Pull the plus cable off the brake solenoid valve, so that the brake remains closed. ¾ Move the travel lever fully forward, with the engine running at 3100 rpm, the high pressure must then raise to 300 bar. The same pressure must be reached when shifting the travel lever to reverse. ¾ If the high pressure is not reached: Join the high pressure hoses on the rear travel motor together to by-pass the motor. Then move the travel lever forward and repeat the high pressure test. During this test only the front travel motor is connected to the system. If the high pressure value is now reached, perform the same measurement with the front motor (join the high pressure hoses on the rear motor and shift the travel lever to reverse position) Nominal value: approx. 300 bar

High pressure ports

Fig. 27:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 16

Service Training If the charge pressure is reached during the test in Fig. 19, the charge pressure must be checked together with the high pressure. Connect 600 bar pressure gauges to the pressure test ports MA and MB. Connect a 60 bar pressure gauge to test port M1. Run the engine with max. speed. ¾ Block the drums or do not actuate the seat contact switch or pull the cable off the brake valve. Actuate the travel lever for a short moment. Nominal value:

Charge pressure approx. 18 to 24 bar High pressure approx. 300 bar

If the charge pressure is not reached, there must be a mechanical defect on the brakes in the travel motors.

Charge pressure

High pressure

Fig. 28:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 17

Service Training Insufficient drive power In case of this fault you should first check the speed of the diesel engine. Nominal value:

Min.: 3075 rpm Max.: 3150 rpm

high idle

If this speed is not reached, perform trouble shooting on the engine.

3100

Fig. 29: The engine speed may be measured with different types of gauges or measuring methods (e.g. vibration reed frequency meter, optical speed sensors etc.)

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 18

Service Training If the speeds are correct, check the travel control. ¾ Detach the control cable. ¾ Move the pump control lever forward and reverse and check, whether the full pump displacement is reached. ¾ Check, whether the travel cable has excessive wear. If the end stops are not reached, continue trouble shooting with Fig. 19.

Detach the travel cable

Fig. 30:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 19

Service Training If the max. travel speed is not reached, adjust the end stops on the travel lever. ¾ Adjust the front and rear stops for the travel lever. ¾ Check the travel cable for wear.

Front stop

Rear stop

Fig. 31

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 20

Service Training The machine drives with the travel lever in neutral In case of this problem you must first check the neutral position of the pump. ¾ Detach the travel cable and make sure that the brakes are closed. ¾ Run the engine at high idle speed -> under this condition the running pump drive centres the pump control lever in neutral position. ¾ The travel cable can now be installed in correctly aligned position.

Detach the travel cable at this point. Check whether ball joint and bore are in line.

Fig. 32:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 21

Service Training If the bores are not in line, the travel cable needs to be adjusted. ¾ Loosen the counter nuts on the bracket. ¾ Adjust the nuts until the travel cable corresponds with the neutral position of the pump. ¾ Retighten the counter nut.

Adjust the counter nut

Fig. 33:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 D 22

Service Training Vibration The vibration system is an open hydraulic circuit and consists mainly of vibration pump, vibration control valve and vibration motors. The gear pump delivers the hydraulic oil through the vibration control valve to both vibration motors, which are connected in series mode. Vibration BW 80/90 AD-2 / BW 100 ADM-2 To steering valve

zum Lenkventil

6

4

5

200 bar

3

2 1

1 1 2 2 3 3

Vibrationspumpe Vibration Pump Vibrationsschaltventil Vibration valve Druckbegrenzungsventil

Pressure relief valve

4 5 6

Vibrationsmotor hinten 4 Vibration-motor rear Vibrationsmotor vorne 5 Vibration motor front Vibrationsabschaltung

6

Cock valve Vibration shut off

BW80_Vibr.eps

Fig. 34: The rotation of the vibration motors causes the rotary movement of the connected vibrator shafts. The centrifugal force of the eccentric weights, which are welded to these vibrator shafts, cause the vibration of the drums. The vibration pump also provides the pressure oil for the steering system and feeds also the charge system for the closed travel circuit.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E1

Service Training Vibration pump Vibration pump and travel pump are joined together to a tandem pump unit. The vibration pump is a directly driven gear pump.

1 6

Housing Cover

2 7/8

Flange Gear wheel

3 9

Shaft Seal

4/5

Sliding flange

Fig. 35: Drive gear and driven gear are positioned by a bearing plate in such a way, that the gears mesh together with only minimal play while rotating. The displacement chambers are formed between tooth flanks, inside wall of housing and front faces of the bearing plates. During operation of the pump these chambers transport the hydraulic oil from the suction side to the pressure side. This causes a vacuum in the suction line, which draws the hydraulic oil from the tank. The tooth chambers transport the hydraulic oil to the pump outlet, from where it is pressed to the consumer. To ensure a correct function of the pump the tooth chambers must be sealed so tight, that the hydraulic fluid is transported from the suction side to the pressure side without any losses. Outer gear pumps are provided with gap seals. This results in losses from the pressure side to the suction side, whereby these losses depend on the operating pressure. To make sure that only minor fluid quantities will leak from the pressure side to the suction side. the bearing plate on the cover side is pressed against the front face of the gears by an axial pressure field. The pressure field is always loaded with the actual system pressure. The hydraulic oil supplied by the vibration pump flows to the vibration control valve and from there to the vibration motors (vibration switched on) or directly to the steering valve (vibration switched off). ________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E2

Service Training Vibration control The vibration is switched on and off by the vibration control valve. The valve consists of a pressure relief valve and a solenoid operated pilot control valve.

