Service Training
Service Training Table of contents Foreword
A1
Documentation
A2
General
A3
Technical data and adjustment values
B1
Maintenance
C1
Maintenance schedule
C2
DEUTZ diesel engine
D1
Operating side/service side
D2
Starter side
D3
Lubrication oil circuit
D4
Coolant circuit
D5
Fuel system
D6
C h ki
d d j ti
th
l
l
D 11
Service Training Vibration
G1
Vibration pump
G3
High pressure relief valves
G6
Control
G7
Vibration motor
G8
Vibration shut-off valve
G9
Drum BW 141 AD-4
G 11
Drum BW 154 AD-4
G 12
Test and adjustment points, vibration system
G 14
Trouble shooting in vibration system
G 18
Steering system
H1
Steering pump
H3
Priority valve
H4
Steering valve
H5
Articulated joint
H8
Test and adjustment points
H 11
Service Training Foreword Reliable construction equipment is of greatest advantage for all parties involved: • for the customer/u customer/user ser it is a basis for an exact calculati calculation on of utilization utilization periods periods and the completion completion of projects as scheduled. • in the rental rental business business it means that that the equipment equipment can can be reliably reliably used used and planned planned without without having having to stock a large number of stand-by machines. • for the manufact manufacturer urer it means that that customers customers are are satisfied, satisfied, provides provides him with a good image image and gives gives him a feeling of confidence. It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine: • the locatio location n of componen components ts in the machi machine ne eases eases mainten maintenance ance work work,, • the high quality quality standard standard of BOMAG is the the basis for for the considerab considerable le extension extension of the service service and maintenance intervals.
Service Training Documentation For the BOMAG machines described in this training manual the following documentation is additionally available: Attention! The currently valid part num bers for the docum ents can be taken from th e Doclist or the Custom er Service page in the BOMA G (BOMAG Secured Area) in acco rdance with the serial numb er of the machine.
1. Operating and maintenance instructions 2. Spare parts catalogue 3. Wiring diagram * 4. Hydraulic diagram * 5. Repair instructions 6. Service Information
Service Training General The tandem rollers of series BW 141 - 154 AD/AC-4 are high performance machines for the extremely difficult use in asphalt compaction and earth work. The machines of this series are powered by engine oil cooled Deutz diesel engines of series BF4M 2011. Engine driven pumps transfer the engine output power via hydrostatic circuits for travel and vibration systems to the drums. These hydrostatic drives ensure lowest possible power losses and a high efficiency. The steering and crab-walk functions as well as the additional e dge cutter option are supplied by gear pumps driven by the auxiliary engine output. The machines are equipped with a 2 cylinder operated articulated steering and a crab-walk function with a separate hydraulic cylinder to offset the front frame laterally relative to the rear frame. For the first time a machine of this product range is equipped with axial piston drum drive motors with reduction gears The discs of the parking brakes are integrated in the reduction ge ars. When starting the engine and opening the brake valve the brakes are relieved by charge pressure. When closing the brake valve or when shutting the engine down the brakes are automatically applied by spring pressure. These parking brakes should not be used as service brake, because the deceleration effect is extremely high
Service Training Technical data and adjustment values The following pages contain technical data valid at the date of printing (see front page of this manual). Attention! The currently valid technical data and adjus tment values can be taken from th e BOMAG Intranet or Extranet (BOMA G Secured Area) in accord ance with the serial num ber of the machine.
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values Status: 2005-06-22
Product type:
BW 141 AD Serie 4
Type No.: Serial numbers from:
920 00 101 920 00 1001
Engine: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage:
Travel pump:
BF4M 2011 4-stroke-Diesel Oil 4 60 kW 2500 1/min 850 +/-150 1/min 2700+/-50 1/min 245 g/kWh 0,3 mm 0,5 mm 210 +8 bar 12 V
BOMAG Central Service
Seite 2 von 2
Starting pressure: 360+/-20 bar Operating pressure, soil dependent: ca.100 bar
Vibration motor: Type: Number: System: Displacement: Frequency: Amplitude:
A4FM 22 2 Axial piston-swash plate 22 cm3/U 40/60 Hz 0,7/0,34 mm
Steering and charge pump: Type: System: Displacement: Max. steering pressure:
HY/ZFFS11/11+8 Tandem-/Gear pump 11 / 8 cm 3/U 200 +/-5 bar
Steering valve: Type: System:
OSPF 400 LS Rotary valve
Filling capacities: E
i
il
13 l (SAE 15W 40 API CG 4 (f
d t il
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values Status: 2005-06-23
Product type:
BW 154 AD Serie 4
Type No.: Serial numbers from:
920 31 101 920 31 1001
Engine: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage:
Travel pump:
BF4M 2011 4-stroke-Diesel Oil 4 60 kW 2500 1/min 850 +/-150 1/min 2700+/-50 1/min 245 g/kWh 0,3 mm 0,5 mm 210 +8 bar 12 V
BOMAG Central Service
Seite 2 von 2
Operating pressure, soil dependent: ca.100 bar
Vibration motor: Type: Number: System: Displacement: Frequency: Amplitude:
A4FM 22 2 Axial piston-swash plate 22 cm3/U 40/60 Hz 0,7/0,34 mm
Steering and charge pump: Type: System: Displacement: Max. steering pressure:
HY/ZFFS11/11+8 Tandem-/Gear pump 11 / 8 cm3/U 200 +/-5 bar
Steering valve: Type: System:
OSPF 400 LS Rotary valve
Filling capacities: Engine oil:
13 l (SAE 15W-40, API CG-4 (for details see maintenance manual))
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values Status: 2005-06-22
Product type:
BW 154 AD AM Serie 4
Type No.: Serial numbers from:
920 51 101 920 51 1001
Engine: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage:
Travel pump:
BF4M 2011 4-stroke-Diesel Oil 4 60 kW 2500 1/min 850 +/-150 1/min 2700+/-50 1/min 245 g/kWh 0,3 mm 0,5 mm 210 +8 bar 12 V
BOMAG Central Service
Seite 2 von 2
Operating pressure, soil dependent: ca.100 bar
Vibration motor: Type: Number: System: Displacement: Frequency: Amplitude:
A4FM 28 1 Axial piston-swash plate 28 cm3/U 46 Hz 0,2 / 0,55 mm
Vibration motor, VARIOMATIC: Type: System: Displacement: Frequency: Amplitude:
A4FM 28 Axial piston-swash plate 28 cm3/U 46 Hz 0,84 mm
Steering and charge pump: Type: System: Displacement: Max. steering pressure:
U 1636 11+8+2,5 Tandem-/Gear pump 11 / 8 / 2,5 cm 3/U 200 +/-5 bar
Service Training Maintenance The products of series BW 141...154 AD/AC-4 are high performance machines for the extremely difficult use in asphalt compaction and earth work. To be able to meet these demands the machines must always be ready to be loaded up to their limits. Furthermore, all safety installations, protections and guards must always be in place and fully functional. Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably higher functional safety, but also prolongs the lifetime of the machine and of important components. The time required for thorough maintenance is only minor when being compared with the malfunctions and faults that may occur if these instructions are not observed. The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance interval all the work for shorter preceding intervals must also be performed. During the 2000 hours interval you must also perform the work described for the service intervals after 50, 250 and 500 hours. During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and lubricants (oils, fuels, grease etc.). This training manual is handed out together with the presently valid operation and maintenance manual.
Maintenance
5.3
Fuels, lubricants and filling capacities
Assembly
Fuel or lubricant Summer
Winter
Quantity approx. Attention Observe the level marks
Engine
Engine oil AC EA: E3-96/E5-02 API: CG-4/CH-4 SAE 10W/40 (-20 °C to +30 °C) SAE 10W/40 (-10 °C to +40 °C) SAE 30
SAE 10W
(+5 °C to +30 °C)
(-5 °C to -30 °C)
SAE 40
SAE 20W/20
13 litres without oil filter
Maintenance
5.4
Running-in instructions
The following maintenance work must be performed when running in new machines or overhauled engines: !
Caution
Up to approx. 250 operating hours check the engine oil level twice every day. Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours. Maintenance after 50 operating hours Check the engine for leaks. Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts. Retighten the bolted connections on the machine. Maintenance after 250 operating hours
Maintenance
5.5
No.
Maintenance chart
Maintenance work
Remark
s r s u n o o h i t c g u i n r t t s a n r e i p n i o g 0 n 5 i 2 n r n e u t f R a
y l i a d , s r u o h g n i t a r e p o 0 1 y r e v e
5.6
Check the engine oil level
5.7
Check the water separator
X
5.8
Check the fuel level
X
5.9
Check the hydraulic oil level
5.10 Check the water level
Dipstick mark
Inspection glass
X
X X
s r u o h g n i t a r e p o 0 5 2 y r e v e
s r u o h g n i t a r e p o 0 0 5 y r e v e
s r u o h g n i t a r e p o 0 0 0 1 y r e v e
s r u o h g n i t a r e p o 0 0 0 2 y r e v e
s r u o h g n i t a r e p o 0 0 0 3 y r e v e
s r u o h g n i t a r e p o 0 0 0 5 y r e v e
d e r i u q e r s a
Maintenance
No.
Maintenance work
Remark
s r s u n o o h i t c g u i n r t t s a n r e i p n i o g 0 n 5 i 2 n r n e u t f R a
y l i a d , s r u o h g n i t a r e p o 0 1 y r e v e
s r u o h g n i t a r e p o 0 5 2 y r e v e
s r u o h g n i t a r e p o 0 0 5 y r e v e
s r u o h g n i t a r e p o 0 0 0 1 y r e v e
5.23 Checking, tensioning, replacing the refrigerant compressor V-belt
X
5.24 Changing the oil in the vibrator shaft tube
X
s r u o h g n i t a r e p o 0 0 0 2 y r e v e
5.25 Change hydraulic oil and breather at least every 2 filter**** years
X
5.26 Change the hydraulic oil filter*****
at least every 2 years
X
5.27 Grease the articulated joint ******
at least every 2
X
s r u o h g n i t a r e p o 0 0 0 3 y r e v e
s r u o h g n i t a r e p o 0 0 0 5 y r e v e
d e r i u q e r s a
Service Training Deutz diesel engine Single drum rollers of series BW141/154 AD-4 are powered by a Deutz diesel engine of product range BF4M 2011. In contrast to the engines 1011/1012 previously used by BOMAG, this engine comes with external oil cooling, i.e. a separate oil cooler with a hydraulically driven fan, instead of the well known integrated oil cooler/fan system. This automotive engine is characterized by the following features: • short and compact design, • low noise level, • low vibration running, • low fuel consumption, • low exhaust emissions, • good access to all service points and • extended maintenance intervals (5000 h) for toothed timing belt, in comparison to the predecessor
Service Training Control side
Service Training Exhaust side
Service Training Lubrication oil circuit
Service Training Cooling The engine cooling system uses an external engine oil cooler.
Service Training Fuel circuit
Service Training
Service Training Checking and adjusting the valve clearance Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the intervals specified in the operating and maintenance instructions. Note:
The valve clearance is measured between the valve stem and the rocker arm. The correct valve clearance on a cold engine (engine oil temperature <80°C) is as follows: Intake valve Exhaust valve
= 0.3 mm (directly after replacing the cylinder head gasket 0.4 mm) = 0.5 mm (directly after changing the cylinder head gasket 0.6 mm)
• Remove the valve cover. • Turn the crankshaft by the V-belt pulley, until both valves on cylinder 1 are overlapping (exhaust valve not yet completely closed, intake valve starts to open). Note: Cylinder 1 is located on the flywheel side; sense of rotati on: V-belt pulley viewed from front in clockwise
Service Training
Fig. 6: Valve adjustment, position 1
Check and adjust the valve clearance on all black marked valves (Fig. 6). A feeler gauge of appropriate thickness must fit through the gap between valve and rocker arm with only little resistance. If the gap is too narrow or too wide for the feeler gauge, the valve clearance needs to be adjusted.
Service Training Assembling the plug-type injection pumps Engines of type 2011 are fitted with individual injection pumps for each cylinder. When installing individual plug-type injection pumps the distance to the camshaft must be correctly adjusted shims, because this determines the start of commencement. 1.Unscrew the plug from the crankcase.
Service Training 3. Turn the engine by the crankshaft pulley, until the plunger stroke of the respective cylinder is at bottom dead centre position.
Service Training 5. Measure measurement ’A’ from crankcase contact face to spring plate contact face of plunger.
Service Training 7.Determine the difference between installation measurement „X“ and the measured dimension ’A’. Example:
Installation measurement “X“ = 60 mm - measured depth measurement A = 59,35 mm Difference = 0,65 mm
8. Choose a compensation gasket from thge table according to the marking.
Service Training 9. Install the selected gasket; observe the assembly position!
Measuring notch on this side!
10.
Pull the locking pin out of the injection pump and insert the locking wire (BOMAG part-no. 079 947 06 / 079 947 07) into this bore. Insert the locking wire into the bore in the injection pump control
Service Training 11.
Assemble the injection pump. Press the injection pump centrically in against the stop. Tighten the nuts. Tightening torque: 21 Nm
.
Service Training 13.
Close the bore again with the locking pin
14.
Remove the locating pin from the governor rod
Service Training 15. Insert the plug with a new copper ring and tighten it: Tightening torque 18 Nm
Service Training Diesel engine: Components and test ports Control side
1
3
2
5
Service Training Electrical connections
3 5
1 2
3
4 1
2
5
4
Service Training Starter side Auxiliary output
Service Training Air filter
1
Service Training
Fuel pre-cleaner
1
Service Training Cooler package
Engine oil cooler
Service Training Travel drive BW 141/151 AD On the machines described in this training manual the travel system consists of a closed hydraulic circuit. It mainly consists of travel pump with integrated safety elements and travel motors with travel gears.
e v l a v e k a r b m o r f
e v l a v e k a r b m o r f
5
6
0 3 Y
l i o g n i h s u l f h t i w l
3 2
5
2 2
6
l i o g n i h s u l f h t i w l i o k
Service Training The installation of a hydraulic pump with variable displacement into a closed hydraulic circuit is a perfect solution for a hydrostatic travel system, because with this design the travel direction can be reversed without any problems. The travel pump is flanged to the flywheel side of the diesel engine. It is directly driven by the engine with constant speed. The tandem gear pump driven by the auxiliary output of the engine is responsible fo r steering, crab walk with additional functions and charge system. The tandem gear pump also serves as charge pump, because the oil flow from steering valve and crab walk valve is flowing to the charge ports on travel and vibration pumps. The oil is cleaned by pressure filters, which are hydraulically arranged directly after the tandem gear pumps. Besides its function of supplying the closed circuit with cool and filtered oil as replacement for leakage and flushing losses, the oil from the charge circuit is also needed for the following machine functions: • to control the variable displacement pumps for travel and vibration systems, • to release the hydraulic multi-disc brakes. All safety and control elements needed for the operation in a closed hydraulic circuit are integrated in
Service Training travel pum p
The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch Rexroth-Hydromatik, type A4 VG 56 HW.
