Service Training
Service Training Table of contents Foreword List of additional documentation General Maintenance
A1 A2 A3 A4
List of components
B1
Kubota diesel engine View of engine Pump installation on diesel engine View of diesel engine, flywheel side Tests and adjustments Adjusting the valve clearance clearance Trouble Shooting
C1 C2 C3 C4 C5 C6 C8
Travel system Travel pump Travel pump control Charge pressure relief valve High pressure relief valves
D1 D3 D7 D9 D 10
Service Training Foreword In 2004 the tandem vibratory rollers of product range BW 100 AD/AC4 and BW 120 AD/AC4 were launched in the market for the first time. They are a further development of the old BW 100/120AD/AC of generation 3, which already were a great sales success. The contents of this training shall enable the service engineer to perform adjustments and trouble shooting as well as all necessary repair work in a professional manner. The owner of the machine should recognize that the service engineer is fully familiar with the machine. He should realize that the service engineer applies the correct measures to detect a possible fault on a machine and that all repair measures are performed with skill and knowledge. Persons participating on this training course should be confident when having to work on this machine.
Documentation For the BOMAG machines described in this training manual the following documentation is additionally available:
Service Training General Machines of product range BW 100/120 AD/AC-4 are tandem vibratory rollers or combination rollers for compaction work in road construction. They are most suitable for the compaction of bituminous materials as well as light compaction tasks in earthwork. Compaction is achieved by the vibration of both drums or the vibration of the drum and the static load of the rubber tires. The power output from the water cooled Kubota diesel engine is transferred to drums or wheels (travel and vibration systems) and to the steering via the hydrostatic drive systems of the machine. This type of power transmission ensures lowest possible efficiency losses. Both drums of the BW 100/120 AD-4 are fitted with both travel motors as well as vibration motors. The motors for the respective drive systems are always arranged on one side of the machine. Since it is beneficial for many applications (e.g. when laying asphalt layers) to work with one vibrating and one static drum, the machine is equipped with a vibration shut-off valve for the rear drum. On machines of type BW 100/120 AC-4 the wheel set is driven by two travel motors. This roller combines the high compaction power of a vibration drum with the excellent surface sealing effect of rubber tires in one machine. This machine obviously achieves considerable savings in costs when compared with a pure vibratory or
Service Training Maintenance The tandem/combination rollers of series BW 100/120 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 machine must always be ready to be loaded up to its limits. Apart from that, all safety installations must always be fully functional when working under the partly very dangerous conditions on a construction site. Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably higher functional safety, but also prolongs t he lifetime of the t he 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 hour interval you must also perform the maintenance work for the 500 and 1000 hour intervals. It should also be clear, that with the 2500 hours interval only the work for the 10 and 500 hour intervals must be performed.
Service Training List of components BW 100/120 AD/AC-4 Engine Manufacturer
Kubota
Type
D 1703 MDI
Cooling
Water
Working cycles
4
Number of cylinders
3
Power DIN 6271 IFN/SAE at 2700 rpm
kW
25,2
Fixed engine speed Stage 1
rpm
2250
Fixed engine speed Stage 2
rpm
2700
Service Training BW 100/120 AD/AC-4 Travel motor (drums) Manufacturer
Poclain
Type
MK 04
Number
2
System
Radial piston motor
Displacement Brake
cm³/rev.
408 yes BW 100/120 AC-4
Travel motor (wheels) Manufacturer
Poclain
Type
MSE 02
Service Training Vibration motor Manufacturer
Bosch
Type
HYZ 8
System
Gear
Displacement
cm³/rev.
8
Frequency stage 1
Hz
55
Frequency stage 2
Hz
70
Amplitude
mm
0.5
Steering pump Manufacturer
Bosch
Type
HYZ 8
Service Training Kubota diesel engine 1703 MDI The tandem vibratory vibratory rollers of series BW 100/120 AD/AC-4 are powered powered by a water cooled 3-cylinder Kubota diesel engine type 1703 MDI. The engine is an upright water-cooled four-stroke diesel engine.