Fig. 36: 1) Spring 6) Pilot valve A) from pump

2) Main control piston 7) Pressure relief valve B) to the vibration motors

3) Ring screen 4) Throttle bore 8) Pilot oil discharge C) to the steering system

5) Magnetic coil

Function: When the engine is not running the spring (1) presses the main control piston (2) down onto the valve seat. This closes port (C) to the steering valve. When starting the engine the pilot control valve (6) is in open position and the oil column between vibration pump and vibration motor will be pressurized. This pressure lifts the main control piston (2) off its seat and opens the valve outlet (C) to the steering valve. The throttle bore (4) provides a connection between valve inlet (A) and pilot control valve, and from there through the pilot oil discharge bore (8) to the steering valve. When applying current to the magnet (5), the pilot control valve will close. This causes a pressure balance between both sides of the main control piston. The piston moves down and closes the valve outlet (C) to the steering valve. The oil must now flow through outlet (B) to the vibration motor. When starting the vibration the oil flow has to work against the resistance of the vibration motors. This increases the pressure in the line between pump and motor. This “starting pressure” is limited to 200 bar by the pressure relief valve (7). At this pressure the cone of the pressure relief valve is lifted off its valve seat against the ________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E3

Service Training pressure of the adjustment spring. The pressure on the spring side of the main control piston is discharged through the pilot oil discharge bore (8) to the steering valve and the main control piston is lifted off the valve seat. The oil flow is guided to outlet (C), until the pressure drops again under the adjustment value of the high pressure relief valve. Now the complete oil flow is again available for the vibration motors. When switching the vibration off, the pilot control piston reopens the passage to the valve inlet via the ring screen (3), the pilot control piston and through the pilot oil discharge bore to outlet (C). The resistance caused by the vibration motors lifts the main control piston off its seat and opens the direct connection from the inlet (A) to the outlet (C). The vibration motors will stop.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E4

Service Training Vibration motor The machines are equipped with vibration motors for both drums. These are connected in series. The motors are gear motors with a fixed displacement.

Fig. 37: Gear motors are quite similar to gear pumps in their design. Only the axial pressure field is shaped quite differently. Apart from this the motor is fitted with a leak oil port. Inlet and outlet ports of the motor are of identical size. The pressure fluid flowing into the vibration motor acts on the gears inside the motor. This causes a torque, which is transferred to the vibrator shaft in the drum via the motor output shaft and the connected coupling. The leak oil from the motor is guided back to the tank through a hose. The steering column is fitted with a cock valve for the deactivation of the rear drum vibration.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E5

Service Training Trouble shooting vibration Vibration frequency too low If the desired vibrator shaft speed is not reached, you should first check the diesel engine speed. ¾ Check the engine speed with an appropriate meter. Nominal value: BW 80 AD-2; BW 90 AD/AC-2; BW 100 ADM-2

3075 - 3150 rpm

If the nominal value is not reached perform trouble shooting on the engine.

3100

Fig 38: For the determination of the engine speed you may use different meters or measuring methods. (e.g. vibration reed frequency meter, optical measuring sensor etc.)

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E6

Service Training If the diesel engine speed is correct, perform a pressure test in the vibration system. ¾ Stand both drums on an elastic base (rubber tires). ¾ Connect a 600 bar pressure gauge to the vibration pressure test port. ¾ Run the engine with full speed and switch the vibration on. Nominal value : Starting pressure: Operating pressure:

approx. 210 bar (for about 3 - 6 seconds) approx. 125 bar

Test port M2

Fig. 40:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E7

Service Training If the starting pressure is not reached, check the vibration control valve block. ¾ Disconnect the high pressure hoses from the valve block. ¾ Close port B on the valve block with a plug (the outlet to the steering valve must remain open, so that the oil from the pressure relief valve can be collected). ¾ Switch the vibration on. Nominal value:

approx. 210 bar

Port to steering valve (B)

Test port M2

Fig. 41:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E8

Service Training If the pressure is not reached, perform steering/charge/vibration pump.

a high

pressure test for

the

¾ Install a 200 bar pressure relief valve with a 600 bar pressure gauge between vibration pump and vibration control valve. ¾ Start the engine and switch the vibration on. Nominal value:

approx. 200 bar

If the pressure is reached, replace the vibration control valve block. If the pressure is not reached, replace the vibration pump.

Install a 200 bar pressure relief valve with a 600 bar pressure gauge in this line and perform a measurement.

Fig. 42:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E9

Service Training If the pressure is not reached during the pressure test in Fig. 40, check the leakage rate of the vibration motors. Stand the machine on rubber tires or similar for this measurement. ¾ Disconnect the leak oil hose and hold into a measuring vessel. ¾ Switch the vibration on. Nominal value: max. 1.5 l/min Replace the motor showing a too high leakage rate.

Fig. 43:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E 10

Service Training If the pressure is reached during the test in Fig. 40, but the operating pressure is too low, you should also check the leak oil rate of the vibration motors. If the operating pressure is too high, check the condition of the vibrator shaft bearings. ¾ Check the end float and the moveability of the vibrator shaft bearings (front and rear). Nominal values:

min 0.52 mm max. 2.00 mm

Fig 44:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E 11

Service Training No vibration If the vibration does not work at all, you should first check the voltage supply for the vibration control valve. Switch the vibration on and check whether there is voltage applied to the plug. Nominal value:

12 Volt

If no voltage is applied, perform trouble shooting in the electric system.

12.0

Fig. 45:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E 12

Service Training If voltage is applied, check the magnetic coil of the control valve. ¾ Measure the current draw of the coil. (For this purpose the measuring unit must be switched in line with the magnet) Nominal value:

approx. 3 Ampere

If the current draw is not correct, replace the magnetic coil.

3,00 A

Fig. 46:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 E 13

Service Training Steering The steering system is an open hydraulic circuit and consists mainly of steering/charge pump, steering valve, steering cylinder and the pressure resistant connecting hydraulic hoses. Lenkanlage BW BW 100 ADM2 Steering system BW80/90 80/90 AD-2 AD-2 / /BW 100 ADM-2 to the brake valve

zur Bremsl sevorrichtung

150 bar

7 6 5 8

1

110 bar

150 bar

3

2 4 vom Vibrationskreis

from Vibration

1

Me pumpe

12 Measuring pump Verteilerventil 23 Distributor valve Druckbegrenzungsventil 34 Pressure relief valve Nachsaugeventil 4 Anti cavitation valve

5

Nachsaugeventile

56 Suction valve Schockventile 67 Shock valve Lenkzylinder 78 Steering cylinder Nachsaugeventil 8 Anti cavitation valve

BW80_Lenk.eps

Fig. 47: The steering pump delivers the hydraulic oil from the tank to the steering valve and to the connected steering unit. This steering unit is installed under the dash board of the machine. If the steering system is not operated, the complete oil flow is guided through the fine filter to the charge port for the travel system and further through the cooler back to the tank. When turning the steering wheel, the distributor valve inside the steering unit guides the oil flow to the piston or the piston rod side of the steering cylinder. A rating pump inside the steering unit measures the oil quantity with respect to the turning angle of the steering wheel and supplies it to the steering cylinder. The steering cylinder extends or retracts and articulates the machine. The steering unit contains an integrated pressure relief valve. This valve limits the steering pressure to 100 bar. Since the oil leaving the steering system is used as charge oil for the closed travel circuit, the charge pressure value must be added to this pressure value. During a pressure test you should therefore measure a total pressure of 130 bar.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 F1

Service Training Steering valve The steering valve block contains mainly of the distributor valve, the rating pump, the steering pressure relief valve and the shock valves. When turning the steering wheel the oil flow from the steering pump is guided through the distributor valve to the rating pump. The rating pump in turn supplies the oil through the distributor valve to the respective side of the steering cylinder. The machine is fitted with a so-called “open centre” Orbitrol valve, i.e. in neutral position of the valve the inflowing oil flows through the tank return bore directly to the charge ports for the closed travel circuit.