T1: Connection to vibration pump T2: Leak oil to tank
3
440
2 1
M
5
to the travel motors Charge pressure
Service Training • Servo control • High pressure relief valves with integrated boost check valves • Charge pressure relief valve • Pressure override Travel pump and vibration pump are connected to a tandem pump unit. The travel pump unit is directly driven by the flywheel side of the engine via an elastic coupling. The pump speed is therefore identical with the engine speed. 6
5 7
8
Service Training Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction (direction of oil flow). A manually operated 4/3-way valve directs the pilot oil flow (from the charge circuit) to the corresponding control piston side in the servo control. The 4/3-way valve is controlled by the travel lever and the travel cable. In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way valve pilot oil (from the charge circuit) is directed to one of th e control piston sides and moves the control piston to the corresponding direction. The swashing lever between the control piston and the swash plate transfers the control piston movement to the swash plate. The needle bearing mounted swash plate swivels to the chosen direction. This causes the axial movement of the pistons inside the cylinder block. The axial movement draws oil into the pump and presses it to the travel motors. All working pistons are drilled through their entire length. Pressure fluid flows through these bores into the areas between the slipper pads and the surface of the swash plate. This forms a hydraulically balanced field, on which the slipper pads can slide without any metal to metal contact between swash plate and slipper pads. The feedback lever on the control piston detects when the swash plate has reached a position that corresponds with the displacement of the travel lever. This feedback lever controls a pilot oil portioning valve which interrupts the pilot oil flow to the control chambers when the swashing angle corresponds with the position of the travel lever. Swashing angle and displacement of
Service Training Since the cross-sections of these valves are very small and the hydraulic oil enters the low pressure side already inside the pump, the system would very quickly overheat if the pressure in the system would be permanently relieved via the high pressure relief valves. For this reason the pump is fitted with an additional pressure override valve. The pressure override valve interrupts the pilot oil flow to the control piston, thereby maintaining the pressure level at the adjusted value of the pressure override valve. If the pressure drops again, the pressure override valve will o pen and the pump can swash back to the previously chosen position. This installation prevents overheating of the hydraulic system and overloading of the diesel engine. Control
The servo control of the pump is an integral part of the pump housing and consists mainly of: • the manually controlled 4/3-way valve (1) • the control piston (2) • the feedback lever (3) • the pilot oil portioning valve (not visible in illustration) and • the swashing lever with the swashing cradle (see Fig. 3).
Service Training The control piston moves to the corresponding direction and operates the swash plate via the swashing lever accordingly. The feedback lever, which is mounted with its ball head in the pump control shaft, follows the control piston and interrupts the pilot oil flow when the control piston has reached a position corresponding with the displacement of the travel lever. The pump can now deliver oil to the travel motors. The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump housing. The supply bores to both control chamber sides are fitted with nozzles (swashing time nozzles). These nozzles restrict the pilot oil flow and enable a very sensitive control of the pump. to – from motor from the charge pump
Leak oil
4/3-way valve
Service Training The feedback lever controls the pilot oil portioning valve so that the swashing angle remains unchanged, until the introduction of a new control command. to – from motor from the charge pump
Leak oil
4/3-way valve
travel pump Control piston
to – from motor
Fig. 6
Control actuated
Service Training Charge pressu re relief valve
The charge pressure relief valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted value. The charge pressure relief valve is installed in the travel pump and internally connected with the vibration pump.
from the charge pump
pilot oil
Service Training High p ressu re relief valv es, (with b ypass for towin g)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit. These valves limit the pressure in the hydraulic circuit to the value determined by the adjustm ent spring.
1 2
Service Training .
to the travel motor
3 4
1 2
4
from the travel motor
Service Training Pressure o verride
Since the cross-sections of the high pressure relief valves are very small, longer responding of these valves would cause very quick overloading of the hydraulic circuit and would subsequently lead to severe damage in pump or other components. In order to avoid this, the travel pump is equipped with another safety device, the pressure override.
2 5
6 1
3 4
Service Training Since the cross-sections of the high pressure relief valves are very small, longer responding of these valves would cause very quick overloading of the hydraulic circuit and would subsequently lead to severe damage in pump or other components. In order to avoid this, the travel pump is equipped with another safety device, the pressure override.
Service Training A shuttle valve ensures that the spool of the pressure override is always subjected to the highest pressure in the closed circuit. As long as the pressure in the closed circuit is lower than the adjustment value of the pressure override, the pilot oil connection via the 4/3-way valve to the corresponding control chamber is released. The pump can now be actuated up to maximum displacement. If the pressure reaches the setting of the pressure override, the spool inside the valve will move and cut off the pilot oil flow to the control piston. The pump cannot be actuated any further. The system pressure is maintained at the setting of the pressure override, until the resistance causing this high pressure in the system is overcome or the pump is returned to neutral position by the operator. Should the pressure in the closed circuit drop below the sett ing of the pressure override, the valve spool will be forced back by spring force, whereby the passage between charge circuit and pump control is opened again. Now pilot oil can flow to the corresponding control piston side again and the pump can be actuated. The spring force of the pressure override and its reaction value can be adjusted via the adjustment screw. Due to its design and the hydraulic arrangement of the pressure override, the high pressure relief valves will not respond. This type of pressure limitation does not relieve any oil from the closed hydraulic circuit via the very tight cross-sections of the high pressure relief valves. This avoids overheating of the hydraulic oil.
Service Training Travel mo tors BW 141/151
The two travel motors are plug-in fixed displacement bent axle motors of series A2FE 32 ccm from Bosch-Rexroth, which drive a travel gear 705 C2H from Bonfigioli.
2
3 1
Service Training 5
4
2
6 8
Service Training Flushing valve on motor deckel 10 8
9
Service Training Drum driv e reductio n gear BW 141/151 4
2
3
7
1
9
Service Training Test and adjustment poin ts travel pump
3
7
6 4
1
8
5
3
4
5 2 6
Service Training Travel mo tor w ith travel gear
5
1
4
4
2
2
3 5
2
1
Service Training Brake valve with ha nd pu mp for eme rgency br ake release
5 4
2
1 3
Service Training Trouble shooting The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults. The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.
Service Training
TROUBLE SHOOTING TRAVEL SYSTEM BW 141- 4-FAMILY
) e ' s l r a e r v t e y u r l e d n N ' n o a n i n d o r d r i e e a t c v h w e e c r i r l a l o f e ( d e r g l e v t n e n a i r o t v o t n a a h s e r m t t i h i t t o w d r o e v n l s s e e o e e p S s l e v v s i o l o M o a r O d t m e c
Service Training Travel system BW 154 AD On the machines described in this training manual the travel system consists of a closed hydraulic circuit. It mainly consists of travel pump with integrated safety elements, travel motors with travel gears and a flow divider.
Service Training Travel pum p
The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch Rexroth-Hydromatik, type A4 VG 56 HW. T1: Connection to vibration pump T2: Leak oil to tank
3
from/to the travel motors Charge pressure Via flow divider
3
440
2 2 1
M
5
5
1
440
5
4
400 26
66
Service Training The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit. These are: • Servo control • High pressure relief valves with integrated boost check valves • Charge pressure relief valve • Pressure override • Travel pump and vibration pump are connected to a tandem pump unit. The travel pump is fitted with a flushing valve for the closed circuit
All safety and control elements needed for the operation in a closed hydraulic circuit are integrated in the travel pump. These are: • High pressure relief valves (440 bar) with integrated boost check valves
Service Training Charge pressu re relief valve
The charge pressure relief valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted value. The charge pressure relief valve is installed in the travel pump and internally connected with the vibration pump.
from the charge pump
pilot oil
Service Training High p ressu re relief valv es, (with b ypass for towin g)
High pressure relief valves are safety elements, which are needed in every hydraulic circuit. These valves limit the pressure in the hydraulic circuit to the value determined by the adjustm ent spring.
1 2
Service Training .
to flow divider from there to the travel mot
3 4
1 2
4
from the travel motors
Service Training Travel mo tor B W 154
The two travel motors are plug-in fixed displacement bent axle motors of series A2FE 32 ccm from Bosch-Rexroth, which drive a travel gear GFT 07 from Bosch Rexroth.
Service Training Travel gear BW 154
Service Training
Service Training
Service Training Flow d ivider BW 154
from or to the travel pump High pressure port B
Service Training On machines of series BW 154 AD/AC with split drums all drum halves or drum halves and wheels or Wheel halves and wheels are driven by own travel motors. These machines are therefore equipped with 4 travel motors. In order to assure that all motors are always supplied with the required oil quantity, a four-fold flow divider is installed between travel pump and travel motors. Flow dividers are used where several consumers have to be hydraulically arranged in parallel mode a nd wherever the use of the consumers requires a differential lock, as it is necessary on rollers of type BW 154. The hydraulic diagram (Fig. 1) shows the flow divider (16) with the integrated secondary pressure relief and boost check valves. Here four travel gears (23) for drum or wheel drive (AC) are hydrauli cally linked in parallel mode. In order to avoid that a motor of any drum half will start to spin, the installation of a ”differe ntial lock” is necessary. To be able to understand the function of a 4-fold flow divider MH4FA one should first examine the function of a 2-fold flow divider based on the constant orifice principle:
Service Training The control piston of the flow divider is fitted with measuring orifices. Since the diameter of the orifice bore remains of identical size and does not change during operation, these orifices are called constant orifices. During operation of the hydraulic system a pressure differential (p) is created at these constant orifices. If the flow rate at the two consumer ports (1 and 2) is of identical size, the pressure difference p1 = pressure difference p2 and the control piston is centred in middle position. If the pressure differential p between inflowing and outflowing oil is bigger on one side, the piston will be forced in this direction. During this process the cross section of the discharge orifice for this outle t is decreased, the discharged oil flow is throttled. This restriction of flow volume to the corresponding consumer is maintained, unt il an equilibrium of the pressure differentials returns the control piston to middle position and the discharge nozzles have identical cross sections again. In this case the division ratio is determined by the opening cross sections of the discharge orifices. The division accuracy depends on the accuracy of the measuring orifices, the spring rate and the friction of the piston in the housing. With low pressure differentials the division accuracy is quite low, i.e. at low flow volumes the flow divider works quite inaccurate. If the volume flow increases and with it also the pressure differential at the constant measuring orifices, the division accuracy will also enhance. Higher pressure differentials at the orifices result in a higher energy conversion. Hydraulic energy is converted to heat energy. The influence of the spring has thereby not yet taken into account.
Service Training
Service Training
Fig. 4
Principle sketch of a four-fold flow divider
If the flow rates are identical on all consumer ports, all control edges are open. If the pressure drops in one of the consumer lines (e.g. ”C”), this is a sign that a higher flow volume flows to this consumer. The related control edge on the control piston moves towards closing, thereby trying to compensate this
Service Training Design and function of MH4FA
The flow divider consists mainly of housing (1), single edge control pi ston (2), sleeve (3), pressure spring (10) and piston (11).
Service Training Since the single edge control pistons (2) only start to regulate after a certain pressure differential is reached, the wheels or drum halves will not start to spin, the machine is maintained in a manoeuvrable condition. The flow divider used in the machine types BW 154 works like a differential lock. Due to this type of operation a lack of oil in the consumer lines may occur when driving around curves. This would obviously cause cavitation, or, in case of sudden reversing operations, pressure peaks in the system. In order to avoid this and resulting damage each consumer port is fitted with a secondary pressure relief and boost check valve.
Service Training Trouble shooting flow divid er
If a malfunction in the travel system is detected during ope ration of the machine, the function of the flow divider can be tested by jacking the complete machine up (all drums must be able to rotate freely). If the drums rotate with strongly different speeds at full engine speed and maximum travel speed (slight speed differences can be caused by resistances in bearings and between the drum halves), the flow divider must be replaced.
Service Training Test and adjustment poin ts Travel pum p
10
9 5
4
3 6
2 8
1 7
Service Training Travel mo tor w ith travel gear
7 1
6 4
3
1
2
4
2
3 5
2
5
Service Training Flow div ider
1
Service Training Trouble shooting The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults. The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.
