Hamm Roller

Ser v i c e Tr ai n i n g

Basi Basisw swis isse sen n/ Fundamentals

Release 2011-10-07

s s l S l a R a t O t n T C n e A e P m M O m a C a d M d n M A n u H u F F

S R O T C A P M O C M M A H

EN

EN 2150228

2150228

s l S R a t O T n C A e P M m O C a M d M A n H u F EN

2150228

01 - Introduction 02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics

1 0 n o i t c u d o r t n I

B as i c t r ai n i n g

1

Introduction

HAMM – Rol ollers lers for fo r soil so il and asphalt comp c ompa act ctio ion n


2

Introduction

Products


3

Introduction

Series

HD CompactLine

3000 Series B as i c t r ai n i n g

HD Series

HD+ Series

DV Series 4

GRW, Static rollers Introduction

Series 3000

S o i l c o m p a c t i o n

Visibility 3-point articulated joint Climbing ability Hammtronic VIO-drum B as i c t r ai n i n g

5

Introduction

Seri rie es HD HD Com ompact pactLi Line ne

S o i l & A s p h a l t c o m p a c t i o n

3-point articulated joint Visibility Clear side - offset Climbing ability Transportation B as i c t r ai n i n g

6

Introduction

Serr i es HD Se


Crab steering Visibility Climbing ability Articulated joint Water sprinkling system


7

Introduction

Serr i es HD+ Se


Visibility Operator´s platform 3-point articulated joint Crab steering Engine management


8

Introduction

Serr i es DV Se

A s p h a l t c o m p a c t i o n

Think Forward Visibility Hammtronic Steering HI-Drive


9

Introduction

Rubb ubbe er tire t ire rolle roll ers and sta static tic com compa pacto ctors rs


Ballast variations Overlap of the wheels 1:1 pressure distribution Water sprinkling system


10

Introduction


11

Introduction

Hamm Int nte ell llig ige ent Techn chnol olog ogy y

Oszillation


12

Introduction

Hammtronic

Diesel management Diesel management Drive control

0 0 0 3 s e i r e S

Drive control An ti sl ip co cont nt ro l

An ti sl ip co cont nt ro l

Vibration control

D V S e r i e s

Steering Vibration control

Ad di ti on al f un unct ct io ns


13

Introduction

Hammtronic Ad A d v an antt ag ages es Diesel management Diesel management Drive control

Drive control Ant i s li p c on tr ol

Lower fuel consumption

Ant i s li p c on tr ol

Vibration control

Ease for the driver Steering

Less operating mistakes

Vibration control

Better compaction quality

fuel saving profitability

f u el s av i n g

fuel saving

ty y


s af et y

s af et y

profitability

Addi Ad di ti on al f un ct ctio io ns

f u el s av i n g

safety

s af et y

safety p r o f i t ab i l i t y pr 14

f u el s av i n g s af et y

p r o f i t ab i l i t y

s af et y p r o f i t ab i l Introduction

Oscillation Vibration

Oscillation

Faster compaction – no grain crushing No destructive shock waves Longer life-time and reduced noise level B as i c t r ai n i n g

15

Introduction

Oscillation

Vibration

Oscillation


16

Introduction

Oscillation

Application of compaction systems in various temperature ranges


17

Introduction

Hamm Com ompactio paction n Quality

n o i t c a p m o c l i o S

HCQ-Indicator

HCQ-Indicator

HCQ-Printer HCQ-AsphaltNavigator

HCQ-GPS-Navigator


18

A s p h a l t c o m p a c t i o n

Introduction

Hamm Com ompactio paction n Quality

HCQ Indicator

HCQ-GPSNavigator

HCQ Printer


19

Introduction

HCQ-GPS-Navigator HMV (rigidity) Numb umbe er of o f passes Calibration of HMV-Values

Quality of compaction

Data analysis


20

Introduction


2 0 l a r e n e G

Nece cess ssa ary machin machine e inf infor ormation mation in case of repa repair ir •

Maschine type (e.g. HD O90V, DV 70 VO, 3414 HT VIO, etc...)

•

8-digit serial number •

always stamped into the right side of the machine frame

•

additional name plate (inside cabin, engine compartment or right side of the frame)

•

the first 4 digits show the machine series

•

the second 4 digits show the serial number for each series

H1800566 machine se series B as i c t r ai n i n g

serial nu number 1

General

Mach chin ine e seri serie es - overvie overvi ew

W al z en zü g e

Statische Walzen

Tan d em w al zen k n i ck g el en k t

Tandemwalzen schemelgelenkt

So i l co m p ac t o r s

Static Static rol lers

A r ti cu l ated t an d em r o l l er s

Pivot steered tandem rollers

3011 11//30 3012 12 O30 R 4011 40 11/ / 4012 40 12 U E5011 2210 2220 0 2315 0 0 2 2320 e i r 2420 e S2520 2620 2720 3205 3307 0 3410-11 0 0 3 4 1 0 1 1 3 e i r 3410-11 e S3412-14 3516-20 3625


H13 133 3 H13 134 4 H135 H127 H132 H124 H155 H141 H142 H144 H154 H158 H188 H159 H189 H169 H179 H269 H206 H160 H180 H161 H176 H162 H177

HW 90 HD 14 TT HD150 TT GRW 10-24

H123 H196 H168 H183 H193 H114 H178 H190

HD10-13 HD8-10C HD10-12 HD13-14 HD85-100 HD70-75 HD90-110 HD120-130 HD+90 D+90--110 110 HD+120-140

2

H139 H170 H171 H172 H122 H152 H153 H163 H185 185 H184

D V 10 DV 2 DV 3 D V 6.4 D V 8.4 H173 H187 DV 6. 6.4 4 PVC H174 H181 DV 8. 8.4 4 PVC H175 H182 DV 6 Su Supe perr DV 8 Su Supe perr D V 40 0 9 - DV 70 0 4 DV 90 VDV 65 D DV 85 H199 H200 H201