1 2 9

3 4

5

8

6

7 Fig. 48: 1 3 5 7 9

Neutral position springs Inner spool Universal shaft Gear Pressure relief valve

2 4 6 8

Housing Outer spool Toothed ring Non-return valve

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 F2

Service Training The rating pump measures the exact oil quantity in dependence on the turning angle of the steering wheel. The oil quantity provided for the steering cylinder articulates and steers the machine. The high pressure relief valve in the steering unit limits the pressure in the steering system to 110 bar. Since the oil flowing out of the steering unit is supplied to the charge system for the closed travel system, the charge pressure must also be taken into account when performing a steering pressure test. The steering unit is fitted with so-called shock valves, which are arranged in each pressure passage to the steering cylinder. These valves are set to an opening pressure of 150 bar. These valves pick up extreme pressure peaks, which may be caused e.g. when driving over obstacles, thus protecting the system against overloads. Each of these shock valves is fitted with an additional anti-cavitation valve. These anti-cavitation prevent damage caused by cavitation when the shock valves should respond. A non-return valve at the inlet of the steering unit makes sure that no oil will be forced back to the pump if the machine is suddenly articulated by an external source. In such a case the steering cylinder would have the function of a pump and force the oil back to the steering pump

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 F3

Service Training Trouble shooting steering Faulty steering function Note: The steering pump works also as charge pump. In case of a problem in the steering system you should first check the steering/charge pump. ¾ Connect a 600 bar pressure gauge to the steering pressure test port (M2). ¾ Turn the steering against one end stop. ¾ Read the pressure gauge. Nominal value:

approx. 160 bar

If the steering pressure is reached, check the moveability of the articulated joint and of the steering cylinder.

Fig. 49:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 F4

Service Training If the nominal value is not reached, check the steering cylinder. ¾ Disconnect the hydraulic hoses from the ports L and R on the steering cylinder and close them with suitable plugs. ¾ Run the engine and turn the steering wheel. Nominal value:

approx. 160 to 180 bar

If the nominal value is now reached, replace the steering cylinder.

Fig. 50:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 F5

Service Training If the nominal value is not reached, check the steering/charge pump. Close the pump outlet with a 200 bar pressure relief valve. Repeat the pressure test. Nominal value:

approx. 200 bar

If the nominal value is not reached, replace the steering/charge pump. If the nominal value is reached, replace the steering valve.

Close this line with a pressure relief valve and measure the pressure at the outlet of the pressure relief valve.

Fig. 51:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 F6

Service Training Wiring diagrams Wiring diagrams are graphic presentations of control logic conditions related to the electric system. They do not contain any information about the wiring, they have the sole purpose to provide information on the control logic. Wiring diagrams are an essential aid for trouble shooting and they allow for a fault-free connection of components during modifications or changes to the electric system of a machine. Design: 1. Table of contents 2. Function groups 3. List of components 1.

Table of contents

The table of contents contains a list of all function groups, components and control module presentations of the machine. The arrangement of all sheets, one after the other, makes up the complete wiring diagram. Example: Function group “Warning installations”, drawing number 990 XXX XX can be found on sheet no. 8 List of components, drawing number 801 502 05 on sheet no. 101

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G1

Service Training 2.

Function groups

Electric circuits forming a function oriented correlation are combined to function groups (brake, warning installations ...) on individual sheets (sheet no.: 1, 2 ....) and subdivided into 10 different current paths (along the bottom line). This helps to follow the functional relation of the electric circuits. Arrangement of current paths The individual current paths are to be read as follows: ¾ from the top (plus potential) to the bottom (minus potential) ¾ from left to right (current paths 1 to 10, along the bottom line, Fig. 52)

Fig. 52 ¾ from function group (sheet no.) to function group (sheet no.) ¾ via cross-references for potentials and relays

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G2

Service Training Line thicknesses In a wiring diagram (Fig. 53) there is a differentiation between two different types of connecting lines: 1. thick connecting lines, standard wiring and components 2. thin drawn connecting lines, wiring on printed circuit boards

Fig. 53: Reference lines, frames Components and connections which apply only for optional machine equipment (optinal equipment, retrofit kits or special constructions, Fig. 54), are drawn with thin dash-dot-dash lines and text in two languages.

Fig. 54:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G3

Service Training Potential cross-references Example potential 15: 4:10 ---------> direction arrow (cross-reference to sheet 4, current path 10) Potential running over longer stretches of the wiring diagram may be interrupted for clarity reasons. In such cases on the beginning and the end of the potential will be drawn. The unity of such interruption points is shown by potential cross-references. Potential cross-references are also used to trace signals, which are transferred from one function group (sheet no.) to another function group (sheet no). Example 1 (Fig. 55): Potential “15" on sheet no. 6 continues to the left on sheet no. 4 in current path ”10" and to the right on sheet no. 8 in current path “1". To the right it ends at the connecting point (without information arrow) on sheet no. 8 in current path ”3".

Fig. 55:

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G4

Service Training Relay cross-references in exploded view Control symbols of parts of electric components (relays, switches, ...) are separately drawn and arranged in such a way, that each current path can easily be followed. The spatial unity of individual contacts is not accounted for. A straight, clear and cross-free arrangement of individual current paths has top priority. Relay crossreferences therefore have the purpose to allow for the tracing of signals, which have to be followed on components with output contacts. Each contactor coil is additionally provided with a contact symbol, which provides information about the types of contacts of a relay and where these contacts can be found in the wiring diagram. Example 2 (Fig. 55):

The contactor coil of relay (K99) can be found on sheet no. 8 in current path “6".

The contact symbol under the relay provides the information that a double-throw contact is energized by the contact types 30, 87 and 87a. This double-throw contact is located on sheet no. 8 in current path “3". 3.

List of components

This is a list of all used components in alphabetical order, related to the name of the component (A01, A02....).