Service Training
TROUBLE SHOOTING TRAVEL DRIVE BW 154- 4
) e s r e v e r
' l a r t u e y N d l ' n n a o i n d d r n r e a i o e v t e h w r c l c a o e r l f e e ( i r v l d a t g n e e r o i v n t n t a a r o h s e t t i i h t t o w d r o e n l s l s e e v e e p o S s e v v s l i M o a a o
Service Training Vibration The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit. The main components of this circuit are • vibration pump, • vibration motors • vibration shut-off valve to shut off both vibration motors • and the pressure resistant hydraulic hoses. Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the diesel engine. When operating a 4/3 way solenoid valve, pilot oil is guided to one of the control piston sides. This actuates the pump from neutral position to one of the two possible maximum displacement positions. If the vibration shut-off valve is not activated the pump now pumps oil to the vibration motors, which are connected in series mode. When changing the swashing angle through the neutral position to the opposite side, the flow direction
Service Training r o t o m l e v a r t t n o r f t r o p l i o k a e l m o r f
t r o p e r u s s e r p e g r a h
8 1
9 1
k n a t o t
r g t r t o n o o i p h l m s i l u o e l f k v s a a s r e l t o r r m a C o r e r f
8
9
7
e n n e d d o u i o u i t t i t t l i a r a r l p p b i b m m v i v r a a t e r r o n o t v t a w h g l o o e o r o i a f r l h v m , , , , f m n e e e e n e v l v l v l v i o l l i o i t a a a a e t r a a v v v v r r e b d i d i d i d i r b i v o o o o u i v s r t n n n n
Service Training Vibration pum p
The vibration pump is a swash plate operated axial piston pump with variable displacement of type A10 VG 45 EZ from Hydromatik. The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit. These are: • servo control • High pressure relief valves with integrated boost check valves • Pressure override T2: Connection to travel pump T1: to tank 3 to / from Vibration shut-off valve 4
1 2
Service Training 3
2
4
1
9
8
7
6
5
Service Training Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction (direction of oil flow). A 4/3-way valve guides guid es this pilot oil to the corresponding control piston side in the servo control. Due to the use of a remote rem ote control (electrically operated via solenoids) solen oids) the pump can only be actuated from neutral to one of the two possible maximum displacement positions. In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way valve pilot oil (from the charge circuit) is directed to one of th e control piston sides and moves the control piston to the corresponding direction. The pump swashes to the adjusted maximum displacement. When changing the swashing angle through the neutral position to the opposite side, the flow direction of the oil and the sense of rotation of the exciter shaft will change. The displacements to both pumping directions have different adjustments. This results in different speeds of the vibration motor to both travel directions. This means: • High displac displacemen ementt – high speed speed (fre (frequen quency) cy).. • Low displac displacemen ementt – low speed speed (fre (frequen quency) cy).. The position of the change-over valves depends on the sense of rotation of the exciter shaft. The
Service Training High pr essur e relief valves 1 2
8
3*
4
6
5
Service Training Control
The control is part of the pump and consists mainly main ly of the 4/3-way solenoid valve, the control piston and an d the swash plate with swashing lever. If one of the two magnets is energized by actuating the frequency selector switch and the vibration control switch, the 4/3 way solenoid valve is switched to open position. Pilot oil flows now to the corresponding control piston side. The control piston slides to the corresponding direction and moves the swash plate via the swashing lever. The pump delivers oil.
1
6 2
5
Service Training Vib Vibrat ration ion mo motor tor s
The vibration motors are fixed displacement displacemen t axial piston motors of bent axle design, type A4 FM 22, from Hydromatik. These motors are designed for two directions of rotation and can therefore subjected to pressure from both sides. The pressure oil provided by the pump flows through the kidney shaped control slots in the valve plate into the cylinder block with the working pistons. The pressure oil causes a stroking movement of the working pistons. Due to the swash plate design this axial movement of the pistons is converted to a radial movement of the motor drive. The output shaft transfers this rotary movement via an elastic Bowex coupling to the exciter shaft with the two eccentric weights. 2 1
3
4
5
6
7
8
Service Training Vibration shut-off valve
Charge pressure
Leak oil from front travel m
1
from/to vibration pump
Service Training Flushing valve
The housing of the vibration shut-off valve contains a flushing valve. The flushing valve is connected with both sides of the closed circuit. When the vibration is switched on the high pressure side of the closed circuit moves the flushing piston and opens a discharge channel for oil from the low pressure side. Oil flows now from the low pressure side back to the tank. This oil is immediately replaced by fresh, cooled and filtered oil from the charge circuit. The flushing quantity is limited by the orifice or nozzle with a bore of (d=2mm). If the flow direction of the oil changes (when changing the vib ration frequency), the flushing valve shifts to the other side and opens the discharge channel for the opposite side of the closed circuit (now low pressure side). If the vibration is not operated the flushing spool is centred in neutral position by two pressure springs. The flushing valve has the function to maintain the temperature in the hydraulic system at a permissible level.
Service Training Drum BW 141 AD-4
13
12
10 7
8
4
53
52
12
10
13
7
8
9
6
2
Service Training Drum BW 154 AD-4
13
13
12
12 13
5
8
10 4
3
5
2
15
10
12
14
7 8
7
11
6 2
3
6
4
11 11
9
Service Training Exciter weights 1
4 5
2
Service Training Test and adjustment points Vibration pump
5
4
1
Service Training Vibration pump
4 2
3
5
Service Training Vibration shut-off valve
1
2
1 5
2 3
5
4
3 4
Service Training Vibration mo tor fro nt/rear
1
2
3
4
4
2
2
3
2
5
1
Service Training Trouble shooting The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults. The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.
Service Training
TROUBLE SHOOTING VIBRATION BW 141-4-FAMILY
f f o d e h c t i r w a s e r e b d ) t n a K o t n O n n o e r r e a f u d c u n d s t s l i o e i e e r p t p p m a r s t e a b i f g a r n v h a i o r s h t a c a e r S ( r r e
Service Training Steering The machines described in this manual are equipped with a hydraulically operated articulated steering.
12
to charging
Service Training The steering system consists mainly of: • the steering/charge pump (1st pump of tandem gear pump), • the priority valve, • the steering valve, • the steering cylinders and • the pressure resistant connecting hoses As the steering pump also supplies the hydraulic oil for the charge circuit for travel and vibration drives as well as the crab walk facility besides the steering, the system is equipped with a priority valve. The priority valve ensures that the steering will always be prioritized under any condition. The priority valve is triggered by the steering valve through the LS-line. This valve restricts the oil flow to charge circuit and crab-walk whenever oil is needed for the steering. However, this does not mean that in such a case there would be a lack of oil for the charge circuit, because the return flow from the steering is directly fed into the charge circuit. The steering pump supplies the hydraulic oil from the hydraulic oil tank through the pressure filter to the priority valve. If the steering is not operated, the complete oil flow will flow through the crab walk valve to the charge ports for the travel and vibration circuits.
Service Training Steering pump The steering/charge pump is a tandem gear pump with fixed displacement. Pump section 1, which is directly mounted to the engine (11 ccm), supplies the steering and the crab-walk valve, the second pump unit (8 ccm) serves the fan motor. After serving the above mentioned functions both pump flows are united for the charge oil supply. The tandem pump is driven by the auxiliary drive of the diesel engine and draws the hydraulic oil directly out of the oil tank. The oil then flows through a pressure filter to the priority valve, the steering valve or the crab walk valve or the blower motor, and from there to the charge circuit. 9
9
6
1
9
3 8 2
7
Service Training Priority valve Since the pressure oil from the steering pump is also needed for the working hydraulics, i.e. the crab walk valve, the machine is fitted with a priority valve. This valve ensures that the steering will always be prioritized under any condition. The priority valve guides the oil to the following consumers: • to the steering valve (port CF) • to the crab-walk valve and from there to the charge circuit (port EF)
Service Training Steering valve The steering valve consists mainly of: • the distributor valve, • the rating pump, • the steering pressure relief valve and • the shock valves. 1 2 9
3
4
Service Training When turning the steering wheel the oil flow from the pump is guided through the distributor valve to the rating pump and from there to the respective sides of the steering cylinders. The rating pump determines the exact oil quantity in dependence on the turning angle of the steering wheel. The high pressure relief valve in the steering unit limits the pressure in the steering system to 170 bar + charge pressure. The steering unit is equipped with so-called shock valves for both pressure sides to the steering cylinder. These valves are adjusted to 235 bar. They compensate extreme pressure peaks, which can be introduced from outside, e.g. when driving over obstacles. The system is thereby protected against overloads. Each of these shock valves is fitted with an additional anti -cavitation valve. These anti-cavitation valves protect the system against cavitation which could be caused by the reaction of the shock valves. A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump if forces are introduced from outside. In such a case the steering cylinders would act as pumps and press the oil back to the pump. Note This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min) will
Service Training The machines are equipped with two steering wheels. However, the machines are fitted with only one steering valve, which is arranged between the steering wheels. Two circulating chains connect both steering wheels with the steering valve.
Service Training Articulated joint The articulated joint is the connection between front and rear frames.
Service Training
Service Training Articulated joint
Service Training Test and adjustment points
3 1
2
4 2
1
Service Training Steering valve
2
3 9 5
6 4
3
4 5
2
1
Service Training Priority valve
1
4
3 2
1
2
Service Training Trouble shooting: The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults. The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.
Service Training
TROUBLE SHOOTING STEERING BW 141-4 FAMILY
w o
Service Training Working hydraulics - crab walk and optional equipment
12
y18
y19
13
y20
y21
to charging
Service Training Crab-walk valve The crab walk facility enables lateral offsetting of the front frame to the rear frame. The max. offset value is approx. 170 mm. This offset between front and rear frame is of great help when pressing edges and cornering along curb stones. The crab-walk control valve consists of the actual electro-magnetically operated valve, the 160 bar (pressure differential) pressure relief valve and the two unlockable non-return valves (pressure retaining valves).
12
Service Training Test and adjustment points
3
1
2
Service Training Proximity switch The proximity switch indicates the position of the crab walk, i.e. middle position front frame to rear frame.
1
Service Training Crab-walk valve
4 1
3
2
1 2
Service Training Crab-walk cylinder
1
Service Training
Trouble shooting The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults. The numerical values specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience:
Service Training
TROUBLE SHOOTING BW 141-4 FAMILY
e v o m o t d r a h / n d o e i t h c e c a v n u n e r o f o t t i t o m u c n o o t n
Service Training Blower drive On the new articulated tandem rollers of series 4 the external blower is hydraulically driven
Check valve or anti-cavitation valve
to charging
to the priority valve, Steering
Service Training Blower motor The blower motor is an 8ccm gear motor with a pressure relief valve flange mounted on the motor inlet side P. The blower speed is identical with the diesel engine speed (when the pressure relief valve is not active), because the displacements of pump (8 ccm) and motor (8 ccm) are identical.
Service Training Test and adjustment points
3 1
2 2
1
Service Training Blower motor
2 1
2
P
1
Service Training Return flow block with thermostat valve
4 2 3 1 1 1
1 1
Service Training Trouble shooting The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past. Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults. The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.
Service Training Water sprinkling system The new articulated tandem rollers of series 4 are equipped with two independently working water pumps. Both pumps can be operated as desired. These water pumps are direct controlled diaphragm pumps, solenoid valves are therefore not required. The water filter is located behind the water tank cover or water pump suction port, at the lowest position of the water tank. The water sprinkler system is controlled by means of the travel lever monitoring and water sprinkler module A03
2 1
Service Training Circuit diagram, water sprinkler system
Service Training AC-Variants: BW 141 - 154 AC-4 On the machines described in this training manual the travel system consists of a closed hydraulic circuit. It mainly consists of travel pump with integrated safety elements and travel motors with travel gears. The AC wheel set is equipped with radial piston travel motors.
e v l a v e k a r b m o r f
e v l a v e k a r b m o r f
3 2
5
2 2
6
l i o g n i h s u l f h t i w l i o k
Service Training Travel mo tors o f the AC wh eel set
The two travel motors in the AC wheel set are radial piston motors
from / to travel pump
from brake valve
from / to travel pump
Service Training Travel motor Poclain MS 08 The AC wheel set is driven by a hydraulic radial piston motor. These travel motors consist of three housing parts, the flat distributor, the cylinder block with the working pistons and the output shaft. 2
3
4 1
Service Training The housing consists of: • bearing section (drive shaft bearings), • torque section (cam race) and • oil distributor. Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure oil presses the working pistons with the rollers against the cam race of the torque section and forces the rollers to roll along the cam race. This transforms the axial movement of the pistons to a radial movement of the cylinder block. The cylinder block transfers this rotation via a splined connection to the output shaft. The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc and the rubber elements to the drum. The function of the radial piston motor is described hereunder. The piston positions described in this explanation can be seen in the related illustration. The movement of a piston along the cam race must be examined in several phases during a full rotation: 5
Service Training Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the roller along the cam and causes a rotation of the cylinder block. Piston position 2:
At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The piston continues his travel along the cam race towards the valley between two cams. As the movement continues the opening cross-section for the oil supply decreases. Piston position 3:
Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first piston out of the dead centre. Piston position 4:
Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now connected with the low pressure side and the reverse movement of the piston presses the oil back to the pump.
Service Training Test and adjustment poin ts
Service Training Travel system
5
6 2
1 1
3 2
4
Service Training AC sprink ler system Emulsion tank
3
1
Service Training Emulsion pump
1 3
2 4
Service Training Electrics This chapter describes all special features of the electrical system.
Function test:
Turn the ignition key to "Ignition ON". • The round gauge runs a 3 second self test. • All control lights are active during this time. • The fuel level gauge shows the actual fuel level. • Brake control light (travel lever in braking position), charge control light (engine stopped) and oil pressure warning light (engine off) are active.
Warning and control lights are integrated in the instrument cluster!
Service Training Seat contact switch
All machines are equipped with a seat contact circuit. The following applies in general:
When the seat is not occupied it can be assumed that in the worst case the machine may perform uncontrolled movements. In such an instance the machine must be shut down at the latest after 4 seconds. During these 4 seconds the driver must be warned about this conditio n by the warning buzzer in the dashboard and the area around the machine by the backup alarm. To start travel movement of the machine the driver's seat must be occupied, as otherwise the diesel engine will be shut down immediately. This prevents the machine from being started from the outside (e.g. through the open window). 1.
Starting of the engine should only be possible with the travel lever in position "Brake".
2.
Driver standing (seat contact control light does not light up): While the engine is running shift the travel lever to travel operation --- then engine shut be shut down immediately, the seat contact light lights up, warning buzzer and backup alarm sound. If the travel lever is returned to "Brake" position during the shut-down process, the fuel solenoid is switched on again and the engine will automatically start. Otherwise the engine must be restarted.
3.