Service Training View of engine: engine:
4
2
1
3
Service Training Pump installation on diesel engine
3
1
2
Service Training View of diesel engine, flywheel side
3
1
2
4
Service Training Tests and adjustments Measuring the compression
Fig. 5: Compression pressure: 1. Run the engine warm and shut it down. Disassemble the nozzle nozzle holders. holders. 2. Install the diesel engine engine compression compression tester to the nozzle nozzle holder holder opening. opening. 3. Make sure that that the throttle lever lever is in top position (no injection) injection) and start the engine with the starter motor. 4. Read the max. pressure. pressure. Repeat Repeat the measurement at least two times. 5. If the measurement measurement is below below the permissible permissible limit value check cylinder, cylinder, piston, valve and cylinder head.
Service Training Checking the valve clearance
Service Training Please note that the TC-mark is only valid for cylinder 1. There is no mark for the other cylinder. Cylinder 1 is in compression stroke when the TC-mark is visible in the window (2) Now turn the flywheel further, until the other valves overlap top dead centre and adjust the valve clearance accordingly. Note: •
•
•
•
The "TC"-mark on the flywheel applies only for cylinder cylinder no. 1. The other cylinder has no "TC"-mark. When the „TC“-mark is aligned with the punched mark on the rear disc, piston no. 1 is in top dead centre position. Now turn the flywheel bz 15° clockwise or anticlockwise to check whether the pistons are in TDC-position (compression position). (The piston is in TDC when intake and exhaust valves do not move. When both valves are moving, the piston is in overlapping position.) Finally turn the flywheel by 360 ° to ensure ensure that „TC“-mark and punched mark mark match exactly. All valve clearances must be set to the nominal value. Turn the flywheel flywheel two to three times in anti-clockwise anti-clockwise direction to check check the valve clearance.
Service Training Troble Shooting Fault
Possible cause
Engine does not start
• • •
• • •
•
•
• • • • •
Remedy
No fuel Air in the fuel fuel system Water in the fuel system
Fill in fuel Bleed Replace fuel and clean or replace the fuel system
Fuel line clogged Fuel filter clogged Too high viscosity viscosit y of fuel or engine oil at low temperatures Fuel with low Ceten-number
Clean Replace Use specified fuel
Fuel loss caused by loose locking locking but on on injection line Incorrect adjustment of injection injection Fuel camshaft worn Injection nozzle clogged Malfunction of fuel lift pump Crankshaft, camshaft, piston or bearings seized
Tighten nuts
Use specified fuel
Adjust Replace Clean Repair or replace Repair or replace
Service Training Fault Engine does not turn regularly
Possible cause • • •
• • • • •
White or blue exhaust gas
• • • • •
Black or dark grey exhaust fumes
Fuel filter filter clogged clogged or soiled Replace Air filter clogged Clean or replace Fuel loss caused by loose locking locking but on on Tighten nuts injection line Faulty function function of injection pump Repair or replace Incorrect injection valve opening pressure Adjust Injection nozzle sticking sticking or clogged Repair or replace Fuel overflow line clogged Clean Malfunction of regulator Repair Too high engine oil level Piston ring ring worn or sticking Incorrect injection setting Insufficient compression Cylinder head gasket defective
Overload Poor fuel quality Fuel filter clogged Air filter clogged
• • • •
Insufficient power
• • •
Remedy
Incorrect injection setting Moving engine parts possibly seized Uneven fuel injection
Correct the oil level Replace Adjust Check compression pressure Repair Reduce the load Use specified fuel Replace Clean or replace Adjust Repair or replace Repair or replace the
Service Training Fault
Possible cause
Too low oil pressure
• • • • •
• • • • •
Excessive oil pressure
• •
Engine overheating
• •
• • • • • •
Remedy
Engine oil level too low Oil strainer clogged Oil filter cartridge clogged Pressure relief valve clogged with dust Pressure relief valve spring fatigued or broken Excessive clearance clearance of crankshaft bearing bearing Excessive clearance clearance of Rocker arm arm shaft Oil passage clogged Different type of oil Oil pump defective
Top up Clean Replace Clean Replace Replace Replace Clean Use specified oil quality Repair or replace
Different type of oil Pressure relief valve defective defective
Use specified oil quality Replace
Engine oil level too low Fan drive belt broken or not correctly tightened Coolant level too low Radiator and and cooling fins fins clogged by by dust Radiator internally corroded Coolant line corroded Radiator cap defective Water pipe damaged
Top up Replace or adjust Top up Clean Clean or replace Clean or replace Replace Replace
Service Training Engine solenoid: The machine is equipped with a solenoid which works according to the principle „ENERGIZED TO RUN“. RUN“. This solenoid has the benefit that the engine will be immediately shut down in case of a fault in the electric system. A disadvantage is the quite costly design of the solenoid with two coils. Nominal currents of windings: Pickup winding (PW)
51 A
Holding winding (HW)
0.7 A
Solenoid
Fig. 14: Function of the engine solenoid: The pickup winding (PW) is directly triggered via potential 30. Once the engine has
Service Training Travel system:
On the machines described in this training manual the travel system consists of a closed hydraulic circuit. It mainly consists of the travel pump with the integrated safety elements, two travel motors, the hydraulic oil filter and the hydraulic oil cooler.