H107 H125 H120 H143 H138 H150 H151 H15 156 6 H15 157 7 H164 H165 H191 H166 H192 H197 H198

General


3 0 s m e t s y s n o i t a m r o f n I

Wir irtg tge en Gro Group up Informa Infor mati tion on Systems

Wir irtg tge en Gro Group up Netw twor ork k

(www.hammag.net www.hammag.net))

Part rts s & Mor ore e WIDOS


1

Information Informa tion systems


www.hammag.net Brochures Internal Reports Job Report ports s Ordering of o f infor i nforma matio tion n material material Sales Sa les Training Traini ng Trainin raining g date dates s Technik-Infos Downloads Medi Me dia a database database


2



Part rts s & Mo r e Most imp import orta ant wea wearr and te t ear pa p arts Serv rvice ice Kits Kit s Emerge mergency ncy Kits K its Lubricants


3



WIDOS Spare parts docu d ocumenta mentatio tion n Opera perati ting ng and maint mainte enance manuals Hydraulic circ circuit uit dia diagrams grams Ele lectri ctric c circu c ircuit it dia diagrams grams Mach chin ine e data Safe fety ty inst instruct ructions ions Technik-Infos Parts info information rmation Serv Se rvic ice e For orms ms


4



4 0 s c i n a h c e M

Dyn yna amic co compa mpact ction ion sy syst ste ems


1

Mechanics

Working princi principle ples s

Vibration


Oscillation

2

Directed vibration

Mechanics

Vibration


3

Mechanics

Circ ircula ularr vibr v ibra ator wit with h oil oi l dampene dampened d cha ch ang nge e-ov ove er unb u nba alances

low frequency frequency big amplitud amplitud e

high frequency frequency small amplitu amplitu de

Direction of rotation Fixed Fixed unb alance alance Moving unbalance Am A m p l i t u d e


4

Mechanics

Direction of rotation r otation - vibrator vibrator Important! Big amplitude

vibrator vibrator turns clockwise!

Otherwi Otherwise se danger danger o f bea b earin ring g dama d amages! ges!

Left side si de view view

Ser Ser i es HD / DV

Vibration • Big amplitude • Small amplitude

Direction of rotation

Series 3000

clockwise


5

Mechanics

Vib ibratio ration n drum dr um HD7 HD70


6

Mechanics

Vib ibratio ration n dru d rum m HD1 HD130


7

Mechanics

Vib ibratio ration n dru d rum m HD7 HD75.4 – sp spli litt dru d rum m


8

Mechanics

Oscillation


9

Mechanics

Ad A d v an antt ag ages es o f o s c i l l at atii o n

• No shock waves • Greater temperature range • Better compaction results • Instant adjustment • Automatic system system • No grain crushing • Good initial grip • Faster and better compaction B as i c t r ai n i n g

10

Mechanics

Dru rum m design - Osci scill lla ati tion on


11

Mechanics

Dru rum m design - Osci scill lla ati tion on


12

Mechanics

Dru rum m desig design n - HD HD120 Osc Oscil illatio lation n


13

Mechanics


14

Mechanics

VIO


15

Mechanics

Drum Dru m d esi esig g n 34 3412 12-3 -341 414 4 VIO VIO


16

Mechanics

VIO Un b alanc alance e

Unbalance mass

Unbalance shaft


17

Mechanics


18

Mechanics


5 0 s c i l u a r d y h s c i s a B

Overview verview hydra hydr aulic symbols sym bols acco acc o r d i n g t o DIN DIN IS ISO 121 12199-1 1

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Contents

CONTENTS: 1. Basic elements elements ............................................................................3 2. Reservoirs ....................................................................................4 3. Service devices / service uni ts ..................................................5 4. Pumps and mo tors ......................................................................5 4.1 Pumps ...................... ................................. ....................... ....................... ....................... ....................... ....................... ....................... ....................... ................ .... 5 4.2 Motors ...................... ................................. ....................... ....................... ....................... ....................... ....................... ....................... ....................... ................ .... 5

5. Valves (actuators) .......................................................................6 5.1 Control valves valves ....................... .................................. ....................... ....................... ....................... ....................... ....................... ....................... .............. ... 6 5.2 Examples ...................... ................................. ....................... ....................... ...................... ....................... ....................... ....................... ....................... ............. 7 5.3 Check Check valves ....................... .................................. ....................... ....................... ....................... ....................... ....................... ....................... ................ ..... 8 5.4 Pressure valves ...................... ................................. ....................... ....................... ....................... ....................... ....................... ....................... ............. 8 5.5 Flow-control Flow-control valves valves ....................... ................................... ....................... ....................... ....................... ...................... ....................... ................. ..... 9 5.6 Types of acti acti vation (valves) ....................... .................................. ...................... ...................... ....................... ....................... .............. ... 10

6. Cylinders ....................................................................................11 7. Measuring Measuring and indic ating devices ...........................................11 8. Top 10 hydraulic symbo ls ........................................................12 Notes..............................................................................................14

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Basic elements elements

1. Basic elements Working line; electr. wire

Control line; Leakage oil line

Component

Mechanic connection (drive shaft, lever, piston rod)

Flexible line (hose)

Crossing with / without connection

Closed pressure port

spring

choke

pneumatic/hydraulic

Basic symbol for pumps and motors

Adjustability in general

Basic symbol for a three-position valve

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TReservoirs

Way and direction of a volume flow (inside a valve)

Rotary movement with rotation direction

Elektric motor

Non-electric drive unit

2. Reservoirs Pressure reservoir without/with gas-tensioning device

(Fluid) reservoir Connection to atmosphere; tube connection above/below fluid level

3.