Driver seated: (seat contact control light does not light up): Normal operation, no warning active. Driver gets up --- control light comes on and both warning buzzers sound. Driver sits down again
Service Training Seat contact switch
1
Service Training Brake switch and angle sensor
2
Service Training Instrument clustere
Service Training Module description Seat occupation monitoring A68 • controls the • Brake control via the proximity switch • Seat contact switch • Engine oil pressure monitoring
Travel lever monitoring A03 • controls the • Travel lever position via the angle sensor • Vibration automatic • Water sprinkling system
Beschreibung UPF04 Travel Lever Monitoring Module / A03 920 225 17
Version history
Table of Contents 1
Version history....................................................................................................3
2
Description of hardware.....................................................................................4 2.1 2.2 2.3
3
Description of function.......................................................................................6 3.1 3.2 3.3 3.4 3.5 3.6
4
Pin assignment digital inputs................................................................................................4 Pin assignment analog inputs...............................................................................................4 Pin assignment outputs.........................................................................................................4 Switching off ...........................................................................................................................6 Travel lever adjustment and neutral position......................................................................6 Constant voltage monitoring.................................................................................................7 Defect on angle sensor ..........................................................................................................7 Vibration control.....................................................................................................................7 Water sprinkling control ......................................................................................................10
Version history for software ............................................................................13
Version history
0
Version history No. Version 1 1.0 2 3 4
Date 18.11.04
Description of version 1. Version created. Description taken from 920 225 01 and changed accordingly.
Resp. Hehner
Description of hardware
1
Description of hardware
The inputs are designed in such a way, that the following table is valid: In p u t
1.1
Per fo rm an c e Rem ark
Input PIN12
HIGH-active
LED lights when applying positive voltage!
Input PIN13
LOW-active
LED lights when applying ground potential!
Input PIN14
HIGH-active
LED lights when applying positive voltage!
Input PIN15
HIGH-active
LED lights when applying positive voltage!
Input PIN16
HIGH-active
LED lights when applying positive voltage!
Pin assignment digital inputs
Signal Name
Module Pin
Switch travel stage
12
Button vibration on
13
Switch position vibration manual
14
Description HIGH LOW LOW HIGH HIGH LOW
= Travel stage fast, = Travel stage slow = Moment. contact funct. = Normal status = manual vibr. nominal on l vib mi l off
LED on LED off LED on LED off LED on LED off
Description of hardware
The hardware is available under BOMAG part-no.: 959 223 13.
Description of function
2 2.1
Description of function Switching off
If operating voltage is applied to the module (PIN1/2 U B, PIN10/11 ground), LED1 will light as a control light. LED 2 flashes as Stay-Alive-Indicator, but with a flashing frequency which depends on the current on input PIN 8 (analogue input 1). The reaction of the module with sufficient supply voltage (higher than 9.5 Volt) is as follows:
Description of function LED2 thereby serves as an adjustment aid. If the flashing frequency increases while turning, the direction of turning is wrong. If it flashes in intervals of a second the adjustment is close to the desired neutral position. If LED2 is flashing in intervals of a second and LED3 lights permanently, the sensor must be fastened in this position. In order to check the setting, the travel lever iss et to parking position and moved from there back and forth as far as mechanically possible. The LED on PIN 4 output Start Interlock should not light up. Otherwise the adjustment must be repeated. 2.3
Constant voltage monitoring
The flashing frequency of LED 2 indicates whether the output voltage of 8.5 V on PIN 9 is outside the permissible tolerance. If this voltage is not high enough, the angle sensor will not work correctly and the output signal of the sensor is undefined. For this reason the flashing frequency of LED2 is set to 80 Hz and LED3 is switched on, if the voltage is too low. At the same time output PIN3 is applied to ground, irrespective of the input signal at analog input 1 (PIN8) (LED on PIN3 is off), to enable starting of the machine also with low battery voltage. This always happens with a low voltage level on PIN9, which may be caused by a low supply voltage of the overall module (with U B < 9,5V the voltage of 8,5V on PIN9 can no longer be maintained) or by a defect. Since the status of insufficient voltage is in any case passed through when starting (in the moment of starting), LED2 and LED3 light up briefly, until the voltage is stable. The complete module works from a minimum voltage of U B = 6,5V. However, the analogue inputs only work from a supply voltage of 9,5 Volt, since the sensor supply voltage of 8,5V can only be generated if this input voltage is available.
Description of function
2.5.1 Manual vibration If positive voltage (e.g. through a throw-over switch) is applied to PIN 14 ( manual vibration on), vibration can be switched on via button input (v ibration on) on PIN 13, irrespective of the travel lever. Vibration is always switched on or off when a clear ground potential is detected on Pin 13. However, no voltage must be applied to PIN 15 ( chip spreader on) (the LED on PIN 15 must not light), since vibration may only be switched on with the chip spreader switched off! If vibration is switched on, the LED on PIN5 lights up. If manual vibration (voltage on PIN14) is switched off or the vibration button is actuated again, vibration is switched off. In tr avel stages 1+2 vibration can at aby time be switched on with the vibration push button
Description of function 2.5.2 Automatic vibration control If a positive voltage is applied to PIN16 ( automatic vibration on ) the LED on PIN16 lights up and vibration (PIN 5) is switched on and off in dependence on the travel lever position, but only as long as no voltage is applied to input PIN15 ( chip spreader ) (LED on PIN15 off). In automatic mode vibration comes ON in speed ranges 1 + 2 at approx. >1km/h. Automatic shut-down is not available.
Description of function 2.6
Water sprinkling control
The sprinkler intervals are controlled by connection of a 12-stage switch to PIN 7. This switch switches resistors in 500 Ω-steps from 500 Ω to 6 kΩ. As the angle sensor, the switch is supplied by the internal 8.5 V power supply and an evaluation only takes place if this supply voltage is supplied free of faults (in case of supply faults the last valid value or the start value 50% Dutycycle is used). 2.6.1 Sprinkling stages
Description of function If no switch is connected ort he voltage measuring value is outside the permissible voltage range, the cycle is et to 50% Dutycycle (meaning that the sprinkler system is switched on für 7.5s and off for 7.5s).
Fig. 6: Disconnecting the sprinkler switch
Description of function
Fig. 7: Example: water sprinkling at standstill
Version history for software
3
Version history for software
__________________________________________________________________________ ____________________ Version management: BOMAG Travel lever position monitoring BW 161/202 Module: BM UPF4 Controller: PIC16F876 __________________________________________________________________________ Version 1.0 from 18.05.2004: ---------------------------Checksum: c4cc Taken over from 920 225 01 Changed: Vibration is switched on via travel lever in travel ranges 1 + 2 at a speed >1.3km/h. Another vibration shut down at a speed >8km/h is not available.
Description UPM1 Sprinkling System Module BW141AC-4 / A04
Version history
1
Version history ................................................................................................... 3
2
Description of hardware .................................................................................... 4 2.1 2.2 2.3
3
Description of function ...................................................................................... 6 3.1
4
Pin assignment digital inputs............................................................................................... 4 Pin assignment analog inputs.............................................................................................. 4 Pin assignment outputs........................................................................................................ 4 Sprinkling cycles, total overview ......................................................................................... 6
Version history for software.............................................................................. 7
Version history
0
Version history No. 1 2
Version 1.0 1.1
Date 10.02.04 25.03.04
Description of version 1. Version created Changes introduced
resp. Hehner Hehner
Description of hardware
1
Description of hardware
The inputs are designed in such a way, that the following table is valid: In p u t
1.1
Perfo r m an c e Rem ar k
Input PIN1
LOW-active
LED lights when applying ground potential!
Input PIN2
LOW-active
LED lights when applying ground potential!
Input PIN3
HIGH-active
LED lights when applying positive voltage!
Input PIN4
HIGH-active
LED lights when applying positive voltage!
Pin assignment digital inputs
Signal Name Emulsion switch
Module Pin 13
Mass bridge (optional)
2
Not used
3
Description Active-LOW = emulsion cycle nominal ON HIGH = Emulsion cycle nominal OFF Active-LOW = sprinkling cycle 3/12 HIGH = Sprinkling cycle 5/20 Active-HIGH = LOW =
LED on LED off LED on LED off LED on LED off
Description of hardware
The hardware is available under BOMAG part-no.: 057 644 39.
PIN 13 RS2 32
2 D E L
2 3 5 D E L
4 3 D D E E L L
1 D E L
4 6 OUT OUT +
+
-
30 6
4
3
2
13
87 87a
30
15/45
Signal IN (Active LOW) IN (Active LOW ) IN (Active HIGH) IN (Active HIGH) OUT (BTS) PWM PWM + Relay – Contact Relay – Contact Relay – Contact Supply voltage Ground
Description Emulsion switch Optional (mass bridge) not used not used OUT 15/54, 11A
IN 12V, 15 A Normally open Normally closed 10-39 V
Description of function
2
Description of function
In the UPM2 software the following sequences were introduced to realize the sprinkling cycles.
2.1
Sprinkling cycles, total overview
In order to realize a switching interval for emulsion sprinkling the system uses input (PIN 13), output (PIN 6) and the relay of the module. Activation of the emulsion sprinkling system takes place with the ground signal on input PIN13. If an additional ground signal (bridge) is applied to the input (PIN 2), the interval time is changed to the following values: Pulse time
Pause time
3 seconds
12 seconds
Without mass bridge on PIN 2 5 seconds
20 seconds
With mass bridge on PIN 2
As long as the emulsion sprinkling system is ACTIVE (ground signal on PIN 13), output PIN 6 (LED 5) and relay (LED 6) are set cyclically ON in intervals for 5 (3) seconds and OFF in intervals 20 (12) seconds. During an OFF-phase the emulsion sprinkling system can be triggered by switching the input
Version history for software
3
Version history for software
Version management: BOMAG Water sprinkling module 538 380 01 Module: BM UPM1 Controller: PIC16F84a
Version 1.00 from 10.01.2004: ---------------------------Checksum: ba0c 1. Version created.
Beschreibung UPM03
Version history
1 2
Version history....................................................................................................3 Description of hardware.....................................................................................4 2.1 2.2 2.3
3
Description of function.......................................................................................6 3.1 3.2 3.3 3.4
4
Pin assignment for inputs .....................................................................................................4 Pin assignment outputs.........................................................................................................4 Emergency operation .............................................................................................................5 Switching off ...........................................................................................................................6 Engine start .............................................................................................................................8 Driving the machine ...............................................................................................................9 Motor protection ...................................................................................................................11
Version history for software ............................................................................12
Version history
0
Version history No. Version 1 1.0 2 1.01
Date 22.08.02 05.12.02
3
05.06.03
1.1
Description of version 1. Version created Software change (start release only via brake switch) Launch of software change in the areas of seat contact control, engine shut-down warning in series production
resp. Kochhan Kochhan Fondel
Description of hardware
1
Description of hardware
The module for seat contact monitoring consists of the modified UPM2-module. The inputs are designed in such a way, that the following table is valid: In p u t
Perfo r m an c e Rem ar k
Input PIN11
HIGH-active
LED lights when applying operating voltage (+UB)!
Input PIN12
HIGH-active
LED lights when applying operating voltage (+UB)!
Input PIN13
LOW-active
LED lights when applying ground potential (0V)!
Input PIN14
HIGH-active
LED lights when applying operating voltage (+UB)!
Input PIN15
HIGH-active
LED lights when applying operating voltage (+UB)!
1.1
Pin assignment for inputs
Signal Name
Module Pin
Seat contact switch
11
Travel lever
12
Signal on input +UB = Driver seated, 0V = Driver standing, +UB = out of neutral, roller driving, 0V = 0-position, roller stopped
LED on LED off LED on LED off
Description of hardware The hardware is available under BOMAG part-no.: 057 667 68.
Description of function
2 2.1
Description of function Switching off
If operating voltage is applied to the module, both the version number and the revision number are first of all indicated by the flashing Stay-Alive-LED (currently 1.02). After this the Stay-Alive-LED Stay-Alive-LED flashes in one second intervals.
Description of function
Description of function 2.2
Engine start
If starting of the engine is detected by the D+ signal (LED on PIN 14 is on), the pickup winding of the shut-down solenoid is additionally switched switched on for another 2 seconds (the LED on PIN4 comes on for this time). The brake valve is now switched in dependence on input PIN 15 (Brake Switch). If the brake switch is closed (LED on PIN 15 lights), the brake valve is closed (LED on PIN 5 is off), the brake closes and the Brake signal light comes on (LED on PIN 6 lights). If I f the switch is open (LED off), the t he brake valve is opened (LED on PIN 5 lights) and the signal light goes out (LED on PIN 6 off). If no D+ is detected, the brake is closed, irrespective of input PIN 15!
Description of function If the travel control lever is actuated with the engine running (D+ on PIN 14, LED lights) while the driver is not seated (LED on PIN 11 is off), PIN 8 Holding Winding is energized (LED on) and the engine stops immediately.
Description of function
Description of function 2.4
Motor protection
If too low oil pressure is detected (ground signal on PIN 13, LED on PIN 13 lights) while D+ is applied (LED on PIN 14 lights), the engine is shut down after approx. 12 seconds.
Fig. 7: Behaviour with too low oil level
Version history for software
3
Version history for software
_________________________________________________________________________ Version management: BOMAG Seat Monitoring for Bw161/202 Module: BMUPM 3 Controller: PIC16F84A __________________________________________________________________________ Version 1.01 from 10.05.2002: ---------------------------Checksum: 671C 1. Version created. Version 1.02 from 14.05.2002: ---------------------------Checksum: 76D2 2. Version created without oil pressure monitoring. Checksum: D089 1. Version created with oil pressure monitoring. Change-over via Define before Compilation! Version 1.02a dated 20.06.2002: ---------------------------Checksum: 816A
Beschreibung UPM03 Vibration Interlocking Module / A71 920 225 02
Version history
Table of contents 1
Version history....................................................................................................3
2
Description of hardware.....................................................................................4 2.1 2.2 2.3
3
Description of function.......................................................................................6 3.1 3.2 3.3
4
Pin assignment for inputs .....................................................................................................4 Pin assignment outputs.........................................................................................................4 Emergency operation .............................................................................................................5 Switching off ...........................................................................................................................6 Switching the vibration on.....................................................................................................6 Switching on the chip spreader ............................................................................................8
Version history for software ............................................................................10
Version history
0
Version history No. Version 1 1.0 2 1.02
Date 30.08.02 08.10.03
3
01.04.04
1.02
Description of version 1. Version created Fault on vibration signal output „Front Vibration“ for Variomatic eliminated. Logics adapted accordingly. Comments added. Changes in the function description implemented
resp. Kochhan Fondel Hehner
Description of hardware
1
Description of hardware
The module for vibration interlock consists of the modified UPM2-module. The inputs are designed in such a way, that the following table is valid: In p u t
1.1
Per fo rm an c e Rem ark
Input PIN11
HIGH-active
LED lights when applying positive voltage!