Charge pressure from brake valve
Charge pressure from brake valve
High pressure test ports MA and MB
Service Training 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 used to release the travel motor integrated brakes: All safety safety and and control elements needed for the operation operation in a closed hydraulic circuit circuit are integrated in the travel pump. These are: High pressure relief valves (380 bar) with integrated boost check valves Charge pressure relief valve (24 bar) Servo control The travel motors (on AD-machines) are hydraulically connected parallel to each other. On AC-machines AC-machines all all three motors are arranged arranged parallel parallel to each other. other.
Service Training T r av av e l p u m p The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch Rexroth-Hydromatik, type A 10 VG 28.
3
5
2
380 bar
4
1
5
380 b
24 b
To the travel motors
Service Training Servo control High pressure relief valves with integrated boost check valves Charge pressure relief valve
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
7
8 5
2
1
4
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 directs the pilot oil flow (from the charge circuit) to the corresponding control piston side in the servo control. The 4/3-way valve is controlled by the travel lever and the travel cable. In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way valve pilot oil (from the charge circuit) is directed to one of the control piston sides and moves the control piston to the corresponding direction. The swashing lever between the control piston and the swash plate transfers the control piston movement to the swash plate. The needle bearing mounted swash plate swivels to the chosen direction. This causes the axial movement of the pistons inside the cylinder block. The axial movement draws oil into the pump and presses it to the travel motors. All working pistons are drilled through their entire length. Pressure fluid flows through these bores into the areas between the slipper pads and the surface of the swash plate. This forms a hydraulically balanced field, on which the slipper pads can slide without any metal to metal contact between swash plate and slipper pads. The feedback lever on the control piston detects when the swash plate has reached a position that corresponds with the displacement of the travel lever. This feedback lever controls a pilot oil portioning valve which interrupts the pilot oil flow to the control chambers when the swashing angle corresponds with the position of the travel lever. Swashing angle and displacement of the working pistons (oil flow rate)
Service Training 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 swashing lever with the swashing cradle (see Fig. 3).
Service Training Travel Travel pum pu mp p contro l When actuating the travel lever the 4/3-way valve moves out of neutral position to the desired direction and guides the pilot oil flow through the pilot oil portioning valve to the corresponding control piston side. 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.
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.
Service Training Charge pres sure relief v alve 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.
Service Training High press ure relief valves High pressure relief valves are safety elements, which are needed in every hydraulic circuit. These valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.
Service Training High pr essur e relief relief valves
1
2
1
Service Training Drum drive motor: Poclain travel motor type MK04 Both drums are driven by Poclain travel motors type MK04. These are radial piston motors. These drive motors consist of the outer housing, the flat distributor, the cylinder block with the working pistons, the output shaft and the brake. The brake is designed as a Hirthtoothing. The housing consists of Ø Ø Ø Ø
bearing section (bearings for output shaft) torque module (cam race) oil distributor and Hirth brake
The function of the radial piston motor is described hereunder. The piston positions mentioned in the description are shown in the corresponding illustration.