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T Service Service devices / service uni ts

Service devices / service un its Filter without with pollution indicator

Manually operated (water) separator

Cooler

Silencer

4. Pumps Pumps and motor s 4.1 Pumps Hydraulic pump (fixed displacement) with one/two flow directions

Hydraulic pump (variable displacement) with one/two flow directions

4.2 Motors Hydraulic motor (fixed displacement) with one/two flow directions

Hydraulic motor (variable displacement) with one/two flow directions

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TValves (HTactuatorsTTTH)

5. Valves (actuators (actuators)) 5.1 5.1 Contro l valves Control valve with three positions and four connections general symbol

Control valve with interim positions and two endpositions, also called proportional valve general symbol

One flow path

Two closed connections

Two flow paths

Two flow paths and one closed connection

Two flow paths connected to each other

One flow path in shunt connection

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TValves (HTactuatorsTTTH) 5.2 Examples

2-port/2-way valve

3-port/2-way valve

4-port/3-way valve directional blocked center valve

4-port/3-way valve directional blocked center valve, in center position fluid is pumped to the tank

4-port/3-way valve with floating position

5.3

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TValves (HTactuatorsTTTH) Check Check valves Check valve simple/spring loaded

Controlled check valve closing/opening avoided by activation

Shuttle valve

Zweidruckventil (UND-Ventil)

Shut-off valve

5.4 5.4 Pressure Pressu re valves

Pressure limit valve adjustable

Pressure control valve adjustable

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TValves (HTactuatorsTTTH) 5.5 5.5 Flow-contr ol valves Choke valve Choke valve Cross sectional area fixed/adjustable

Throttle-check valve Throttle-check valve

Orifice fixed cross-section

Flow-control valve Flow-control valve

5.6

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TValves (HTactuatorsTTTH) Types of activ ation (valves) Activation by muscular strength

Activation by muscular strength pushbutton / pullbutton

Lever

Pedal with one/two directions

Electric activation with magnetic coil

Activation by fluid pressure directly operated; general symbol

Roller tappet

Spring

Activation by fluid pressure indirectly operated by a pneumatic pre-stage

In series activation e.g. solenoid operates a pneumatic valve which operates the main valve

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TCylinders

6. Cylinders Cylinder single-acting with return spring

Cylinder double-acting

Cylinder with (adjustable) damping at the bottom-side

7. Mea Measur suring ing and ind icatin g devices Manometer

Thermometer

Volumetric flow meter / indicator

Pressure sensor

Pressure switch

Temperature sensor

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Top 10 10 hydraulic symbols

8. Top Top 10 hydraulic hyd raulic symb s ymbols ols (Fluid) reservoir Connection to atmosphere; tube connection above/below fluid level

Filter without without with pollution indicator

Cooler

Hydraulic pump (fixed displacement) with one/two flow directions

Hydraulic pump (variable displacement) with one/two flow directions

Hydraulic motor (fixed displacement) with one/two flow directions

Hydraulic motor (variable displacement) with one/two flow directions

4-port/3-way valve directional blocked center valve, in center position fluid is pumped to the tank

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Top 10 10 hydraulic symbols

Pressure limit Pressure limit valve adjustable

Cylinder double-acting

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Notes

Notes

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6 0 s t i u c r i c d e s o l c s c i l u a r d y H

Prin rincip ciple le of close clos ed hydra hydr aulic circu ci rcuits its

Basic training

1

Hydraulics – Principle of closed hydraulic circuits


Hochdruck High pressure

Basic training

Niederdruck Return line pressure

Saugdruck Suction pressure

Lecköldruck Case drain pressure

2

Steuerdruck Pilot pressure

Stelldruck Control pressure




Basic training




3






Basic training




4






Basic training




5






Basic training




6






Basic training




7






Basic training




8





7 0 s p m u p n o t s i p l a i x a s c i l u a r d y H

Vari ria able displ di spla ace ceme ment nt pu pump mp with me m echa chanic nic control co ntrol unit


1

Hydra ydraulics ulics – Varia riable ble displa displace ceme ment nt pumps


2


Vari ria able disp di spla laceme cement nt pu pump mp with me m echa chanic nic control co ntrol unit External External charge pressure supp ly

Scheme

Orifices dri ve control pressure





3




Vari ria able disp di spla laceme cement nt pu pump mp with me m echa chanic nic control co ntrol unit Design

Caution ! No ch arge pump installed! installed! Charge pressur e supply via steering steering pump !





4




Vari ria able disp di spla laceme cement nt pu pump mp with me m echa chanic nic control co ntrol unit Mechanic control unit






5





6


Vari ria able disp di spla laceme cement nt pu pump mp with me m echa chanic nic control co ntrol unit Charge pressure supp ly from steering steering r eturn line via hydraulic oil filter

Centring hydr. neutral position

M 18x1,5

Centring mech. neutral position

Port PS oil su pply t o the brake release valve M 14x1,5

Charge Charge and and hi gh pr essure valve

Case drain port por t T2 from the br ake release valve

(with bypass bypass for t owing) reverse forward max. 350bar

M 22x1,5

Charge pr essure valve max. 22 bar


7


Vari ria able disp di spla laceme cement nt pu pump mp with me m echa chanic nic control co ntrol unit Emergency mergency s top ports X3 ,X4