Input PIN12
HIGH-active
LED lights when applying positive voltage!
Input PIN13
LOW-active
LED lights when applying ground potential!
Input PIN14
HIGH-active
LED lights when applying positive voltage!
Input PIN15
HIGH-active
LED lights when applying positive voltage!
Pin assignment for inputs
Signal Name
Switch rear vibration
Module Pin
11
Description HIGH = Vibration nominal on, LOW = Vibration nominal off
LED on LED off
Description of hardware
The hardware is available under BOMAG part-no.: 057 667 68.
Description of function
2 2.1
Description of function Switching off
If operating voltage is applied to the module, both the version number and the revision number are first of all indicated by the flashing Stay-Alive-LED (currently 1.02). After this the Stay-Alive-LED flashes in one second intervals.
Description of function Switching between these inputs only leads to changes on the outputs, if the input PIN 12 „Vibration Activation Switch“ is switched off (LED on PIN 12 off)!
Einsc halten Vibration
Betriebsphase 1 PIN: +UB
1
PIN: 12 Vibrationseinschalter
PIN: 14 Vibration ein Vorne **
PIN:
11
2
3
4
5
6
7
8
9
10 11 12
Spannung ein
LED an
Spannung aus
LED aus
Vibration soll ein
LED an
Vibration soll aus
LED aus
Auswahl ein
LED an
Auswahl aus
LED aus
Auswahl ein
LED an
Description of function 2.3
Switching on the chip spreader
The chip spreader can only be switched on if the vibration is switched off (input on PIN 12 “Switch on Chip Spreader” open, LED on PIN 12 is off). If this condition is fulfilled, the chip spreader can be switched on (LED on, voltage applied to input PIN 15) or off (LED off, no voltage applied to input PIN 15), in dependence on input PIN 15 „Chip Spreader On“. If vehicle voltage is switched to PIN 15 (LED lights), PIN 7 will drop dead immediately (LED on PIN 7 goes out) and PIN 6 („Chip Spreader Valve “) is switched on (LED on PIN 6 goes out). PIN 5 „Chip Spreader On“ (LED On) can be switched on via momentary contact switch PIN 13 „Momentary Contact Switch Chip Spreader“ only 2 seconds after these outputs had been switched. If the switch is actuated before these 2 seconds have expired, PIN 5 will automatically be switched on after these 2 seconds. If the switch is actuated again, PIN 5 is switched off (LED off). The next actuation switches it on again, etc. However, if the „ Actuator Chip Spreader On“ on PIN 15 is switched off (LED off), PIN 5 is immediately deenergized (LED off). After 2 seconds PIN 7 „ Vibration Valve Rear “ switched on (LED on) is switched on, and PIN 6 „ Chip Spreader Valve “ is switched off (LED off).
Einsc halten Splittstreuer
Betriebsphase 1 PIN: 15 Splittstreuer ein Einschalter
Auswahl ein
2
3
4
5
6
7
8
9
10 11 12 LED an
Description of function If the chip spreader is switched off, the system waits approx. another 2 seconds, before the vibration can be switched on again. This also means that, if the vibration is switched on before the chip spreader has been switched off, it will take at least 4 seconds until the vibration will start.
Version history for software
3
Version history for software
__________________________________________________________________________ ____________________ Version management: BOMAG Vibration interlock for BW 161/202 Module: BM UPM 3 Controller: PIC16F84 __________________________________________________________________________ ____________________ Version 1.01 from 20.06.2002: ---------------------------Checksum: 4E60 1. Version created. Version 1.01 from 13.08.2002: ---------------------------Checksum: 420B Momentary contact switch for chip spreader supplemented Version 1.01b dated 19.08.2002: ---------------------------Checksum: 9F34
Inhaltsverzeichnis: table of contents: Blatt Nr.: sheet no.: 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 019 020 101
BW 141−4 ....... BW 203−4 BW 141−4 ....... BW 203−4
Zeichnungsnummer drawing − no. 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04 920 100 04
Funktionsgruppe
function unit
Stromlaufplan Versorgung, Starten, Steckdose Bremse, Sitzkontakt, Not−Aus Überwachung, Warnsummer Berieselung, Kantenschneidgerät Drehzahlverstellung Motor, Signalhorn Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) Asphalt Manager, Evib−Meter, Temperatur Asphalt Drucker, BCM 05, GPS Tachograph Geschwindigkeitsanzeige Heizung, Klimaanlage Kabine Kabine Arbeitsscheinwerfer ROPS Hundegang
Circuit Diagram supply, starting unit, socket brake, seat contact, emergency off monitoring unit, warning buzzer sprinkler system, edge cutter motor speed, warning horn illumination, working light (StVZO) vibration, warning buzzer, chip spreader, speed selection asphalt manager, Evib−meter, temperature asphalt printer, BCM 05, GPS tachograph speedometer heating, air conditioning cab cab worklamp RORS crab walk
Elektrokasten Elektrokasten Bauteilliste
cross−bonding box cross−bonding box component listing
Vibration,Fahrstufenumsch.,Rückfahrwarns., Splittstreuer
X2:3−1 X2:1−1
X2:1−2
X2:2−1 X2:5−1
F01 Sicherung fuse
F105 6:1 F37 5:2
X2:6−1 X2:4−1
F93 9:2 30 7:6
X2:7−1
P0123
B : 9 8 X
A : 9 8 X
S00 X91:A
30 X13:A P01
K11 2:19 87
Zündstartschalter ignition switch
K30 10:1
F05 Sicherung fuse
X2:2−2
15 54 58
1917
15 3:1 2 1
X2:9−1 Sicherung fuse X2:9−2
F00 Sicherung Battrie fuse, battery
87a
50a
2 X13:B
X2:3−2
30
X1:10
X13:C
K11 6:1
F119 F119 2:13
2:12 F119
F119
X2:23−1 V01 option BW161−4 ...202−4 F15 Sicherung fuse 125A
+ G01
S30
86 K62 85
K08 2:14
2:3
X51:C
B+
W G02 Generator generator B−
X91:B
P00 Betriebsstundenzähler operating hour meter
D+
B+
X14:A X6:−
30
K31 10:17
1
50
Y01
2
Y01
2:11 X6:+
X6:+
4:7
H52
87a
A13 6:2
X14:B
X1:206
X1:29
X1:135
X1:103
X6:6
3:13
1
1
BW161−4 ...203−4
Starter starter
BW161...203−4
15(7)
S(2) A13
1 T(4)
−
4:2
30
Y139
M01 R19
Heizflansch heating−flange
X1:104
2 50(5)
3 Batterietrennschalter switch battery disconnect 4
1 R09 2
X1:101
87 (6)
Batterie battery
−
Meldeleuchte Ladekontrolle indicator light, charge control X6:+ 2:14 K05 H08 3:8 X1:27 X6:14 87 2
X2:23−2
2 30 (5)
B+ 2:6
1
6:1
BW141...154−4
R(6) B53 K08 (R)_t
2
86
K11
+
XS 12V
L(1) 85
−
31(3)
1
M− 3:3
BW161...203−4
X1:127
X1:53 31 3:1
Startmehrmenge start boost fuel
Magnetventil Minusabgleich Kontrollampe Glühüberwachung 2:5 solenoid valve boost−fuel indicator light, glow plug Temperatursensor temperature switch Steuergerät Heizflansch controll unit, heating−flange
2:14
Steckdose socket
2:12 15
15 4:1 X2:11−1 Sicherung fuse
X2:10−1 F14
F25
Sicherung fuse
X2:10−2 X1:66
X2:11−2
1
S06
BR/BN
B63
F25 5:1 X23:A
X11:A
Initiator Bremse proximity switch, brake
Sitzkontaktschalter switch, seat contact
2 X23:C
86
4 X23:B X1:67
K22 BL/BU X11:C
SW/BK X11:B
X6:12 +
8
30
) 4 5 / 5 1 ( 1
11
H20
− X6:− 4:15 3:15 X6:− Meldeleuchte Sitzkontakt indicator light drivers seat
12
14 7
A68 Modul Sitzkontakt modul seat contact
15
87a
MD+ 4:1
X1:6
85
X1:65
K22 3:10 87
A03.3 8:5
6
4 X1:8
X1:202 B20 4:10
X1:123 21 Not−Aus−Schalter switch, emergency off
S01 Not−Aus−Schalter switch, emergency off
X1:195
2 V41 (1) 2:20 31
1
1
K05
86
2
X1:137
85
M− 4:9 X1:63
Hubmagnet shut off solenoid, engine
11
21 31
12
22 32
1
Y04 1
2
2
Y04
X1:205
X1:127 2:12
+ Warnsummer warning buzzer +
3:3
H82 −
X6:11 H01
X31:2 X6:− 3:15
BW 161..203−4 X1:137 Bremsventil solenoid valve, brake
X31:1
− 2:11 X6:−
BW 141..154−4
A15
X7:9
V02
30/40Amp
2:18 M−
X6:9
3 1 : 9
X1:47 X1:136
X1:198 Y13
3 : 3
X1:43
22
4 − 4 5 1 . . 1V03 4 1 W B
2
13
) D N G ( 9
8:3
1
(A8) V48
5
S01 3:11
H14
X1:118 Meldeleuchte Bremskontrolle indicator light, brake
X1:53
31 4:1
Überwachungsmodul monitoring module
3:20 15 X2:12−1
X2:13−1
F129 Sicherung fuse
F04 Sicherung fuse
X2:12−2 Meldeleuchte Wasserrestmenge indicator light, water res.
H80
H79
X7:17
X7:15
X1:203
5 5 B
4:8
X7:+ 4:17
2:17 X6:+ H73
H09
4:8
H49
H15
X6:16
X6:17
X1:20
X1:21
X6:15
V42 (A2)
2
87
87a
87
87a X1:128 X27:1
1
3:20 31
MD+ 5:1
X1:92
r g / n B55 g
B33
2 3:20 MD+
X1:97 B21
X1:91
h w / s w
X27:2 X1:127
Kühlmittelvorrat Motor indicator light, eng. coolant res. option
X1:72 X1:44 X7:2
1 2 R
K104 5:10 X1:93
X26:2
X1:94
X1:95
X1:96
2 2 R H70
3 : 6 X 6 9 1 : 1 X
4 : 6 X 7 9 1 : 1 X
p
1
B06
2
P
1 2
B30 B03 p
_t
1 1 2 2
Q
B21
p
0 0 2 : 1 X
1
P01 X7:−
3:16 X6:− X6:− 4:19
2
Wasservorrat water gauge
Tankanzeige level gauge
1
9 9 1 : 1 X
r b / r b
Q P19
X1:23
3:17 B20 30
H38
X6:13
X1:22
X6:2
X7:6
X1:24
X1:34
X1:125 X10:2
X1:185 X10:1
8:14
4:16 X6:− X6:− 7:6
R03
2 B124 X7:10
3:5 M−
2 gn
X7:+ 6:8
H23
1
K62 2:7
4:15 X7:+
0 2 R
5 5 B
X6:5 X1:17
30
X7:20
Meldeleuchte Motorüberhitzung idicator ligh, engine overheating Meldeleuchte Luftfilter indicator light, air cleaner Differenzdruck Hy. idicator ligh, hydr.oil filter
X7:7 X1:19
X6:20
Meldeleuchte Motoröl indicator light, engine oil pressure
H21
X1:54
F04 9:6 X1:71 X26:1 1 br R14 p
X1:57
Meldeleuchte Hydrauliköltemperatur indicator light, hydr.oil temp.