Fig. 56: Cross reference of components Example (Fig. 56): The warning horn “B 11" is located in wiring diagram on sheet no. 8 in current path 3. ________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G5

Service Training Electric system Table of potentials Potentials P30 30 31 15 L B 50

Meaning Battery Plus for the optional sprinkler pump and fender flash lights via fuse F68 Battery Plus Vehicle ground, battery Minus is energized when the ignition is ON Voltage for charge control light connection Connection on starter Pre-heating control light

Power supply (sheet 002) Battery The minus pole of the battery G01 is permanently connected to vehicle ground (potential 31). The plus pole of the battery (G01) is connected to potential 30. The potentials 31 and B+ are always directly connected to the battery. The voltage can only be interrupted by disconnecting the battery. Starting (sheet 003) Ignition switch (S00) in position „0“ (ignition off) The ignition switch is permanently supplied with voltage via potential 30, fuse F00. The connection to terminals 15, 19, 17 and 50a is interrupted. Ignition switch (S00) in position „I“ (ignition on) with the engine at rest In this condition current flows from terminal 30 on the ignition switch (S00) to the output terminal 15. Terminal 15 now supplies the voltage for the machine. Ignition switch (S00) in position „II“ (preheating) Preheating of the engine takes place via terminal 19/17 with the help of the glow plugs R02

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G6

Service Training Ignition switch (S00) in position „III“ (starting) To start the diesel engine: - the emergency stop switch must not be operated (page 3) - the travel lever must be in position „0“ (coil K05 is not energized) - no engine oil pressure is applied, the coil of relay K96 is energized, the normally open contact 87/30 of relay K96 (page 3/7) is closed. In this condition current flows from terminal 50a of the ignition switch (S00) to the starter. The starter now provides the voltage for the working coil (AW). Once engine oil pressure has built up (Bo6 page 4/8) voltage is no longer applied to the coil, the contact of K96 now changes to 87a/30. Voltage is now applied to the holding coil (HW). If the pressure should now drop while the engine is running, the contact of relay K96 will interrupt the voltage supply to the holding solenoid (HW) and the engine will stop. Relay K96 is therefore monitoring the engine oil pressure.

Ignition switch (S00) in position „0“ (ignition off) when the engine is running If the ignition switch S== is switched to position “0” while the engine is running, both potential 15 and the holding coil (HW) will be deenergized. The engine will stop.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G7

Service Training Monitoring (sheet 004) This sheet of the wiring diagram contains several monitoring functions of the machine. - The charge control light H08 has ground connection to the generator via potential L and lights up when the battery is being charged. - The operating hour meter starts to count the operating hours as soon as voltage is applied to the holding coil of the engine solenoid. It therefore counts the actual operating hours of the engine. - In connection with H34 the relay K37 has the function to achieve an optimal preheating time for the engine. - If the coolant temperature is too high, the temperature switch B53 will close, the lamp H28 will light and the warning buzzer (page 8/4) will sound. Apart from that this sheet also contains the control lights H20 and H01. H20 shows if the seat contact switch (S06) is not closed. Control light H01 lights up when the travel lever is in position „0“. In this position the brake is also closed.

Brake (sheet 006) The brake remains closed as long as the travel lever is in position „0“ and as long as the emergency stop switch is actuated. Releasing the brake: The brake valve Y07 (page 6/path 9) is supplied with voltage via the emergency stop switch after closing the contact 30(87 of the relay K48 (page 6/path 7) and the brake will open.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G8

Service Training Vibration (sheet 007) The vibration can only be switched on when driving the machine in the first speed range and by pressing the push button in the travel lever. The proximity switch B38 (below the travel lever) supplies the voltage for the coil of relay K29 (page 7/path 3), i.e. the proximity switch is closed. This closes the contact 30/87 (page 7/path 3) of relay K29. Pressing the push button S13 (page 7/path 6) supplies the vibration relay K04 (page 7/path 6) with ground potential. This energizes the solenoid valve for vibration Y71 (page 7/path 3).

Proximity switch vibration

Fig. 57: Water sprinkler system (sheet 10) The pressure sprinkler system only works if the travel lever is not in „0“-position !!! (water economy mode), i.e. the travel lever must be actuated out of neutral position to work the pressure sprinkler system. The water sprinkler switch S05 (page 10/path 5) will only be provided with voltage if the contact 30/87 of relay K48 (page 6/path 7) is closed and if the emergency stop switch S01 (page 3/path 7) has not be actuated. The interval switch A01 (page 10/path 5) is energized and the coil of relay K23 (page 10/path 5) is supplied with voltage. Contact 30/87 of relay K23 (page 10/path 3) closes and the water pump M02 will start to run. The gravity feed sprinkler system works under any condition (independently from the travel lever position) after the switch S05 has been set to position “ON”. This activates the solenoid valve Y06.

________________________________________________________________________________________ BW 80 AD-2/BW90 AD/AC-2 /BW 100 ADM-2 G9

Inhaltsverzeichnis: table of contents: Blatt Nr.: sheet no.: 001 002 003 004 005 006 007 101

BW 80/90 AD−2, BW 100 ADM−2, BW 90 AC−2, BW 80 ADS BW 80/90 AD−2, BW 100 ADM−2, BW 90 AC−2, BW 80 ADS

Zeichnungsnummer drawing − no. 801 502 22 801 502 22 801 502 22 801 502 22 801 502 22 801 502 22 801 502 22 801 502 22

Funktionsgruppe

function unit

Stromlaufplan Versorgung, Motor, Starten Bremse, Rückfahrwarneinrichtung, Doppelfahrhebel Vibration, Signalhorn, Rundumkennleuchte, Berieselung Beleuchtung Option, Sitzkontakt, Motor aus Elektrokasten Bauteilliste

Circuit Diagram supply, engine, starting unit brake, back up alarm, 2 travel lever vibration, warning horn, rotary beacon, sprinkler system illumination option, switch seat contact, engine off cross−boonding box component listing

19.3.2003 Kneip 19.3.2003 Nallin

Stromlaufplan circuit diagram

001

001

801 502 22 001

2,5qmm

P30 4:10

6qmm

30

Hauptsicherung Batterie fuse, main, battery

2X6qmm

2

2:8

S00 Zündschalter ignition switch

30A

1 X1:39 1X1:38

P01

58

−

2X6qmm

X1:27

6qmm

2:6

0,16A

86

BTS 6:12

15 2:11

85

22

Brücke entfällt bei Option Sitzkontakt Motor aus only acc. to option switch seat contact