Connection drill

Test Test po rts X1 ,X2

Bowden cable

5 - 22 bar (in front of orifice) M 12x1,5

Test Test po rt Fe = charge pressure max. 22 bar M 18x1,5

Ai A i r b l eed R M 12x1,5

distributor block with scavenge system


Port T1 to t he cooler M 22x1,5

8


Vari ria able displ di spla ace ceme ment nt pu pump mp with hydraulic hydraulic control unit


9



10


Vari ria able disp di spla laceme cement nt pu pump mp with hydraulic hydraulic control unit External External charge pressure supp ly

Scheme

Orifices dri ve control pressure





11




Vari ria able disp di spla laceme cement nt pu pump mp with hydraulic hydraulic control unit Design






12




Vari ria able disp di spla laceme cement nt pu pump mp with hydraulic hydraulic control unit Hydraulic control unit






13





14


Vari ria able disp di spla laceme cement nt pu pump mp with hydraulic hydraulic control unit Speisedruckversorgung FS Suppl y Valve Valve Fa1 M 18x1,5

(von Filter) M 18x1,5

Variable displacement pump - vibration

Supply brake release valve Fa M 18x1,5

Case drain p ort T1 (vibration pump) M 22x1,5

High pr essure cut-off max. 450 bar

Ai A i r b l eed R M 12x1,5

High pressure port B = forward

Test Test po rts control pressures X1 = forward X2 = reverse 5 - 22 bar M 12x1,5 (in front of orifice) B as i c t r ai n i n g

SAE ¾“

Remote control port Y2 = reverse

Centring hydr. neutral position 15

6 – 18 bar M 14x1,5 Hydra ydraulics ulics – Varia riable ble displa displace ceme ment nt pumps

Vari ria able disp di spla laceme cement nt pu pump mp with hydraulic hydraulic control unit High pressure port Variable displacement A = reverse SAE ¾“ pump – vibration

Charge pr essure valve

Case Case drain por t T2

max. 22 bar

M 22x1,5

Test Test po rts M A = reverse MB = forward max. 480 bar High pressure cut-off max. 450 bar M 12x1,5

Centring mech. neutral position

Test Test po rt PS = control pressure 22 bar (after orifice) M 14x1,5

Einspeis e - u. HD.ventile (mit Bypass zum Ab s c hl epp en) en ) Rückwärts Vorwärts max. 500 bar B as i c t r ai n i n g

16

Remote control port Y1 = forward 6 – 18 bar M 14x1,5

Test Test po rt G =charge pressure max. 22 bar M 12x1,5 Hydra ydraulics ulics – Varia riable ble displa displace ceme ment nt pumps

Vari ria able displ di spla ace ceme ment nt pu pump mp with ele electric ctric contro c ontroll unit


17



18


Vari ria able disp di spla laceme cement nt pu pump mp with ele electric ctric control c ontrol unit Scheme

External External charge pressure supp ly

Orifices Orifices dri ve control pressure





19




Vari ria able disp di spla laceme cement nt pu pump mp with ele electric ctric control c ontrol unit Design






20




Vari ria able disp di spla laceme cement nt pu pump mp with ele electric ctric control c ontrol unit Electric control unit with proportional solenoids






21





22


Vari ria able disp di spla laceme cement nt pu pump mp with ele electric ctric control c ontrol unit Test Test p orts Variable displacement pump drive

Control pressure X1 = small amplitude X2 = big amplitude 5-22 bar M12x1,5 (in front of orifice)

Ai A i r b l eed R M12x1,5

Test Test port po rt Ps = control pressure 22 bar (after orifice) M14x1,5

Test Test port po rt G = Charge pressure max. 22 bar M12x1,5

Charge pressure press ure valve not inst alled alled !!! Charge pressure controlled by drive pump

Centring

Frequency Frequency adjustment

mech.neutral position high frequency small amplitude


Case Case drain por t T2 (from drive pump) M 22x1,5

23

Test Test p orts MB = small amplitude M A = big Amplitude max. 423 bar high pressure cut-off 420 bar M12x1,5


Vari ria able disp di spla laceme cement nt pu pump mp with ele electric ctric control c ontrol unit Variabl Variable e displ acement acement pump - drive

Centring

Proportional solenoid b = big Amplitude a = small Amplitude

hydr. neutral position

High pressure cut-off max. 420 bar

High pressure port B = small Amplitude SAE ¾“

Charge and high pressure valves valves small amplitude big amplitude max. 420 bar

Frequency adjustment low frequency big amplitude

Test port s charge pressure M18x1,5

High pressure port A = big mplitude SAE ¾“


Charge Charge pressure supply Fa

Case Case drain po rt T1

(from drive pump port Fa1) M 18x1,5

M 22x1,5

24


Dif iffere ferent nt valve pl pla ate desig designs ns


25



26


Valve plate plate without withou t high h igh pressure cut off o ff Charge and high pressure valves with bypass bypass for towing

valve movement – charging

valve movement – high pressure






27




Valve plate plate wi with th hig h igh h pre pr essu ssure re cut of off f Charge and high pressure valves with bypass bypass for towing








28




Valve plate plate wi with th hig h igh h pre pr essu ssure re cut of off f Charge and high pressure valves with bypass

bypass bypa ss for towing








29





30


Separa paratin ting g the th e hyd hydro rost sta ati tic c driv dr ive e power po wer tra tr ain (e.g. towin tow ing) g)


31



32


Sepa parating rating th the e hy hydr dros osta tati tic c drive dr ive power po wer tra tr ain (e.g. towing tow ing)) high hig h pressur e valves with bypass