Meldeleuchte Wegfahrsperre indicator light,anti−theft device
Geber Wasserstand sender, water level
X2:13−2
M− 6:11
X10:3 X1:127
X1:53
Meldeleuchte Wasser im Diesel indicator light, water in fuel Wasserabscheider Meldeleuchte reserve Kraftstoff sensor, water seperator fuel indicator light, fuel oil Geber Kraftstofftank sender, level gauge
X6:10 X6:10 8:8 31 5:1
3:20 F25 4:3 MD+
F25 17:1 MD+ 9:1 X2:18−1 Sicherung fuse X2:18−2
F37
2:5
Sicherung fuse F37
X2:7−1 F61
g e n s u f u r e h c i X2:7−2 S
F06 X1:46
X2:6−2
Schalter Berieselungspumpe switch, water pump
4
30
30
K80 5:11 87 87
43
23
33
13
44
24
34
14
23
1 0 2 10
15/54 30
X1:146 X16:1
4 1 : 1 X
8,5VOLT X18:1 +
Intervallschalter interval switch A01
−
8:1
GND
+
M02
M18
−
− X16:2 X1:147
8:3
X18:3
30
1−12
K82 5:18 87
5:8
87a
87a
X9R:6 X1:140
X1:109
X1:111
X1:50 X1:51 13
S108
+ n n o o i i s s r r e M03 e V v − − C − C A A y r l u n n o X15:2
14 X1:52 X1:117 1 Y99
X1:53
2
1 Y20 86 K104
86 K80
85
86
K82
86
2
Y21 2
V14
K79 85
86
1
K83
85
V15
85
85
V29
X1:127
X1:110
X1:112
X1:127
4:20 31 Berieselungspumpe sprinkler pump
f u a t p u ä , r r e t e g t t i u e c n e h g c s d n e e , t n n o t a t K u r b e h t s s a u T p
4
8 0 1 S
87
X1:118
30 K83 5:19 87
b n a w o 4 t d ä , r r e t e g t t i uX9R:4 e c n h e g c d s X1:139 n e e , t n n o t a t K u r b e h t s s a u T p
3 S83
5:8
X15:1
X1:174
X9R:5
3
S82
8 0 1 S
13 A04 Modul Berieselung modul, sprinkler system X1:173
+
X17:2
X9R:3
13
24 14 X1:119 X1:120
X17:1
X1:69
87a
S19
X1:145
7
X18:2
2 1 : 1 X
Emulsionsberieselung emulsion sprinkler
17:1
A03 Modul Vibration modul vibration
X1:124
102 S114 0
K79 5:12 87a
F06
31 Emulsionspumpe emulsion pump
4:5 Magnetventil Berieselung solenoid valve,sprinkler system ZA Kantenschneidgerät option edge cutter
5:2
5:1
Magnetventil Kantenschneidgerät ab solenoid valve, edge cutter, down
5:15
Magnetventil Kantenschneidgerät auf solenoid valve, edge cutter, upwards
5:16
6:1
2:19
K11
K11 7:1
2:5 F105
X2:14−1
2:19 F119
F119 14:14
Sicherung fuse
F105
F23
Sicherung fuse
X2:5−2 X2:14−2 30
K35 6:12 87a
87
X1:42
87
X1:30
86
S120
Schalter Motordrehzahl switch motor speed
33
11
23
X1:138
86
K139 L0R
F23 10:2
30
K114 6:5 87a
K35
2
85
3
85
0
S03 34
12
Meldeleuchte Motordrehzahl incicator light, motor speed
24
4:19 X7:+
Taster Signalhorn switch warning horn
X7:+ 8:7 +
5 0 1 : 1 X
X1:102
H60
4
6 0 1 : 1 X
X1:60 2:14 A13
− X7:5 X1:28
X1:16 86 K114 85
X1:127 5:20
(A7) V47
2 1
87
30 X1:137
X1:134 X U A
87a K139 6:11
2 + AW HW Y120
− 4:15 M−
+ B11 Signalhorn warning horn
− M− 7:8 31 7:1
31 6:12
6:9
6:5
Motordrehzahl motor speed
6:20 K11 X2:16−1
F08 Sicherung fuse
Meldeleuchte Blinker indicatot light, indicators
X2:16−2 X1:38
4:20
H06
X6:−
X6:7 2:5
Schalter Arbeitsbeleuchtung switch, working head lights
V07
V06
X6:18
X6:19
X1:129
S14
0 1
Überwachungsmodul monitoring module
Brücke entfäfft bei Anbau ZA StVZO Beleuchtung not. incl. if StVZO Illumination is assembled
7:20 31 31 8:1
14 X1:55
S26
H06
30
F07 Sicherung fuse X2:7−2 Warnblinkschalter X1:37 hazard light
13
K11 8:1
Meldeleuchte Warnblinker indicator light,hazard light
H05
X7:1 A15 X6:1 X7:8
S14 7:11 23
11
53
12
54
33
7:9 S14 S37 7:12
43
34
13
23 X2:19−1
44
14
24
Sicherung fuse
F09
1 S117 2 X57:2 X58:2
X57:8
r e u i e r e t s b t t t l i l l p ä f t S n A e Z
r e d n a o e i r t p p s o p o i t . h c c c g a i n y t i l l n e o d
X1:100 X5:LA + E08
+
X94:1 X25:1
31
E28
rechts right
56b 31
links left X58:3
7:13
6:20 31 Arbeitsscheinwerfer working head lights ZA Splittstreuer option chip spreader
−
56b E18 31
+ E73
E04
X1:73 X4:3
X1:99 X5:R3
X57:1 − X58:1
−
6 3 : 1 X
−
+
+
−
− 49
E19
49a
31 t h g i r / s t h c e r
t f e l / s k n i l
X25:2 X94:2 X1:148
A02
X4:1
−
+
X4:4 X4:4
X57:4 X57:7 X58:4 X58:7
E11 −
X25:5
9 0 E
0 1 E
1 1 E
7:10
7:11
7:12
7:10
7:11
7:12
9 0 E
0 1 E
1 1 E
+
X5L:C 7:13 X5:LC X1:110
E13 −
Bel. Geschwindigkeitsanz. illum. speedometer
−
X58:3 X57:3
+ X25:4 E13 − X25:6
Sicherung fuse
F10
X2:20−2 F09 14:9
24
0 4 : 1 X
1 4 : 1 X
X1:59
X1:133
X5:LB + E12 E14 −
X4:2
−
Sicherung fuse
F12 F11
X2:21−2
X5:R4 2 : 4 X
X2:22−1 Sicherung fuse X2:22−2
F10 9:2
X1:58
+
12
X1:107
X1:108 X5:R1 56b
E16
X57:5 + X58:5
31
56b E17 31
E15 −
3 1 E
2 1 E
4 1 E
5 1 E
7:14
7:15
7:16
7:17
7:14
7:15
7:16
7:17
3 1 E
2 1 E
4 1 E
5 1 E
+ E15
X5:R2
−
7:10 X5L:C
X5:R5
6:20 M−
Blinkrelais indicator relay
+
E11
31
Bel. Temp. Asphalt illum. temp. asphalt Bel. Evib−Meter illum. Evib−meter X1:53
Arbeitsscheinwerfer working head light
+
X4:3 X25:3
X1:132
X1:74 X4:1
+ E10
E09
E09
56b 56b E27
E02
5 3 : 1 X
X1:25
23
X2:21−1
X2:20−1
X2:19−2 X1:26
option StVZO Beleuchtung StVZO illumination
X6:8
7:10 S37 L0R S37
11
Schalter Beleuchtung switch head lights 012 S15
Schalter Blinker switch indicator
15A
24
Schalter Steckdose switch socket
X1:39
M− 7:18 X4:5 X1:127
Blinkleuchte VL indicator front,lh.
Blinkleuchte VR indicator front,rh.
Blinkleuchte HL indicator rear,lh Blinkleuchte HL indicator rear,lh
Blinkleuchte HR indicator rear,rh. Blinkleuchte HR indicator rear,rh.
7:2 X58:3
7:11 M− Parkleuchte links parking light lh .
Schlußleuchte links tail light,lh Schlußleuchte links tail light,lh
Parkleuchte rechts parkin g light rh.
M− 8:9 31 7:9
Scheinwerfer links head light LH
Schlußleuchte rechts tail light,rh Schlußleuchte rechts tail light,rh
Scheinwerfer rechts head light RH
7:20 K11 Aufnehmer Fahrhebel transducer travel lever
F03 Sicherung fuse 8,5VOLT 12:1
5:13 8,5VOLT
B39
3
X1:31
X93:2 2 X93:1 5:12 X1:143 9 (8,5V)
) D N G ( 0 1
13
M0A 1
X1:70 11 (GND)
6:10 X7:+
23
X93:3
14 ) 4 5 / 5 1 ( 1
X1:144 8
X1:48
13
6
24
13
3:20 A03.3
23
4:19 X6:10 16
1 V46 H14 (A6) 1
3:20
V45 (A5) 2
12
X1:2
S12
3 S13
11
23
12
24 X1:5 V44(4)
X1:3
4 1 : L 9 X
4 1 : R 9 X
−
1 2
X1:118 31
X1:63
Taster Vibration switch vibration
Asphalt Manager
H14
X3:2
X1:127
X8:2 X1:78
Y56
S74
− X7:− 9:14
11
13
23
14
24
0
X1:11 15
X1:13
X1:15
A71 Modul Vibrationsverriegelung modul vibration, interlock 12
13
5
4
7
8
8:10
) D N G ( 0 1
) D N G ( 9
6
A73 9:2
1 3 Y
11:1 V2 11:1
X1:77 X8:1
L0R
2
Y57 Y57
+
14
+ H33
8:9 A71
BW161...BW203−4
X3:1
X1:9 4:20 X7:−
X1:7
Schalter Vibration klein/groß switch, vibration low/high
X1:126 3
X7:18
24
A03
8:2
1 2 : R 9 X
13 14
) 4 5 / 5 1 ( 1
1 3 Y
Schalter Splittmenge switch quantity,chip
S73 14
8:10 A71 8:15 15
X1:64 2 : L 9 X
23
VBH
2 1
14 X1:1
5
A03.3 9:1 R 9:2 K G S35
13
Schalter Splittstreuer switch, gravel scratter
S02
X1:49
3
8:9 X1:31 S36
24
14
Schalter vorne hinten switch front/rear
X1:31 8:11 BW161...BW203−4
A03 Modul Vibration modul vibration
A03 8:9
7:10
+ H13
− X7:14
S08
GND
K11 9:1
Meldeleuchte 2. Gang indicator light, 2nd speed range X2:15−1 Vibrationsschalter man./autom. Fahrstufenschalter X2:15−2 switch, vibration, man./autom. speed range selector
X1:79 X9:1
X1:75 X28:1
V08 1
Y30
X1:83
X1:186 X29:1 1
Y31
X1:118 V12
V11
1
Y57
1 Y54 2
2 X9:2 7:20 M− X1:80
X1:81
X28:2
X1:89
X1:87
X1:171 V18
1
1
1
V19
2
1 Y131
2
X29:2 M−13:6
V21
Y55 2
2
2
2
Y66 Y67 X1:84
X1:82
X1:172
X1:88
X1:90 31 9:1
vorn hinten Magnetventil kleine Amplitute front rear vibration low Fahrstufenumschaltug speed range selection Warnsummer Rückfahrwarneinrichtung Magnetventil große Amplitute warning buzzer back up alarm vibration high
Vibration vorne an vibration, front on Vibration hinten an vibration, rear on Vibrationsabschaltung nur AD−Version
Magnetventil Hydromotor solenoid valve, hydraulic motor Magnetventil Verstellzylinder solenoid valve, ajustable zylinder ZA option
8:5
R
8:6
A03.3
2:5
F93
F93 Sicherung fuse
A73
8:13 5:17 MD+ 7:17
F10
8:20
K11
2 − 7 2 : 2 X
X2:17−1 F101 Sicherung fuse
X2:17−2
X20:43 F101 9:12
X2:52
X88:28
X20:13
X20:44
1 R31 2
2 3 : 8 8 X
3 + 5 : 3 8 N 8 A X C
8 3 : 8 8 X
X88:26
X20:1
X20:2
X76:D
X76:F + N A C
− N A C
F04
+ N A C +
X1:151
P34 +
F1 − − X76:E X20:8
S01 3:11
F2
−
−
_t
1 R30
−
P28 G
2 X20:39
X1:152 option X1:122 option
Evib−Meter Evib−meter
Diagnose diagnostics
X20:25
RXD 10:2
X2:26−1
X20:23
TXD 10:2
V25 32
X2:55
V26
X2:25−2
5
7 3 : 8 8 X
5 1 : 8 8 X
4 5 : 8 8 X
B15.2 11:1
X2:26−2
X2:57 6 5 : 8 8 X
3 2 : 8 8 X
1 : 8 8 X
9 : 8 8 X
9 2 : 8 8 X
7 5 : 8 8 X
8 5 : 8 8 X
1 3 : 8 8 X
X20:40
9:4 F101
X20:35 + B106 − X20:36
+
_t P16
X2:25−1
X2:54
X20:10 1 4 : 8 8 X
F04 12:1 X20:38
X1:121 − N A C
P33
X20:5 X76:G CAN2− X20: X20:66 X76: X76:H H GND X76:C X20:4 8:20 31 _J Display display
31
9 5 : 8 8 X
0 6 : 8 8 X
6 3 : 8 8 X
4 1 : 8 8 X
4 : 8 8 X
5 : 8 8 X
5 3 : 8 8 X
A83
X20:20
15 30 CAN2+
X2:24−2
6 : 8 8 X
4:20
1 R20 2 7 : 0 2 X B : 6 7 X
1 − 7 2 : 2 X
V22
3 − 3 : 3 8 N 8 A X C
3 : 8 8 X
1 R21 2
3 : 0 2 X A : 6 7 X
X2:24−1
X2:4−2 X2:53
V27
1 R32 2
Messtechnik Rechner measurement calc. unit X88:27
X20:14
X1:59
CAN3+ 10:2 CAN3− 10:2
X20:9
X20:37
Temperatursensor temperature switch Temperaturanzeige temperature gauge, coolant
1 : 8 7 X d e e r / t o r
2 : e 8 t i 7 h X / w ß i e w
schw/black X78:3 X20:19
4 3 : 0 2 X
3 3 : 0 2 X
4 : 9 7 X
3 : 9 7 X
5 6 : 8 8 X
6 6 : 8 8 X
7 6 : 8 8 X
8 6 : 8 8 X
5 5 : 8 8 X
7 4 : 8 8 X
6 4 : 8 8 X
X2:56 9 2 : 0 2 X
8 1 : 0 2 X
0 3 : 8 8 X
F101 10:1
D N G A
7 1 : 0 2 X
7 : 8 8 X
3 : 0 8 X
X1:45 X7:11
0 3 : 0 2 X
7 2 : 0 2 X
1 3 : 0 2 X
4 : 0 8 X
1 : 0 8 X
1 : 9 8:15 X7:− 7 X
B85
H04
X7:− 13:5
B84 Y140
X20:11
X20:15
X 1 0 7:1
X108:1
1
Y141
1
B97 X80:2 X20:24
Aufnehmer Verstellmotor transducer, motor
X20:28
X79:2 X20:32
AGND 10:2
Aufnehmer Beschleunigung links trancducer, acceleration,left Aufnehmer Beschleunigung rechts trancducer, acceleration, right Meldeleuchte Betriebsstörung indicator light, breakdown
X2:51
2 X 1 0 7:2
X108:2
2
X20:12
X20:16
31 10:1
Prop−Ventil Erreger auf solenoid valve exciter up Prop−Ventil Erreger ab solenoid valve exciter down
2:6 K30
K30 14:1
9:15 F101 9:9 CAN3− 9:9 CAN3+ 9:19
RXD
9:19
TXD
option TM2
X103:F
X103:E
X100:F
X100:E
Schalter GPS Switch, GPS CAN3+
X101:2 4 : 2 T S
6:19
F23 X20:22
ST1:3
X103:K X100: 100:K K
X101: 101:44
X74:7
X101:1 3 : 2 T S
32 5 : 2 T S
X101:3
6 : 2 T S
1 : 1 T S
2 : 1 T S
X101:5
1 : 2 T S
X102:1
2 : 2 T S
X102:2 3
S153
X100:L
X100:I
X103:L
X103:I
X75:1
5