R02

R02 3X8A

B

K37 Glühkerze Header plug

2:9

2:6

87 K37

X11:4 X11:2 M− 31 Batterietrennschalter switch battery disconnect

2:8

K96

6:2

6:16

K33 3:18

30 X1:48

X1:46

X1:50

2,5qmm

2:4

B

25qmm

50

M01 Starter starter 2:5

M−

X10:ws

0,8 kw

weiß white HW 1,1A/AW 35A Y13

X10:rt

Hubmagnet Motor shut off solenoid engine

Versorgung, Motor, Starten supply, engine, starting unit

P00 Betriebsstundenzähler engine hour meter

B06

B53

1

2:13

− M− 2:15

2:14 X1:60

4

2

M−

3

_t

P

X10:sw

Brücke entfällt bei Option Sitzkontakt Motor aus only acc. to option switch seat contact engine off

D+

rot red

schw./black

25qmm

−

Meldeleuchte Vorglühen indicator light, glowing

19.03.2003 Kneip 19.03.2003 Nallin

6:16

87a

2:14 Y13

X1:51

X11:3 X1:8

B06

UMP15 6:2

87 K96

K37

G01 Batterie battery

− X1:28

87a

+ H34 0,16A − X1:21

5 sec.

− X1:26

X1:33 3:13

K05 3:2

X1:35

+ H28

engine off

30

40A

0,16A

+ H09

X1:33

30

−

21

3:11

X1:52

B 2:8

55AH

S01 Not−Aus Schalter switch, emergency off

X1:34

IG

G02 Generator generator

+

F14

4qmm

X1:53

X1:54

4

Meldeleuchte Kühlmitteltemperatur indicator light, engine coolant temp.

K96 X1:36

R02

ZA option

50a

H08 Ladekontrolle charge control

2,5qmm

3

19 17

+

L S30

15

HW

2

Meldeleuchte Motoröldruck indicator light, engine oil pressure

15A

1 F14 2:11

0,16A

A

X1:32

Sicherung fuse ZA option

F14 Sicherung fuse

X11:5

X1:37

F00

30A

1

P0123

AW

F00 30A

30

2

2,5qmm

2

X11:6

2

15 3:1 2

2 F68

2X4qmm

15

6:2

31 3:1 Geber Motoröldruck pressure switch engine oil Geber Kühlwasser temperature switch, collant

1

1

801 502 22 002

15

2:20

15 4:1 B Sicherung fuse 15A

Initiator Fahrhebel "0" prox. switch, travel lever "0"

F25

2

X1:59

30

K48 3:3

X8:2 Fahrhebel"0"=low

sw bl

1 B08

BR/BN

87a

ZA Doppelfahrhebel option 2 travel lever

87

X1:42

X1:22

K137:30

6:9

15 in

87a

−

X15:2

X16:3

−

stehen

X12:2

87

K137:87

21

12

1s 2s 4s Zeitrelais timing relay

X1:29 B32

2 sec.

S01

anzugsverzögert

22

11

Not−Aus−Schalter switch, emergency off

15out

30 87a 87 S− S+

2:16 X1:33

K33 30 3:6 87a

87

−

3:11 H01 X16:2

S05 4:10

6:9

BL/BU

3 sitzen

2 30

K34 3:7

only acc. to option switch seat contact, engine off

S06 1

2:13

K113

Entfällt bei Anbau Sitzkontakt, Motor aus

entfällt bei option Doppelfahrhebel not incl. if 2 travel lever are assembled

X8:1

V

X12:1 BR/BN

ZA Doppelfahrhebel option 2 travel lever X8:3 Schalter Fahrhebel X1:58 switch,travel control lever

0,7A

H07 −

H01 3:14

SW/BK

SW/BK

X15:1 +

X1:31

X1:24

2

sw/weiß bl/white

BL/BU

S55

X16:1

X1:25 X1:3−1

X1:4−1 86

86

K05

V03 V04

+ H20

+ H01

UMP3

WAGO

B32 3:16

X1:4−2 86

K48

85

X1:30

X1:3−2

0,16A

X1:45 Y04

V05 2

85

2,75A

X1:57 2:20

X1:8

31

X1:23

Sitzkontaktschalter switch, seat contact 2:9

3:7

3:19

2:20 K33

1

K34

85

B32

Zusatzausrüstung option

− 0,16A

86

K33

85

−

X1:41

3:7 6:2

Meldeleuchte Bremse indicator light brake

X1:49

Magnetventil Bremse solenoid valve brake

X1:60

X1:8

31 4:1

Warnsummer warning buzzer

Initiator Rückfahrwarneinrichtung proximity switch,back up alarm

3:4

Meldeleuchte Sitzkontaktschalter indicator light,drivers seat contact

19.03.2003 Kneip 19.03.2003 Nallin

Bremse, Rückfahrwarneinrichtung, Doppelfahrhebel brake, back up alarm, 2 travel lever

1

1

801 502 22 003

15

15 5:1 2

Berieselungsschalter switch sprinkler system

Schalter Rundumkennleuchte switch, rotary beacon

C

F03 Sicherung fuse

Taster Signalhorn switch warning horn

20A

Fußschalter Emulsion foot switch, emulsion Za

56

S

X1:55

P30

BR/BN

S12

S13

B38

S03

23

V06 1

K23 85

SW/BK

BL/BU

X9:3

X9:1

X13:2

24

24

X18:1

V07 2

X1:20

7,2A

X1:19

13

23

14

24

X1:40

X1:61

X1:17 X19:1 Y06

1

+

1

M02

7,2A

M03

2 4

− X17:1

X1:56 X1:43

−

1,25A

E32

2,5A

4,2A

86

+

+

K29 85

−

1,5A

X1:8

X1:57

1

V01

Y21 1

V02

B11 −

2

3:20 31 Magnetventil Vibration solenoid valve, vibration

87a

23

+

Y71

X1:49

S38

X1:18 86

A01 X14:2

ZA Doppelfahrhebel option 2 travel lever

X1:44

0

4

24

24

X1:18

X1:9 4

S34

30

4:11 87

87a 4

3

0

P30 5:8

K23

X9:2

X13:1

30

4:6 87

S19

X1:13

X1:7

X1:47

3

23

S05

2:20

3

S05

23 K04 31

Za option

3:12 S05

30

56b

K29

X1:7

Druckberieselung pressure sprinkler

option

X14:1

Schalter Kantenschneidgerät switch, edge cutter

3

nur für AC−Typen only acc. to AC−types

3:20

X1:8

X1:60

5A

2

X17:2

X18:2

X1:6

X1:57

Y20

2

X19:2 X1:23

X1:57

X1:6

X1:49 31 5:1

Vibrationsschalter Fahrhebel vibration switch travel lever

Berieselungspumpe sprinkler pump

Signalhorn warning horn Rundumkennleuchte rotary beacon

Berieselungsventil solenoid valve sprinkler Intervallschalter interval switch

Initiator Vibration proximity switch, vibration 4:2

19.03.2003 Kneip 19.03.2003 Nallin

4:10

Vibration, Signalhorn, Rundumkennleuchte, Berieselung, Kantenschneidgerät vibration, warning horn, rotary beacon, sprinkler system, edge cutter