A

B

Disengaging isengaging closed hydraulic cir cuits: Unscrew the nut (B) by two turns. Then screw in the hexagon socket bolt (A) on the high pressure valves until it is flush with the nut (Pos. 2). Re-enga e-engagin ging g closed hydraulic ci rcui ts: Unscrew the hexagon socket bolt (A) up to the stop. Then tighten up the nut (B) (B ) B as i c t r ai n i n g

33



34



8 0 s r o t o m n o t s i p l a i x a s c i l u a r d y H

Fixed displace disp laceme ment nt axial axial piston pis ton mot m otor ors s

Gr u n d l ag en s c h u l u n g

1

Hydraulik Hydra ulik - Axialkolbe Axialkolbenmotoren nmotoren


2


Fixed displa disp laceme cement nt axi axia al pisto pis ton n motor mot ors s witho wi thout ut sca sc ave veng nge e valve Scheme




3



Fixed displa disp laceme cement nt axi axia al pisto pis ton n motor mot ors s with wi th scave scaveng nge e va valve lve Scheme

B

B

B

A

T A A




4



Fixed displa disp laceme cement nt axi axia al pisto pis ton n motor mot ors s with wi th scave scaveng nge e va valve lve Scheme

T

(T)




5



Fixed displa disp laceme cement nt axi axia al pisto pis ton n motor mot ors s with wi th scave scaveng nge e va valve lve High pressure port A big amplitude M 27x2

Impo mportant rtant ! Check direction o f rotation rot ation after repair! repair!

High pressure port B small amplitude M 27x2

Integrated scavenge system (controlled by orifice)

Scavenge Scavenge valve valv e

Conn ection T1

Case Case drain por t T2

M 16x1,5 (closed)

M 16x1,5


6


Ax A x i al p i s t o n m o t o r w i t h v ar arii ab abll e di d i s p l ac acem emen entt – ele lectr ctrically ically cont c ontrol rolle led d


7



8


A x i al p i s t o n m o t o r – var Ax v arii ab abll e displacement Scheme




9




A x i al p i s t o n m o t o r – var Ax v arii ab abll e displacement Design




10




A x i al p i s t o n m o t o r – var Ax v arii ab abll e displacement Ad A d j u s t i n g s c r ew displacement V min.

Proport ional solenoid Verstellung

Case drain p ort T M 18x1,5

Test Test por t G 80 - 400 bar M 14x1,5

Connection r pm sensor

High p ressure port A SAE ¾“

High p ressure port B SAE ¾“

Test Test po rt M1


Ad A d j u s t i n g s c r ew

M 14x1,5

displacement V max.

Shuttle

Scavenge Scavenge valve v alve 11

Scavenge block Hydraulik Hydra ulik - Axialkolbe Axialkolbenmotoren nmotoren


12



9 0 s r o t o m n o t s i p l a i d a r s c i l u a r d y H

Radial piston pisto n motor mo tors s


1

Hydr ydra auli ulic c – Radia diall pis piston ton mot motors ors

Design


2


MS Mot otor or – View and and co conn nne ect ctor ors s

Case drain port - 1

High pressure - L

Gear shifting - Y

Parking brake

High pressure - R


3


MS Mot otor or – Sect ctio ional nal view v iew


4


MS Mot otor or – Exp xplo loded ded view v iew


5


MS Mot otor or - As Assembl sembly y

Bearing support


Hydrobase

6

Parkin Parkin g br ake


Functioning


7


MS Mot otor or - Fun unct ctio ioni ning ng

1-Gear


2-Gear

8


As A s s em emb b l y : Hy Hyd d r o b as ase e


9


MS Mot otor or - Hyd Hydro robase base

MS MOTOR

Hy d r o b as e

B ear i n g s u p p o r t

Pa r k i n g b r a k e

Drive unit uni t Piston Cam rin g Cylinder blo ck Valving

Bearing support


10

Hydrobase



MS Mot otor or – Cyl Cylin inde derr bl bloc ock k

Mono-block lock

Bi-block


11


MS Mot Motor or - Pis Pisto ton n Roller Piston Bushing

block + piston without lunambule latera laterall skidding skidd ing

Clip

block + piston + lunambule without clips rotation

Piston ring Lunambule

block + piston + Lunambule Lun ambule + Clips


12


MS Mot otor or - Valv lvin ing g

2-C valvin valv ing g

1-C valvin valv ing g


13



Machined chi ned va v alving lvi ng


Molded ol ded valv valvin ing g

14



nb of ho les les = 2x nb of cams B as i c t r ai n i n g

nb of pistons= nb of h oles oles 15



2 indexes in dexes

Mind mounting m ounting orienta orientation!! tion!!!! B as i c t r ai n i n g

16


MS Mot otor or – Valv lvin ing g se s eali ling ngs s Static seali sealing ng

O-Ring Back-up Back-up ring ri ng

Spool poo l / cover B as i c t r ai n i n g

17


MS Mot otor or - Be Bea ari ring ng su supp ppor ortt MS MOTOR

Hydrobase

B e ar i n g s u p p o r t

Pa r k i n g b r a k e

Roller Bearin Bearing g Sealing

Bearing support


Hydrobase


18


MS Mot otor or - Be Bea ari ring ng su supp ppor ortt Beari Bearing ng grea gr ease se case / exte xt ernal ambia mbi ance nc e seali sealing ng Tapered roller bearin bearings gs – “ O-Mounting” Front ro nt tapered tapered rolle roll er bearing bearing Snap ring rin g

Valving tapered rolle roll er bearing bearing

Shims

Housing Housi ng / bea bearing ri ng grea gr ease se case seali sealing ng B as i c t r ai n i n g