2 3 − 1 : 5A76 0Druckerkontroller 1 Xprinter controller
A77 Spannungsregler Voltage regulator
ST1:4
X74:2
GPS Antenne GPS antenna F150 Sicherung fuse
A87 USB−CAN Schnittst. USB−CAN Interface BCM
9:20
AGND
1 2
A93
X106:1−20 20 P11 Drucker printer
P15
5
A92
4
BCM05
BCM 05 BCM 05
GPS Receiver GPS receiver
X75:2
A94
Papiervorschub paper formfeed 2:4
9:15
1
S166
CAN3−
X20:26
K31
K31 11:1
GPS GPS Antenne GPS antenna
31
31 12:1 ZA
9:20 B15.2
B15.2 12:1
8:7 V2 8:7 Y57
V2 11:10 Y57 11:10 X1:188 X68:B 2 A51 5
X1:187
X1:189
X68:A 3
X68:C
4 1
BW161 AD−4 BW161 ADH−4 BW190 AD−4 BW202 AD−4 BW203 AD−4 BW161 AD−4 AM BW190 AD−4 AM BW202 AD−4 AM BW203 AD−4 AM BW144 AD−4 BW144 AD−4 AM BW154 AD−4 AM
11:7 X67:B 11:6 V2
X67:B 15:5
11:6 Y57 X1:188 X68:B 2 A51 5
Tachomodul 5 module, tachograph
4
X1:187
X1:189
X68:A 3 1
X68:C
1
4 B
3 B
11:7 X67:A
4 4:1
Tachomodul module, tachograph
1:3
A16 2
BW141 AD−4 BW141 AD−4 AM BW151 AD−4 BW151 AD−4 AM BW151 AC−4
2:1
X67:A 15:5
1:2
A16
6
3
11:4 11:4
X67:B 11:10
11:4 11:4
X67:A 11:17
7.8.9
1 : 1
5 : 5
4 : 5
3 : 5
2 : 5
1 : 5
4 : 3
3 : 3
2 : 3
1 : 3
1 : 6
3 B
4 B
B4
B3 B 3 A2 A3 A1 A3 A2 P09
C3
Anzeige indicator A5
B1 P09
B2
A1
B3
A5
B4
A6
C3
A6
1 G02 15:9
10:20 K31
Anzeige indicator
R33 2
Platine Frequenzanzeige circuit board, fequency indicator
Platine Frequenzanzeige circuit board,frequenzy meter
K31 13:1
9:8
F04
F04
4 5 / 5 1
11:20 B15.2
IN
8:3 8,5VOLT
X1:32
4 5 / 5 Lern 1
Test
+
− T U O
1 X1:33
P04 − ZA option Geschwindigkeitsanzeige speedometer
X2:59
X2:59 X1:194
X1:193
X1:192
X1:194
X24:4
X24:3
X24:1
X24:4
BW161 AD−4 BW161 ADH−4 BW190 AD−4 BW202 AD−4 BW203 AD−4 BW161 AD−4 AM BW190 AD−4 AM BW202 AD−4 AM BW203 AD−4 AM
t s e e t e s g o i e n z g a n i A d
s u d o n m r a n e r l e o L t
A05
OUT+ X2:58 FM1 Multifuse
17:1
1 : 0 3 X
3 : 0 3 X
BW141 AD−4 BW151 AD−4
2 : 0 3 X K B / W S
B15
N B / R B
B15
X30:4 Sauer
BW141 AD−4 AM BW144 AD−4 AM BW151 AD−4 AM BW154 AD−4 AM BW144 AD−4 BW154 AD−4
BW151 AC−4 BW161 AC−4 e t i h w / S W
K B / W S
Schönbuch
Bosch Rexroth
X32:2 N B / R B
N B / R B
B15 U B / L B
X32:1
K B / W S
B15 U B / L B
X32:3 Poclain
U B / L B
X24:2 X1:191 10:20 31
31 13:12 Aufnehmer Geschwindigkeit transducer speed
F31 14:1 D
F31 Box 1
F40 14:2
G 4
B
F42 Box 1
0123
S44 Schalter Kabinenlüfter switch, cabin ventilator 4
2 A72 Steuergerät control unit
87 1 : 0 4 X
Thermofühler Klimaanlage temperature sensor
3 : 0 4 X
2 : 0 4 X
11
X63:7
K85 14:18 87a
B103
X52:2 X50:1
2 X49:2
ge
rt
or
3 : 5 4 X
4 : 5 4 X
ge
rt
M09
M09
br
br
X42:1
2 : 5 4 X
X63:6
X53:6 1
4
7
ZA option
6 Diagnose diagnostics
_t B131 Thermofühler Heizung temperature sensor, heating
P18
E30 Heizung heater timer
X43:4
5
X56:1
X55:1 X21:1 2
1
8
3 : 3 5 X
10
5 : 3 5 X
1
2
X45:1
X54:1 1
Y138 2
8:11 M− X55:2
E30 13:18
1
Y15
V09
X40:4
3
X43:2
or
17:5 11:20 K31
1
HP
X43:3 2 : 2 4 X
6 2
15
2
B104 P LP Überwachung Kühlmitteldruck 3 monitoring coolant pressure
3 : 2 4 X
S28
X49:1 1
X43:1 4
4 : 2 4 X
5
12
X63:4
F15 BOX 1
6
A72:2 14:15
X52:1 1
_t
X1:207 X1:18
Schalter Kabinenheizung switch, cab heating
1 6
4 : 5 6 30 X
F15 14:1
F
8
3
d h w i g i o m h l
3 : 5 6 X
F40 BOX 1
F42 15:5
7
L M H C
2 : 5 6 X
H
X56:2
Y14 V10
Magnetventil Heizung solenoid valve, heating unit
13:14 E30
2 X54:2
12:20 31
31 17:1 K31 14:1
Kabinenlüfter cab ventilator
Kraftstoffpumpe fuel pump heating unit Klimakompressor air conditioning compr. ZA
ZA
option
option
X91:A
10:20 K30 13:19 F40
K30 16:1 7:16
X65:1
X51:B
F09
F09
30
F119
X51:A
13:11 A72:2
X63:8
6:10
K32 14:17 87 13:19 F31 13:19 F15
16:7
F31 15:1 F15 15:1 E F110 Box 1
F113
5
K 127 14:12 87
F114
20A
30
K 128 14:13 87a 87
S147
30
K 129 14:14 87
30 K118 14:20 87a
B : 2 7 X
A89 A : 2 7 X
1 : 0 7 X
E23 E28
+
− 2 : 9 6 X
1 : 1 7 X
+ −
2 : 0 7 X
1 : 9 3 X
A : 3 7 X
+ E23 −
+ E25
2 : 1 7 X
30
14
S26
13
20A
14
30
K 130 14:16 87a 87
S53
87a
B : 4 7 X
B : 5 7 X
A90
A91
A : 4 7 X
+ E25
5
86
K 128
85
86
85
+
K 129
86
K 130
86
86 K32
86 K85
86
85
85
85
85
K118
E27 −
− 2 : 9 3 X
K 127
− E28
1
X64:2
A : 5 7 X
+
+ E27
−
F116
B : 3 7 X
A88
1 : 9 6 X
20A
X63:5
87a
X66:1
87
F115
13
−
85
13:19 K31
K31 15:1 Arbeitsscheinwerfer vorne working lights, front
Arbeitsscheinwerfer vorne working lights, front
Arbeitsscheinwerfer hinten working lights, rear
Arbeitsscheinwerfer hinten working lights, rear
Xenon
14:7
14:9
14:10
Schalter Arbeitsscheinwerfer switch, worklamp
14:11
14:4
13:2
14:4
Schalter Arbeitsscheinwerfer switch, worklamp
14:12 F31
Wischer vorne windscreen wiper, front
14:12 F15 A
13:11 F42
1
11:20 X67:A option Tachograph 11:14 X67:B
F41 Box 1
X67:A
B
F27 Box 1
X67:A
Wischer hinten windscreen wiper, rear
2
3
X67:B
S20 0 12
S21 012
7 2 01 5
X67:B X67:B 1
S38
X64:4
5 S158
15
+ B51 option
11:13 G02 option Tachograph
+ E29 −
X48:2
6 : 4 6 X
5
1 : 3 6 X
1 : 2 6 X
2 : 2 6 X
8 : 4 6 X
K141 15:19 87
4
30
1
87a
2 : 3 6 X
1
E71 1
31
B51 X61:C 3 5 : 4 4 X
b 1 3 : 4 4 X
a 3 5 : 4 4 X
X61:A 3 5 : 6 4 X
A 3 1 . x a m
b 1 3 : 6 4 X
a 3 5 : 6 4 X
2
2
K141
− XS 12V
4
S163 5
30
X67:C
E70 −
3 : 4 6 X
7 2
01
R80
+
E32
5 : 4 6 X
A12 Radio radio
7 : 4 6 X
X48:1
X67:A
+
S45
C
F28 Box 1
− X64:1
X67:C X67:C
X44 a 3 3 5 5 b 1 1 3 3
3 5
a 3 5
M04 31 X44:31
b 1 3
+ M06
2,5A
−
X46 a 3 3 5 5 b 1 1 3 3
3 5
a 3 5
b 1 3
M05
+ M07
31
I
t r e n g i ö m z r e 3 v l l a f b A
15 31
−
X61:2 15:16 15:14 X61:2 X46:31 X61:B
14:20 K31
K31 16:1 Kennleuchte rotary beacon
Steckdose socket
Nachtbeleuchtung night lamp Kabinenleuchte cabin inside light
Wascher vorn washer motor,front Wischermotor vorn Wischermotor hinten wiper motor front wiper motor rear Wascher hinten washer motor,rear
Heizung Heckscheibe heating rear screen 15:18 Kontrolleuchte indicator
14:20 K30 Schalter Arbeitsscheinwerfer switch, worklamp 14:20 F09
2 S147
A
S53
S26
F114 1 30
K127 16:7 87
87a
2
2,5qmm
C
30
K128 16:9 87
A F108 1
13
30
K135 16:14 87
87a
14
D
F115
13
14
14
B
F113
13
F116
87a
3 30
K129 16:10 87
4 30
K130 16:11 87a 87
87a
2,5qmm
+ E23
K127 86
+
K128
86
+
E25 −
E23 −
85 + E28
85
+
K129
86
K130
86
K135
−
+
E27 −
−
86
+ E25 +
E28 −
85
85
85
E27 −
−
15:20 K31 Arbeitsscheinwerfer vorne working head lights, front
Arbeitsscheinwerfer vorne working head lights, front
Arbeitsscheinwerfer hinten working head lights, rear 16:3
XENON
ZA zur Zeit in Entwicklung option is in development at the moment
16:4
16:5
16:7
16:16
Arbeitsscheinwerfer hinten working head lights, rear
Arbeitsscheinwerfer hinten working head lights, rear
5:20 F25 5:17 F06 12:20
F04 Taster Hundegang push button, crab walk
X1:131
X9L:3
S115
3
X12:A
X9L:5
S116
4 N B / R B
K B / W S
K138 17:16 87
B10
30 87a
K03 17:18 87
3
4
30 87a
BL/BU
X12:B
X12:C X1:113
X1:130
X1:115
X9L:4
X9L:6
X1:141
X1:142
X1:56
X7:13 + H02
1 Y19
−
13:5 X7:−
V16
X1:127
Y18 1
2
2
X1:114
K138 V17
86
K03
85
X1:116
86
85
X1:127
13:15 31
31 18:1 Meldeleuchte Hundegang indicator light, grab walk Näherungsinitiator Knickgelenk proximity switch, articulated joint ZA option
Magnetventil Hundegang solenoid valve, crab walk
17:11
17:13
A05
X7:1−20 9 8 7 6
P16
5 4 3 2 1
201918 1716151413 121110
X6:1−20
A15 Zentralstecker Sammelanzeige (Ansicht von hinten) mainplug monitoring module (view from backside)
A83 Messtechnik Rechner measurement calc. unit
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
X88:1−68
61 62 63
23
26
16
8 13 14 15
1 2 3 4
9 10 11 12 17 18 19 20 21 27 28 29 30 35 36 37
22 23 24 25
Asphalt Manager asphalt manager
31 32 33 34 38 39
X20
64 65 66 67 68
u e a l u l b b
(Buchse)
40
5 6 7
X20:1−40
u e a l u l b b
blau blue
blau blue
V48
1
V47
1
V46
1
V45
1
V44
1
V43
1
V42
1
V41
8 7 6 5 4 3 2
AC−Maschine
2 2 2 2
A04
2
A71
A03
2 K11
2
K05
K114
K03
K22
K35
K62
K79
K80
1 1 2
1 B − A : 4 1 X
R09
C − A : 3 1 X
2 3 4 5
6
K82
K83
K138
K139
K104
ZA option
X2:1−26 B − A : 9 8 X
A68
asphalt manager
7 8
9
10 11 12 13 14 15 16 17 18 19 20 21 22
23 2 4 2 5 2 6 27 1 2 5 6 7 0 2 2 2 2 V V V V V
5152535455 56 57 5859
X2
6061
1 7 9 5 4 9 1 5 3 5 7 1 2 4 3 3 8 0 6 9 0 1 2 0 0 9 0 3 6 0 1 1 2 1 1 0 2 0 0 1 0 0 1 1 1 F F F 1 F F F F F F F F F F F F F F F F F F
ZA option
A02 X1:1−208 78
76
75
1 2
77
80 79
82 84 86 88 90 81 82 83 85 87 89 91 92 93 94 95 96 97 98 99
110 100 101 102 103 104 105 106 107 108 109
112 111
114 113
118
116 115
117
137
127 119 120 121122 123 124 125 126
128 129 130 131 132 133 134 135 136
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e e g g i g n i u e e z z z i n n e a a g g H M t t t t s t s n n t , h h h i i C h u l u e l c i c i c i c e e B i e t e e g k k L L L L g i g g a e g i g l l l h i k k l l i e i i l n n n n e i e n u u u p e h i d d g n n e o o o o r r r a d d d z i r n i n n n h h t i s n n n n u o o o a r n e a c c t g g w w i t e a e t e e e e v v m r r t e t e i r t m m m g n n h h z k s X X X s i o z n X s s h e t k l e e r u l u c c e s a a s s n l l , t , t , t , r n n n l n n t o o K l g s s h t g g g c e u i t e H s s t o o o e e n n o l i t i t i s s e e t n n n a u t e e o o t i t i t r e e e c ä ä e e e n t r r ä r ä r v t a u u u r S h n e e a r a r a i e i e G G a h h h T q S n k k r a r a a n s M e e e e i M g h r n e r r k k r c c c k r k i t z t z b b r o g k k N t g t g t g t g e n s i s i n c i e t e b i b i b e e i i i e i i i i e k n i i A l l l l c t s l e a a a i u l F l a a r n n n n e n n a a a a e l n n V V V B B S S V V g w w w o e o b l l l l r g e u o o C h h h h n r o o e e l l l l l r r r R A A n a n r t r i r n t r a u u u u e k n t r t r − c c c c r r u u u u u t o e e e e t v k e r i k c a k k B r s r s r s r s S S S k t k g d d d d u u d d d d d k k d u b b b n t e n n e e e e l e r p l i l i o o o o o l e l e a t e l a l e i n o o o o t e l e S o o o o P P P e n l B I B B M M M M M E E R S U U U E P E E M M M M S D S E E U V V V V G G G . f 1 0 1 8 3 3 0 5 5 3 4 2 0 6 0 1 8 9 9 P 1 8 1 1 4 1 5 5 1 1 9 1 2 1 4 6 3 9 1 1 1 1 7 7 1 7 7 1 4 1 8 9 1 1 1 1 1 . 5 7 9 5 8 9 5 9 1 8 4 2 3 7 8 1 1 7 7 3 9 8 9 2 0 0 9 8 0 3 3 3 0 0 0 l 0 0 1 0 0 1 0 1 1 1 1 0 0 0 1 1 1 1 1 0 1 0 1 1 1 1 0 1 1 1 1 3 1 1 1 1 B 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 e m 1 2 2 3 3 3 4 4 5 5 2 3 5 5 5 6 1 6 7 8 8 1 1 2 6 7 3 3 7 8 9 0 1 2 3 4 a 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 5 6 6 6 6 7 7 7 7 7 8 8 8 8 8 9 9 9 9 9