Emulsionspumpe emulsion pump Magnetventil Kantensschneidgerät ab solenoid valve, edge cutter, down Magnetventil Kantensschneidgerät auf solenoid valve, edge cutter, high

1

1

801 502 22 004

15

4:11

0 1 S16 13

23

X1:1

X1:2

F08 Sicherung fuse

15A

H06 0,16A

4 X1:5

11

Warnblinkschalter switch, hazard light 01

24

E23

X2:3

012 S15 12

X1:10

64

33

Schalter Blinker switch indicator 44 L0R

24

11

63

34

43

5A

−

14

H05

0,16A

+

+

− 5A

−

−

option working heat lights

−

1,75A

5A

X6:4

X5:6

X6:5

X6:2

+

+

+ −

1,75A

1,75A

−

ZA Arbeitsbeleuchtung StVZO

X5:3

1,75A

−

0,8A

X6:3

E14 + +

−

0,8A

0,8A

−0,8A

− E13

E11

−

E15

X1:11

49

option working heat lights StVZO

X5:2

E12 +

E10 +

− E09

49a

A02 X5:1

X2:1

24

+

E25

X1:12

X3:1

X5:5

E14

ZA Arbeitsbeleuchtung

X1:15

+

E08 1,75A

15A

5

23

X4:3

X3:3

− 5A−

E13

13

F12

S37

23

E23

E Sicherung fuse

4 X1:16

12

+

1,75A

15A

−

S14

+ + E25

+

F11

23

X5:4

X2:2

Meldeleuchte Warnblinker indicator light, hazard light

X1:14

S15 5:12 X3:2

D Sicherung fuse

+

X7:2

24

D

X4:2

14

S15

X7:1

F F12 15A Sicherung fuse 6 X1:15

F11 Sicherung fuse 5 X1:16

5:7

X4:1

15A

P30

2

2 E

Beleuchtungsschalter STVZO switch, lighting STVZO

2

Schalter Arbeitsbel. vorn switch, working head lights front

4:20

X5:1

X6:1

X1:23

X1:6

31

4:20

31

X1:6

X1:23

X1:23

X1:8

31

Arbeitsscheinwerfer VL working head light front, LH

Arbeitsscheinwerfer VL working head light front, LH

Arbeitsscheinwerfer VR working head light front, RH Schlussleuchte links Tail light, lh.

Meldeleuchte Blinker indicator light, indicators

Blinkleuchte VL indicator front, LH Blinkleuchte HL indicator rear, LH

Arbeitsscheinwerfer VR working head light front, RH

6:1

Parkleuchte links parking light, LH

Blinkleuchte VR indicator front, RH

Parkleuchte rechts parking light, RH

Blinkleuchte HR indicator rear, RH

Schlussleuchte rechts Tail light, rh. Schlußleuchte links tail light, LH

19.03.2003 Kneip 19.03.2003 Nallin

Beleuchtung illumination

1

1

Schlußleuchte rechts tail light, RH

801 502 22 005

2:16

UMP15

3:14 UMP3 2:19

30

3:8

K137:30

X1:39

F139 Sicherung fuse

2

1

2

Nachrüstsatz convension kit

1

30

K137 6:10 87

3:8

87a

3

K137:87 A68

15/54 K22 6:14 87

30

87a

X25:1 + H82

X26:1 +

−

−

X25:2

X26:2

15/54

Modul Sitzkontakt modul seat contact H82 Warnsummer warning buzzer

86 K137 85

2 1

X1:64

2

X1:62

X1:63

X12:2

X12:3

BTS

2:11 2 V10 1

S06 Sitzkontaktschalter switch, seat contact

2

BTS

3

1

87

30

2 2:16

V08

K96 1

86 sitzen

stehen

V09

K22 85

1

2:18

2

B06

X12:1 2:11

Y13

5:20

31

X1:8

X1:60

6:11

21.03.2003 Kneip 21.03.2003 Nallin

Option, Sitzkontakt, Motor aus option, switch seat contact, engine off

6:3

1

1

801 502 22 006

K113

Nachrüstsatz Sitzkontakt, Motor aus convension kit, seat contact engine off

Zeitrelais timing relay

Option Doppelfahrhebel option, 2 travel lever

F139 Option Sitzkontakt, Motor aus option switch, seat contact engine off

K137

A68 Modul Sitzkontakt modul seat contact

1 2

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

40

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

36 36

F03

F00

F68

F00

F139

3 4

F08 F11 F12

Sicherungen/fuses

K37

K04

5 2

4

K37

19.03.2003 Kneip 19.03.2003 Nallin

A02

option pressure sprinkler

6 3

K22 Option Druckberieselung

Zeitrelais timing relay

Option Beleuchtung option illumination

64

F25

Sicherungen/fuses

37

38

39

39

F14

K23

Option Sitzkontakt, Motor aus option switch seat contact, engine off

K29

K34

K48

Elektrokasten cross−boonding box

K33

K96

K05

Relais relay

1

1

801 502 22 007

25. 3. 3 Kneip 25.3.03 nallin

Bauteilliste component listing 1 3

801 502 22 101

002 003 004 003 004 002 005 005 005 005 005 005 005 005 005 005 005 005 005 005 004 002 002 004 005 005 005 005 005 002 003 002 006 002 2 002 3 003 005 005 003 002 002 003 002 002 006 006 004 003 006 004 004 003 003 002 003 002 003 006 002 9 004 10 004 15 002 15 002 4 002 5 002 6 002 003 003 004 004 004 003 006 004 004 005 005 005 004 002 004 005 004 003