19



20


As A s s em emb b l y : Par Park k i n g b r ak ake e


21


MS Mot otor or - Pa Park rkin ing g brake b rake MS MOTOR

Hy d r o b as e

B ear i n g s u p p o r t

Parki Parki ng brake

Discs Other parts

Bearing support


Hydrobase

Parkin Parkin g brake

22


MS Mot otor or - Pa Park rkin ing g brake b rake

Inner disc Outer disc


23



Static sealing

Dynamic sealing B as i c t r ai n i n g

24



Gehäuse Valving Sealing Bearing

Brake pist on

Belleville washer

Moving ovi ng O-Rin -Ring g

Bra Br ake shaft B as i c t r ai n i n g

25



Release of parking brake without hydraulic pressure


26


MK 04


27


MK 04

Claw bra br ake

SAE Flang Flange e B as i c t r ai n i n g

28


MK 05 - radi rad i al


29



30



0 1 s c i r t c e l e s c i s a B

Electri lectric c symbols symb ols

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Contents

CONTENTS: CONTENTS:.....................................................................................2 1. Earth, groun d, equip equip otential ......................................................3 2. Fuses .................................. ................................................... ................................... .................................... ....................... ..... 3 3. Connectors ..................................................................................3 4. Switches .................................. .................................................... ................................... ................................... .................. 4 4.1 Contacts in general ....................... ................................... ....................... ....................... ....................... ...................... ....................... ................. ..... 4 4.2 Delayed Delayed cont acts ....................... ................................... ....................... ....................... ....................... ....................... ....................... .................... .........4 4 4.3 Ad di ti on al s ymbo ym bo ls ....................... ................................... ....................... ....................... ....................... ...................... ....................... ................. ..... 5 4.4 Schalter mit mehreren Schaltstellungen ...................... .................................. ....................... ....................... .................. ...... 6

5. Electrom echanic drives ..............................................................6 6. Ac A c c u m u l ato at o r s u n d f u el c ell el l s ......................................................7 7. Electron ic devices .......................................................................7 7.1 Resistors ...................... ................................. ....................... ....................... ...................... ....................... ....................... ....................... ....................... ............. 7 7.2 Capacitors ....................... ................................... ....................... ....................... ....................... ....................... ....................... ....................... .................... ........7 7 7.3 Light sources ...................... ................................. ....................... ....................... ....................... ....................... ....................... ....................... ................ ..... 8 7.4 Inductance ...................... .................................. ....................... ....................... ....................... ....................... ....................... ....................... .................... ........8 8

8. Electron ic devices .......................................................................8 8.1 Diodes ...................... ................................. ....................... ....................... ....................... ....................... ....................... ....................... ....................... ................ .... 8 8.2 Transistors ...................... .................................. ....................... ....................... ....................... ....................... ....................... ....................... .................... ........9 9

9. Monitorin g and reproducing devices devices ........................................9 10. An A n t enn en n as and an d r adi ad i o ..................................................................9 11. Measuring Measuring , cont rol and feedback feedback cont rol sy stems.............10 11.1

Displaying Displaying measuring measuring devices devices ....................... .................................. ...................... ....................... ....................... ................ ..... 10

11.2

Electrical Electrical cl ocks ...................... ................................. ...................... ....................... ....................... ...................... ....................... .................. ...... 10

11.3

Remote Remote monit oring devices devices ..................... ................................. ....................... ...................... ...................... ......................10 ...........10

11.4

Indicator Indicator lamps, signaling devices devices ..................... ................................. ....................... ...................... ......................10 ...........10

12. Top 10 Electri Electri c symb ols ........................................................12 Notes..............................................................................................13

HAMM AG

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Earth, ground, equipotential

1. Ea Earth, rth , ground gro und,, equipo tential ground (general symbol)

function ground

2. Fuses fuse (general, lead fuse)

fuse with alarm contact

fuse switch fuse switch

fuse disconnector fuse disconnector

fuse load fuse load disconnector

3. Connectors female connector female connector

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Switches

4. Switches 4.1 4.1 Contacts in general general Normally open contact; switch in general three alternative display formats

break contact

4.2 4.2 Delayed Delayed cont co ntacts acts

normally open contact activation delayed

normally open contact activation delayed

break contact fall-back delayed

break contact fall-back delayed

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Switches 4.3 4.3 Additio nal symbols

power switch

disconnector

normally open contact with automatic fall-back

break contact with automatic fall-back

limit switch normally open contact

limit switch break contact

two-way switch with automatic fall-back from left position (filled triangle) and non-automatic fall-back from right position (open circle)

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Electromechanic drives 4.4 4.4 Schalter mit mehreren mehreren Schaltstellun gen

multi-position switch with four positions

multi-position switch with position chart activation direction and field are shown by arrows positions are labeled by numbers

multi-position switch in any position three successive contacts are bridged

5. Electro Electromechanic mechanic driv es electromechanic drive with one coil

thermo relay e.g. with a bi-metal

electromechanic drive with a response delay

electromechanic drive with a fall-back delay

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Ac c u mu l ato at o r s u n d f uel c ells el ls

6. Accumul Ac cumul ators un d fuel cells cells fuel cell, accumulator

7. Electro Electronic nic devic es 7.1 Resistors resistor

variable resistor

resistor with a sliding contact (potentiometer)

resistor with a sliding contact and „off“-position

varistor (resistor depending from voltage)

7.2 Capacitors capacitor

polarized capacitor; electrolytic capacitor

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Electronic devices 7.3 7.3 Ligh t sou rces light bulb light bulb

light-emitting light-emitting diode

7.4 Inductance

Inductance

*)

According to DIN EN 60617-4 only the version with the 4 arcs is valid. The version with the rectangle filled black is no longer valid.