Service Training Piston position 1: Ø
The oil enters into the oil distributor under pressure, flows through the distributor and presses against the piston. This is the start of a rotation. Due to the pressure on the back of the piston the roller will move along the cam, thereby causing a rotary movement of the cylinder block.
Piston position 2: Ø
At this point point the oil flow to the the piston has reached reached its largest largest cross section. section. The The piston continues its travel along the cam race towards the valley between two cams. The opening cross section decreases with continuing rotary movement.
Piston position 3: Ø
Once the piston has reached the deepest point the oil flow to the piston is cut off. The piston is no longer driven. It has reached its dead centre. Another piston must now be driven to move the previous piston out of dead centre position.
Piston position 4: Ø
By driving other pistons the previous piston is moved out of dead centre position. The oil behind the piston is connected with the low pressure side and the retracting piston presses it back to the pump.
Piston position 5:
Service Training Brake actuation MK04 motor (drum drive motor) The travel system is equipped with a Hirth-type brake in the travel motors. This brake serves as parking brake to park the machine. (to secure the machine when the engine is running or to park the machine with the engine shut down) and as emergency brake. The brake control is accomplished via a 3/2 way valve which is located at the front in the engine compartment. If the solenoid valve is supplied with electric current when the engine is started, the valve will switch over and guide charge pressure into the brake housings. This releases the brakes. If the solenoid valve is de-energized while the engine is running (e.g. when actuating the emergency stop switch), the oil pressure in the brake housings is relieved to the tank and the brakes will close.
Hirth gearing
Service Training During travel operation the machine is braked by the closed hydraulic circuit. When moving the travel lever to neutral position the supply from the pump is interrupted. The machine will stop. However, both travel motors are additionally fitted with brakes. These brakes work only as parking brakes. The brakes are automatically relieved by the charge pressure building up when starting the engine. Should the charge pressure drop considerably (failure or shutdown of the engine, damage in the hydraulic system), the brakes close automatically. When shifting the travel lever to neutral position the brake closes after a short while. The brake closes also when the seat contact switch is open. The brakes can be relieved mechanically mechanically with screws. The mechanical releasing of the brakes works as follows: follows:
-
Unscrew the 2 plugs (191) Press the screws (192) against the springs (193) Tighten both screws (192) alternately and in steps until they bottom (approx. 2 revolutions) (max. revolutions) (max. 35 Nm)
To close the brake, proceed in reverse order.
Service Training Wheel drive motors on AC-machines The rubber tires of the BW 100/120 AC-4 are driven by two two radial piston motors Poclain MSE 02 which are joined parallel to each other and also parallel to the drum drive motor. The function of the motor is identical with the previously described Poclain motor MK04. However, the main difference is the design of the integrated brake. The MSE02 is fitted with a multi-disc brake. This consists of inner and outer discs which run permanently in an oil bath. Since the brake is normally only applied in events of emergency, it is almost wear free. If needed, the brakes can be released with the help of a brake releasing device. For this purpose a ball valve is installed in the engine compartment. By operating this valve oil can be directly guided to the motors (drum as well as wheel drive motors). For this purpose the steering wheel must be slowly turned for approx. two turns in clockwise direction. In this case the steering wheel or Orbitrol has the effect of a pump and delivers oil to the brakes (to the drum as well as the wheel drive motors). The brakes are thereby is released.
Service Training Trouble shootin g travel system Machine does not drive
Checking the function of the brake valve > Switch the ignition on > Release the parking brake by shifting the the travel lever out of neutral position > Measure the voltage supply on the solenoid valve Nominal value: 12 V If the voltage supply is not correct perform trouble shooting in the electric system. If the voltage supply is correct
the current consumption current consumption of the brake valve must be checked next: > For this purpose the meter must be connected in line line with the solenoid of the brake valve > Switch the ignition on
Service Training If the solenoid coil is o.k., check the solenoid valve.