B06 B08 B11 B32 B38 B53 E08 E09 E10 E11 E12 E13 E13 E14 E14 E15 E23 E23 E25 E25 E32 F00 F00 F03 F08 F11 F11 F12 F12 F14 F25 F68 F139 G01 G02 H01 H05 H06 H07 H08 H09 H20 H28 H34 H82 H82 K04 K05 K22 K23 K29 K33 K34 K37 K48 K96 K113 K137 M01 M02 M03 P00 R02 R02 R02 S00 S01 S01 S03 S05 S05 S06 S06 S12 S13 S14 S15 S16 S19 S30 S34 S37 S38 S55

7 11 11 7 11 13 7 11 3 4 10 7 2 15 2 18 13 8 4

4 2 14 11 6 6 7 6 3 14 13 10

9 10 11 19 3 18 8 19 7 6 7

3 3 4 7 2 17 3 20 13 7 1 3

13 14 15 16 18 2 17 4 19 20 2 7 3 8 8

18 2 7 17 6 19

004 11 005 10 006 16

A01 A02 A68

Startschalter Schalter NOT AUS Schalter NOT AUS Taster Signalhorn Berieselungsschalter Berieselungsschalter Sitzkontaktschalter links Sitzkontaktschalter links Vibrationsschalter Fahrhebel links Vibrationsschalter Fahrhebel rechts Warnblinkschalter Beleuchtungsschalter StVZO Schalter Arbeitsbeleuchtung vorne Emulsionsberieselungsschalter Batterietrennschalter Schalter Kantenschneidgeraet Schalter Blinker Schalter Kennleuchte Schalter Fahrhebel

Gluehkerze Gluehkerze Gluehkerze

Betriebsstundenzaehler

Starter Berieselungspumpe Emulsionsberieselungspumpe

Schrittrelais Vibration Relais Startstrom Relais Hubmagnet Motor Relais Berieselungssystem Relais Vibrationsschalter Relais Warnsummer Betriebsstoerung Relais Sitzkontaktschalter Zeitrelais Relais Fahrhebel 0−Stellung Relais Motoroeldruck Zeitrelais Relais Sitzkontaktschalter

Meldeleuchte Bremse Meldeleuchte Blinker Meldeleuchte Warnblinker Warnsummer Betriebsstoerung Meldeleuchte Ladekontrolle Meldeleuchte Oeldruck Motor Meldeleuchte Sitzkontaktschalter Meldeleuchte Kuehlmitteltemperatur Meldeleuchte Vorgluehen Warnsummer Sitzkontakt Warnsummer Sitzkontakt

Batterie Generator

Hauptsicherung Batterie Hauptsicherung Batterie Sicherung Vibration Sicherung Blinker u. Arbeitsscheinw. Sicherung Scheinwerfer links Sicherung Scheinwerfer links Sicherung Scheinwerfer rechts Sicherung Scheinwerfer rechts Sicherung Hubmagnet Motor Sicherung Magnetv. Fahren u. Bremse Sicherung Potential 30 Sicherung Hubmagnet Motor

Blinkleuchte vorne links Blinkleuchte hinten links Blinkleuchte vorne rechts Blinkleuchte hinten rechts Parkleuchte links Schlussleuchte links Schlussleuchte links Parkleuchte rechts Parkleuchte rechts Schlussleuchte rechts Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer vorne rechts Kennleuchte

Druckschalter Motoroel Naeherungsinitiator Fahrhebel ’0’−Stell. Signalhorn Naeherungsinitiator Rueckfahrwarneinrichtung Naeherungsinitiator Vibrationssperre Temperaturgeber Kuehlmittel

Intervallschalter Berieselungssystem Blinkrelais Modul Sitzkontakt

Bl. Pf. Benennung 006 4

Name

Starter switch Switch, emergency off Switch, emergency off Push button, warning horn Switch, sprinkler system Switch, sprinkler system Switch, seat contact, lh. Switch, seat contact, lh. Switch, vibration, travel lever, lh. Switch, vibration, travel lever, rh. Switch, hazard light Switch, lighting StVZO Switch, working head lights, front Switch, emulsion sprinkler system Switch, battery disconnect Switch, edge cutter Switch, indicator Switch, warning light Switch, travel control lever

Glow plug Glow plug Glow plug

Operating hour meter

Starter Sprinkler pump Emulsion sprinkler pump

Toggle relay, vibration Relay, starting current Relay, shut off solenoid, engine Relay, sprinkler system Relay, switch, vibration Relay, warning buzzer, failure indication Relay, switch, drivers seat Timing relay Relay, travel lever 0−position Relay, engine oil Timing relay Relay, switch, drivers seat

Indicator light, brake Indicator light, indicators Indicator light, hazard light Warning buzzer, breakdown Indicator light, charge control Indicator light, engine oil pressure Indicator light, drivers seat contact Indicator light, engine coolant temp. Indicator light, glowing Warning buzzer, seat contact Warning buzzer, seat contact

Battery Generator

Fuse, main, battery Fuse, main, battery Fuse, vibration Fuse, indicators a. work. head light Fuse, head light, lh. Fuse, head light, lh. Fuse, head light, rh. Fuse, head light, rh. Fuse, shut off solenoid, engine Fuse, sol. valve, travel and brake Fuse, potential 30 Fuse, shut off solenoid, engine

Indicator, front, lh. Indicator, rear, lh. Indicator, front, rh. Indicator, rear, rh. Parking light, lh. Tail light, lh. Tail light, lh. Parking light, rh. Parking light, rh. Tail light, rh. Working head light, front, lh. Working head light, front, lh. Working head light, front, rh. Working head light, front, rh. Warning light

Pressure switch, engine oil Proximity switch, travel lever ’0’ pos. Warning horn Proximity switch, back up alarm Proximity switch, vibration lock Temperature switch, collant

Interval switch, sprinkler system Indicator relay Modul seat contact

title

TYP

max 6 Amp

8A 8A 8A

0,8 kw 7,2A 7,2A

BOSCHW

BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW 13sec. BOSCHW BOSCHW

0,16A 2 Watt 0,16A 2 Watt 2 Watt

0,16A 2 Watt 2 Watt

55AH 40A

30A 30A 20A 15A 15A 15A 15A 15A 15A 15A 30A 30A

21W 21W 21W 21W 10W 21W 10W 21W 10W 10W 55W 55W 55W 55W 55W

max 300mA 50W max 300mA max 300mA

30A

25. 3. 3 Kneip 25.3.03 nallin

Bauteilliste component listing 2 3

801 502 22 102

Bl. 004 004 003 003 003 004 004 006 006 006 005 005 003 003 003 003 005 004 004 005 005 004 004 002 003 003 004 004 005 006 004 005 005 005 004 005 005 005 005 005 004 004 004 004 004 002 003 003 004 005 005 005 003 003 002 002 002 003 003 003 002 002 002 002 002 002 002 002 006 004 003 003 004 004 003 002 004 002 003 004 004 002 002 002 002 002 004 004 003 004 004 004 003 003 002 003 004