8. Electro Electronic nic devic es 8.1 Diodes diode

photodiode

light-emitting light-emitting diode

HAMM AG

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Monitori ng and reproducing devices devices

8.2 Transistors

NPN-transistor NPN-transistor with with housing

PNP-transistor with housing

9. Monitorin onit oring g and reprodu reproducing cing devices devices

speakers (SP)

microphone

10. 10. Antenna Ant ennas s and radio

antenna

HAMM AG

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Measuring, easuring, c ontrol and feedback feedback cont rol systems

11. 11. Measur easuring ing , contro con troll and and feedba feedback ck control contr ol systems 11.1 11.1 Displaying measur measur ing devices voltmeter

amperemeter

11.2 11.2 Electr Electr ical cloc ks clock general symbol

clock with switch

11.3 11.3 Remote Remote moni tor ing devices

telemetry transmitter

telemetry receiver

11.4 11.4 Indicator lamps, si gnaling devices indicator lamp lamp lamp, general symbol

HAMM AG

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Measuring, easuring, c ontrol and feedback feedback cont rol systems

indicator lamp flashing

visual alarm visual alarm electromechanic, indicator, falling disk

position indicator position indicator idle position and two working positions

acknowledge indicator acknowledge indicator

horn

buzzer

HAMM AG

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Top 10 10 Electr Electr ic symb ols

12. 12. Top 10 10 Elect Electri ric c sy symb mbol ols s ground (general symbol)

fuse (general, lead fuse)

normally open contact

electromechanic drive with one coil

fuel cell, accumulator

resistor

capacitor

inductance

diode (general symbol)

light bulb

HAMM AG

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# 2145192

Notes

Notes

HAMM AG

18/08/2009

13/14 13/14

# 2145192

Notes

HAMM AG

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# 2145192

Termina rmi nall desi designation gnations s agree agr eeabl able e to DIN 7255 72552 2

HAMM AG

18/08/2009

1/8

# 2145190

CONTENTS:

CONTENTS: CONTENTS:.....................................................................................2 1. Ignition system ............................................................................3 2. Preheating reheating system syst em ......................................................................3 3. Battery .................................. .................................................... .................................... ................................... .................... ... 3 4. Electric motor s ............................................................................3 5. Direction indicators ....................................................................4 6. Al A l t ern er n ati at i n g c u r r ent en t g ener en erat ato o r ....................................................4 7. Al A l t ern er n ato at o r .....................................................................................4 8. Lightin g system system ...........................................................................5 9. Wash Washer er system syst em ............................................................................5 10. A 10. Ak k u s t i s c h e Warn War n anl an l age ag e ........ Fehler! Textmarke nicht definiert. 11. Switches ....................................................................................6 12. Relays ................................... ..................................................... .................................... ................................... .................6 6 13. Contacts ....................................................................................7 14. Ad A d d i t i o n al t erm er m i n al d esi es i g n ati at i o n s ............................................7 Notes................................................................................................8

HAMM AG

18/08/2009

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# 2145190

Ignition system

1. Ignition system Terminal 1 1a, 1b

Meaning ignition coil, ignition distributor, low voltage ignition distributor with 2 separate circuits

2

Kurzschließklemme, magneto

4

ignition coil, ignition distributor, high voltage

4a, 4b

ignition distributor with 2 separate circuits, high voltage

7

Terminal of base resistors, to / from ignition distributor

15

switched plus after battery

15a

output of series resistor to ignition coil and starter

2. Preheating system Terminal

Meaning

15

input ignition switch

17

start

19

preheat

50

starter control

3. Battery Terminal

Meaning

15

battery plus via switch

30

direct input from battery plus

30a

input 2nd battery and change-over relay 12/24V

31

return wire battery minus or ground

31a

return wire to 2nd battery minus, change-over relay 12/24V

31b

return wire to battery minus or ground via switch

31c

return wire to 1st battery minus, change-over relay 12/24V

4. Electric motors Terminal

Meaning

32

return wire

33

main connector (interchanging 32 und 33 possible)

33a

limit stop

33b

shunt field

33f

2nd lower speed step

HAMM AG

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# 2145190

Direction indi cators 33g

3rd lower speed step

33h

4th lower speed step

33L

rotation direction left

33R

rotation direction right

86

input terminal of contactor

5. Direction indi cators cators Terminal

Meaning

49

input flasher unit

49a

output flasher unit, input direction indicator switch

49b

output 2nd direction indicator circuit

49c

output 3rd direction indicator circuit

C

1st direction indicator control lamp

C2

2nd direction indicator control lamp

C3

3rd direction indicator control lamp

L

direction indicators left

R

direction indicators right

L54

output for combined direction indicator and brake lights on tractors and trailers (left)

R54

output for combined direction indicator and brake lights on tractors and trailers (right)

6. Alternating cur rent genera generator tor Terminal

Meaning

51

direct-current voltage at rectifier

51e

like 51, with additional choke coil for day operation

59

output alternating voltage, input rectifier, switch

59a

output charge armature

59b

output rear light armature

59c

output brake light armature

63

controller terminal to change voltage

63a

controller terminal to change current

64

generator control wire

7. Alternator Terminal 61 HAMM AG

18/08/2009

Meaning charge control 4/8

# 2145190

Lighting system B+

battery plus

B-

battery minus

D+

generator plus

D-

generator minus

DF

dynamo field

DF1

dynamo field 1

DF2

dynamo field 2

U, V, W

three-phase current terminals

8. Ligh ting system Terminal

Meaning

54

brake light in case of combined lights and on trailer outlet

55

fog lights

56

high beam

56a

high beam and control lamp

56b

low beam

56d

headlight flasher

57

parking light motorcycle

57a

parking light

57L

left parking light

57R

right parking light

58

side-marker lamps, licence plate illumination, instument lighting, tail light

58L

light switch terminal for left side-marker lamps and tail light (if switchable separately)