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g y t n r r i i l t e t e t t i n g t l i l l n n o i o n l a a i i k f f i u t i t o c l l n j i i i o q t h d i n h l l f a g o e l t t l i o p u o s e g e n l d i r i r n . . n t a a r r i u i e n u o i a f e o t , , r a n l d e r t d d g d n e l o n n r c a a d l i r r r y y n a n u y h h n i o i o o i o u t o s e t o e i e s e t t h , , e e v c n k a c t a h l i c , h h , r l , a a a , r a , c g i r h t e r a r o h r r r h h h n i p a r e l e m c a e p c c t c c k l i e a d d d d t c t c b l t t i t a , , e e e e e i i i n v i x i , p e t i , e e e e l , h e e e e w w w w t a c c w h m s w w e h h h c p p p p s s s s r a c c c b c i c e r s r i t t a s i t c t o o s g s s s e f . f . e e t a a t n s t r i e e i i e a e t , r , r , r , r i f i f r , d i , r , s r , t t r w r d r w r r o r u u w a r w w a s s a a s u d d u u u h e e e e e e j t w c r r t c y e t s e t s y h c c c c t a c c c w e a e e a a a t g u u u u r r r r , u r r r t i t u u , r e , a i r u r r m r r e e r n d d d d e u u e o d k k e n m d d o e u d e e i u u m s i n s s s s p s s p s s a a p l a i c c p s s d p u s r n n n n m s s m n n e e m o x n n s n n m c e x n m s o e e o e a a a a a a a a a a r r r r r r e r r e e r p p e o r r r e e r r e e V P P W T T T T T P P T S T S S T C P T T S T P T S T
e g u . . . . . . . . . . . . . . . . h a h l h l h l h r h l r h r h r h h g r l h l h l h l h r h r h r , t , t , t , t , t , t , t , l , r , r , r , r , r , r , r , e t e t r n n n n n n n n r e . a a a a a a a a . u o o o o o o o o t m e r e r e r e r e r e r e r e r f r f r f r f r f r f r f r r h h l r f a r o , , , , , , , , , , , , , , , , , , t t t t t t t t t t t t t t t t t t e d . . . . . . h h h h h h h h h h h h h h h h h h p e l h h h . h l h . g l g l g l g l g l g l g l g l g l g l g l g l g l g l g l g l g l g l r r h e , h i i i i i i i i i i i i i i i i i i m p l , r h , , , , t t l r e s n r r n r r , . . d d d d d d d d d d d d d d d d d d t , . . l a a o a a t . . t h h , , o r a a a a a a a a a a a a a a a a a a r e e r e h h n n f h l h h , t , e e e e e e e e e e e e e e e e e e r f r e r h r t g l g r o i o , r i i , r , r , r , r , l i , t , l , t , h h h h h h h h h h h h h h h h h h h h r t t r t t g g g g g g g g g g g g g g g g g g g g o t o t o t o t o t o g h h g h h i a a t i l l n i n i n i n i n i n i n i n i n i n i n i n i n i n i n i n i n i n n i n a a a a a a i g g g g n i n i i i i i l l d d i l k c i c i c i c i c i c k l r k r k r k r k r k r k r k r k r k r k r k r k r k r k r k r k r k r i l i l r i l i l a a k m m d i d d d d r u l u n d a a a a a a e e o o o o o o o o o o o o o o o o o o l l l n n n n n I I I I I I I I P T T P T T H H W W W W W W W W W W W W W W W W W W
l e r r r s e e t e t e t l i l l s i i f l f e s t D l l e e a k h r e k c e h e g n n O O e o e i r d a e l b l k − . − l e i l . , , l t i t i t i t i l r e s e g e g r e g n e i r t n g u t o e t h n d r a e l g e e e e a d i h e k s n n t y y c u k k k k r l i m u u r a g a c i o m m s i z c i f g i g i g i g d H H t l a h b e e i o i t t l i g i g t m l l f o h y e n r r s r l p d d d d e l g B n n o K n s a H u o e e e e n n n n K H M e s u u m a A s t l t r r b L r r i i i i r l u u r r a d l o i o K o l e l e l e r n r r t o o w w w w e a a e k i e e A n e o t h h h h l t h l t a h d d r t h h t e t l m o a l t i t l c c c a h a c c c a t a c c s l r a a e d t i a K s t a s s s s h a M t s s r h s r h n i i s n s R b r h e e e e c k k h e a R h r i e e e r e a n c n c e e c i c c s s F r r g t i B B V s e s s c t G G G s s s r r r r t s e s G u r u r s r e e r l r r r s s r l u r r r r k l g a h h g u u u u u n e e e e t d d t a n r e e e e t a t a t e c t t c h t n a z z r a W m c a i a h a W r a u c u o m m m m r e r e r u m m m r c r r r r l n n e r h r h h h s e h h h e e h h s e m e e d p p r e e l o e s s p h e e e p k p e e r k h a e e e e p r r p s t h c m b p e c e n f n f n f n f n m e f e m n f n t n f n f n m u t e f e f m u u u f i f e e u a a e u a u u u e r e e m g u u u u e i n r a i e U D N S A A A A T D D T S A L L T K N A A A T D T G T
e g i e z s t s t s n s s t s t s e a s s s s t h h g s s s s s t t h h h s k i k k k h c c c t k k k k h c c c c k e i n n n n n e e i i i i i n n n n e r e r e r e l l l l l r r e z e i l i l i l i r r l n k s e e e e e e e e n n n n n n n n a g t s t s r i s e t e t e t e t e t e t e t e t s h n n n n n n n t s s h h h u d r t k c r r r r r r r n s k t n n n n n n n n n k i i i i i i i i c c o o o o o o o o n r e v a i k i s t s n l n c l v v v v v v v h h h h h h h h r n l i i e e w l i r e r s s t r r r r r r r r r r r r r r r r r r r e h h h s k s c c s t f e e e e e e e e e e e e e e e e e e p c e n n e n n k f f f f f f f f f f f f f f f f f n l n t r e k h e t e n t e e s l r r r r r r r r r r r r r r r r r i i n t m s c r h e r r n t e e e e e e e e e e e e e e e e e e k n e e r n n n c e i o i i o i i i e t e e t e t e l r w w w w w w w w w w w w w w w w w w n t T G v h h v h h l r r i n n i n i n i n i n i n i n i n i n i n i n i n i n i n i n i n i n h h r h h e g g t e e i e t e t e t e t e t e e c c t c c f f e u e e e e e e e e e e e e e e e e e n n h u h u r r h h h h h h h h h h h h h h h h h h h h h t u u t u h e l e c l e l e e e c h t c c c c c c c c c c c c c c c c c c c c c c h l c s s s s s s s s s s s s s s s s s h h c w w s s s s u u u u u u u s s u s s n n s s s s s s s s s s s s s s s s s s s c c l e l e l e l e l e l e e u u l t t e u u i i t i t i t i t i t i t i t i t i t i t i t i t i t i t i t i t i u u k l l l l e e i i k k k k l e e e e e e e e e e e e e e e e e e l e n k l r h h k r h h h h e b n l n l n l n l n k i l i i i i i e e l a c c a c c c c b r r b r b r b r b r b r b r b r b r b r b r b r b r b r b r b r b r B B B B B B B B P S S P S S S S A A A A A A A A A A A A A A A A A A
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n e e r . . c h h s r r r , r , r a r e a a e r t e r e e r h , , t t c m t − h h n i b i g g i i l i b w v l s d d a t E t a a c t h h , , i e e t g n g p i i l l h h h n o i g u g m r t i g g l g n l a o a n i n e i i n i t t n a i k t r n h c e k d r r l i m t o o i i g d s a e a i u t l n l n W W I H W N i I
. . e r t f r h , r , e r g i l k e e h e a h . . d h r s s n i a l h r b a a g e , t , d w w n h t h n d d ) e . h ) 5 e 1 1 2 2 3 3 4 4 g i g e d a n n , l k 0 l l r i l a d d i 3 1 l i l i s p p p p p p p p m o i e r a r p b . i d t . t b p t o v e r m m m m m m m m e w t o a a t a . . n u a r t t n a e c o a a l a l a l a l a l a l a y o n r p p l m m p p d m o l h h l s t . d d l e a o c r r t t t r t e t i i i i i i l u u y a n n , , i v ( e t t e s t s k i r k r k r k r k r k r k r k r t n c s h t o n n n o , w w t a h p ( e h t g r s a a t r i e n p c p o o o o o o o o i u h h s u u u h e h r l r r . . e g a n c e t s g g w w w w w w w w e e g b l v r r v i l f g g g g l l g g e d t o g g i e l b i i f i i e o s l l a t c c k n l l n n n n n n n n r n a s r o r , t e e k r a i n i n l l o i n i n i n i k s y e i r v d d i n i m t r g d d t t t t o d d o n i n a n a t n n n t o o o o o o o o k c + d k k S i i i t r i r u c r z r r a a u a a a r l . n n b r a t o o a a n n n n n n n n o D a i r n e i a a b o d s P a i i r t i a o p a n a a e e h e e e o a p e o n p o s a e e e e e e e e e e m m v g s s h i p p h h s h h h w s w w c s h r i s c u v m h h x x x x x x x x m M G r y a r , , , , , , , , , , , , , , , , , , , , , , , , , , , f , , , , , , , , , , , , , , i , e e e e e e e e e e e e e e t e e e e e e e e e e e e e e e e e e e e e e e e e e e e e t e s s s s s s s s s s s s s s t n s s s s s s s s s s s s s s s s s s s s s s s s s s s l u u u u u u u u u u u u u u u u u u u u u u u u u u u u s u u u u u u u u u u u u u u a e u F F F F F F F F F F F F F F F F F F F F F F F F F F F M f F F F F F F F F F F F F F F B G
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s t r e s n n n a s t e e e h t t t k c n w e n i n i n . i n r r n t e i b e l e r n h h h a e m l l t s t l i o t o e e O a v h g g g s g g h t e o b Z h r r n n n c n n u b a s e e t u t u t u g r u t u t u r V c e e t a h g k / h s / e e s . r r S s h h h h h n n r l h h n g i k n c c c c c u i e n c c l h h r g s t d e n a s u u u z e e f e u u r i , i a a t i i e e e i r l l e n t e b e n e e e d i e e e m F F l l u w w l l l e l h u n l l u g e r r t k r n n e S g g r r r a e e e h r r c l i e e e e e e e h e n n b b b n a e e u n n b b e n h i i e n l a h t U t e e s s s h l t r e c e e l r t l t l t l t c s b t t r e e e s s t c s o a l z z A a h e i b t i t i t e t t t s s i i c a l s t m n e l s i i i a a a a a n n n h n n d d r h k r i s n i i l e e t l t e e s e e b n h h k e l h h h g c h i i a a n n s c r T c b b e b h e b n n c c e h c i s c c k a t e O s a a s h d d d d d d d d e t c c b r r b r a n c e a a b r r p p t e k n t s s s n b s s l n n n t n i c n n n n n n n n H l k s s S S A A A K r z a e a g s N s s s k s s B K K K A A S S u r a s a e r r s a a a a a a a a t n r r r r r r t n n r r r r r r r r a a n n n i f S t n h e T e t t t t t t t g h r e W n t o e e e e e e i l e i u r n i o i o i o b o i o t e t i e t e t e t e t e t e t e t e K k T s s s s s s s s c n c d d a t t t t t t t r r r t t t r t t l r r r r r r r r u t s l l l l l l l l l l l l l l r o a a a n u l h e e i i e f s l s t e k e e a e e e e e e e e i a r a a a a a t a a a a a a a t e b r w w b i z d r r r r l e u a h r a r a h d d d d d d d z r h s t z b h h h h t b h h h h h h s u b a h b i b a e m h b h l e e o r o e e i i i i i i i i e t c a a i i i c c c c c c a i i c c c c c c c c a G G G V V G H W W W W W W W W H S S F T S V V V W B E S S S S S S B V V S S S S S S S S T
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