Name V01 V02 V03 V04 V05 V06 V07 V08 V09 V10 X1:1 X1:2 X1:3−1 X1:3−2 X1:4−1 X1:4−2 X1:5 X1:6 X1:6 X1:6 X1:6 X1:7 X1:7 X1:8 X1:8 X1:8 X1:8 X1:8 X1:8 X1:8 X1:9 X1:10 X1:11 X1:12 X1:13 X1:14 X1:15 X1:15 X1:16 X1:16 X1:17 X1:18 X1:18 X1:19 X1:20 X1:21 X1:22 X1:23 X1:23 X1:23 X1:23 X1:23 X1:24 X1:25 X1:26 X1:27 X1:28 X1:29 X1:30 X1:31 X1:32 X1:33 X1:34 X1:35 X1:36 X1:37 X1:38 X1:39 X1:39 X1:40 X1:41 X1:42 X1:43 X1:44 X1:45 X1:46 X1:47 X1:48 X1:49 X1:49 X1:49 X1:50 X1:51 X1:52 X1:53 X1:54 X1:55 X1:56 X1:57 X1:57 X1:57 X1:57 X1:58 X1:59 X1:60 X1:60 X1:60

2 3 4 5 4 5 7 8 15 2 14 7 12 7 7 19 2 6 10 19 10 7 10 10 10 7 3 20 2 17 11 11 13 8 7 7 19 9 12 3 7 13 7 7 18 3 19 19 11 11 13 13 9 7 7 1 3 3 3 18 6 17 7 2 11 18 6 19 11 2 18 13 10 6 6 3 4 6 2 5 10 18 2 7 15 17 7

17 19 4 4 11 1 12 13 17 5 Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten ELEKTROKASTEN Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten

Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode

Pf. Benennung

Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box

Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode

title Stecker Stecker UF4004 UF4004 Stecker Stecker Stecker FE5B FE5B FE5B

TYP

25. 3. 3 Kneip 25.3.03 nallin

Bauteilliste component listing 3 3

801 502 22 103

Bl. 006 004 006 006 006 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 003 003 003 004 004 004 002 002 002 002 002 002 002 002 003 006 003 006 006 004 004 004 004 003 003 003 003 003 004 004 004 004 004 004 006 006 006 006 003 004 002 004 004 004

X1:60 X1:61 X1:62 X1:63 X1:64 X2:1 X2:2 X2:3 X3:1 X3:2 X3:3 X4:1 X4:2 X4:3 X5:1 X5:1 X5:2 X5:3 X5:4 X5:5 X5:6 X6:1 X6:2 X6:3 X6:4 X6:5 X7:1 X7:2 X8:1 X8:2 X8:3 X9:1 X9:2 X9:3 X10:rt X10:sw X10:ws X11:2 X11:3 X11:4 X11:5 X11:6 X12:1 X12:1 X12:2 X12:2 X12:3 X13:1 X13:2 X14:1 X14:2 X15:1 X15:2 X16:1 X16:2 X16:3 X17:1 X17:2 X18:1 X18:2 X19:1 X19:2 X25:1 X25:2 X26:1 X26:2 Y04 Y06 Y13 Y20 Y21 Y71

Name

11 13 13 18 18 2

Pf. 11 18 10 11 3 3 2 3 2 2 4 15 15 7 7 13 18 19 7 13 15 14 17 20 14 16 15 16 2 2 2 5 6 6 13 13 13 6 7 6 6 7 7 11 7 10 11 4 4 3 3 19 19 17 17 17 8 8 10 10 15 15 6 6 7 7 Solenoid valve, brake Solenoid valve, sprinkler system Shut off solenoid, engine Solenoid valve, egde cutter Solenoid valve, egde cutter Solenoid valve, vibration

ELEKTROKASTEN Elektrokasten Elektrokasten Elektrokasten Elektrokasten Blende vorne Blende vorne Blende vorne Blende hinten Blende hinten Blende hinten Lenkkonsole Lenkkonsole Lenkkonsole Blende vorne Blende vorne Blende vorne Blende vorne Blende vorne Blende vorne Blende vorne Blende hinten Blende hinten Blende hinten Blende hinten Blende hinten Lenkkonsole Lenkkonsole Initiator Fahrhebel Initiator Fahrhebel Initiator Fahrhebel Initiator Fahrhebel Initiator Fahrhebel Initiator Fahrhebel Hubmagnet Hubmagnet Hubmagnet Elektrokasten Elektrokasten Elektrokasten Elektrokasten Elektrokasten Fahrersitz Fahrersitz Fahrersitz Fahrersitz Fahrersitz Fahrhebel Fahrhebel Fahrhebel Fahrhebel FAHRERSTAND FAHRERSTAND Motor Motor Motor Rundumkennleuchte Rundumkennleuchte Berieselungspumpe Berieselungspumpe Emulsionspumpe Emulsionspumpe FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND

Benennung

title

Magnetventil Bremse Magnetventil Vibration vorne gross Kraftstoffpumpe Heizgeraet Magnetventil Kantenschneidgeraet Magnetventil Vibration Magnetventil Fahrtrichtung vorwaerts

Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Screen front Screen front Screen front Screen rear Screen rear Screen rear Steering box Steering box Steering box Screen front Screen front Screen front Screen front Screen front Screen front Screen front Screen rear Screen rear Screen rear Screen rear Screen rear Steering box Steering box proximity switch, travel lever proximity switch, travel lever proximity switch, travel lever proximity switch, travel lever proximity switch, travel lever proximity switch, travel lever shut off solenoid, engine shut off solenoid, engine shut off solenoid, engine Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Cross−bonding box Driver‘s seat Driver‘s seat Driver‘s seat Driver‘s seat Driver‘s seat Travel contr.lever Travel contr.lever Travel contr.lever Travel contr.lever Operators platform Operators platform Engine Engine Engine rotary beacon rotary beacon sprinkler pump sprinkler pump emulsion pump emulsion pump Operators platform Operators platform Operators platform Operators platform 2,75A 1,25A 1,1/35A 2,5A 2,5A 1,5A

TYP