58R

light switch terminal for right side-marker lamps and tail light (i f switchable separately)

58b

Tail light changeover for two-wheel tractors

58c

Trailer plug, single-wired taillight fused in trailer

58d

adjustable instrument lighting

9. Washer Washer system sys tem Terminal

Meaning

53

input wiper motor plus

53a

limit stop plus

53b

shunt coil

53c

window washer pump

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# 2145190

Ac ou s t ic war n in g s ys t em 53e

brake coil

53i

wiper motor with permanent magnet, third brush for higher speed

10. Acoustic Acoust ic warning system Terminal

Meaning

71

input tone sequence control unit

71a

output to horn 1 and 2 low

71b

output to horn 1 and 2 high

72

alarm switch - rotating flashing beacon

85c

alarm switch – sound on

11. Switches Terminal

Meaning

81

input for break contact, change-over contact

81a

1st output

81b

2nd output

82

input for normally open contact

82a

1st output

82b

2nd output

82z

1st input

82y

2nd input

83

input multi-position switch

83a

output 1

83b

output 2

12. Relays Terminal

Meaning

84

input actuator and relay contact (start of coil)

84a

output actuator (end of coil)

84b

output relay contact

85

output actuator (end of coil, minus)

86

input actuator (start of coil)

86a

input 1st coil

86b

input 2nd coil

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# 2145190

Contacts

13. Contacts Terminal 87 87z, y, x 87a 87b, c, d 88

Meaning input break contact and changeover contact input break contact and changeover contact (several inputs) output break contact and changeover contact output break contact and changeover contact (several outputs) input normally open contact

88z, y, x

input normally open contact (several inputs)

88a (87)

output normally open contact and changeover contact

88b, c, d

output normally open contact and changeover contact (several outputs)

14. Additional Addit ional terminal designation designations s Terminal

Meaning

52

signal from trailer

54g

solenoid valve for permanent brake in trailer

75

radio, cigarette lighter

77

door valve control

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# 2145190

Notes

Notes

HAMM AG

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# 2145190

Cable bl e colours colo urs and cross-sections agreea agr eeabl ble e to DIN 72551 72551

HAMM AG

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# 2145186

CONTENTS:

CONTENTS: CONTENTS:.....................................................................................2 1. Cable colour col ours: s: .............................................................................3 1.1 Most common col ours, abbreviations abbreviations and applications ......................................3 1.2 Most important wires of direction indi cation and and light ing system......................3

2. Wire cross -sectio -sectio ns ....................................................................4

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# 2145186

Cable colours:

1. Cable Cable colour col ours: s: Um die einzelnen Leitungen einfacher auseinander zu halten, wird ein Farbsystem verwendet, mit welchem die einzelnen Leitungen gekennzeichnet sind. Je nach Herkunftsland und Alter des Fahrzeugs können diese Farben sich unterscheiden, die hier angegebenen Farben sollten sich aber in jedem deutschen Fahrzeug, das nach dem 2. Weltkrieg gebaut wurde, wiederfinden (wie in der DIN 72551 festgelegt). Viele Leitungen sind zweifarbig. Die erste Farbe (Grundfarbe) dient zur Feststellung des Verwendungszwecks, Verwendungszwecks, die zweite Farbe (Kennfarbe) dient zur Identifizierung der speziellen Leitung (z.B. Blinker links/rechts). Die Kennfarbe ist meist in Form einer (verdrillten) Linie oder Ringen auf der Leitung angebracht.

1.1 1.1 Most common colou rs, abbrevia abbreviations tions and applications applications Colour

Ab br evi ati on

Ap pl ic ati on

light blue

hb

control and signal lamps

brown

br

ground

yellow

ge

low beam

green

gn

ignition coils to interruptors

grey

gr

rear lights, side-marker lights and licence plate illumination

violet

li

code colour

red

rt

starter to alternator, ignition and light switch; load/fuses directly connected to terminal 30

black

sw

battery to starter, ignition and light switch, ignition in general

white

ws

high beam

1.2 1.2 Most important wires of direction indication and and lighting system Base colour

Code colour

ws ws

Ap pl ic ati on high beam left

sw

ge

high beam right low beam left

ge

sw

low beam right

gr

sw

parking light left

gr

ro

parking light right

sw

ws

direction indicator left

sw

gn

direction indicator right

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# 2145186

Wire cross-sections

2. Wire Wire cross-sectio ns The most common cable cross-sections in vehicles are 0.5, 0.75, 1.0, 1.5, 2.5, 4, 6 and 10mm2. For single laid wires cable cross-sections above 1 mm 2 are recommended for stability issues. For cable bundles the single wires may be thinner. There are two rules of thumb for wire cross-sections:  

max. 5A/mm2 for permanent load max. 10A/mm2 for short-term load

If the load limit for a wire is achieved, the next bigger cross-section should be chosen especially for longer wires. Examples for cross-sections to use: Current Current

Cross-section Cross-section

Application

< 2,5 A

0,5 - 0,75 mm2 rear light, parking light, inside light, control lamps

<8A

1,5 mm2

direction indicators, head lights, wipers, horn

< 16 A

2,5 mm2

collector wires for head lights

< 40 A

6,0 mm2

power supply, ignition switch, fuse box

> 40 A

16 - 35 mm2

HAMM AG

18/08/2009

starter (depending on cable length and power)

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# 2145186

Hamm Roller

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