> Connect a 60 bar pressure gauge to to the pressure test port > Start the engine and move the travel lever out of neutral. > Read the pressure gauges. Nominal value: approx. charge pressure 24 bar
Pressure test ort M3
Service Training If the charge pressure value is not reached check the brakes in the motors. > Connect a 600 bar pressure gauge to pressure test port (M1). > Close the brake (travel lever in neutral) > Start the engine > Turn the steering against an end stop and read the pressure gauge Nominal value approx.: 170 bar
Service Training If the steering pressure is correct check the charge pressure relief valve of the travel pump. > Unscrew the plug. > Take the valve insert out. > Check the valve visually. Replace the valve immediately if damaged.
Charge pressure relief valve
Service Training If the valve is o.k., check the brakes. > Disconnect the brake hoses from front and rear travel motor, one after the other, and close them with plugs. > Perform a pressure test on the pressure test port (near hydraulic oil filter M 3) after each disconnection of a brake hose
If the charge pressure value is not reached replace the corresponding motor.
Service Training If the charge pressure is correct check the high pressure of the travel pump. Attention! The following test must not exceed exceed 5 seconds !
> Close high pressure ports A and B. > Connect 600 bar pressure gauges to the high pressure test ports > Run the engine in idle speed and actuate the travel pump quickly to both directions. > Read the pressure gauges. Nominal value: approx. 400 bar
Close the ports
Service Training If the high pressure value is not reached replace the high pressure relief valves. If the problem still exists after replacing the high pressure relief valves, replace or repair the travel pump.
High pressure relief valves
Service Training If the high pressure value is reached, the travel motors must be checked individually. > Reconnect the high pressure hoses from the front travel motor to the travel pump. > Repeat the pressure test If the high pressure value is not reached replace the front travel motor. If the high pressure value is reached replace the rear travel motor.
Connect hoses from front travel motor or close ports to rear travel motor
Service Training If the charge pressure is reached in the test described under Fig. 2, charge pressure must be checked together with high pressure. > Connect 600 bar pressure gauges to the pressure test test ports MA and MB. (Travel pump) > Run the engine with max. speed > Block the drum or disconnect the cable from the brake valve. > Actuate the travel lever for for a moment and read the pressure gauge Nomi Nomina nall valu value: e:
char charge ge pres pressu sure re appr approx ox.. 22 to 24 bar bar high pressure approx. 380 bar
Service Training If the charge pressure is reached check the control chamber pressure. > Connect pressure test ports to the control chambers (X1 and X2). > Connect a 60 bar pressure gauge to the pressure test ports > Block the drum or disconnect the cable from the brake valve. > Actuate the travel pump to full displacement and read the pressure gauge. Nominal value:
approx. 24 bar
If the control chamber pressure value is not reached replace or repair the travel pump.
Control chamber
Service Training If the control chamber pressure is reached and the high pressure value is correct, release the brakes in both travel motors mechanically > Check whether the machine is able to drive If the machine drives replace or repair the travel motor with the defective brake. Mechanical releasing of brake (AD-machines only) is accomplished as follows: follows : - Unscrew the 2 plugs (191) - Press the screws (192) against against the springs (193) - Tighten both screws screws (192) alternately alternately and in steps until they bottom (approx. 2 revolutions) (max. revolutions) (max. 35 Nm)
Service Training Insufficient travel power With this fault the engine speed must be checked first. Nominal value:
Stage 1 = 2250 rpm Stage 2 = 2700 rpm
If the nominal speeds are not reached perform trouble shooting on the engine.
If the speed values are correct check the travel control. > Detach the control cable > Shift the pump control lever forward and reverse and check whether the pump swashes to maximum displacement. > Check whether the travel cable is worn.
Service Training If the end stops stops are not reached adjust the end stops. Adjust the end stops for the speed on the setscrews > Check the travel cable for wear.
End stop for travel speed in reverse
End stop for travel speed in forward
Service Training The machine moves with the travel lever in “Neutral” With this fault the neutral position of the pump must be checked first. > Shift the travel travel lever to ”Neutral” position > Disconnect the travel cable from the pump Check, whether bores in ball socket and pump control lever are in line.
Service Training If the bores are not in line adjust the travel cable. > Slacken the counter nut on the back stop. stop. > Adjust the nuts until the travel cable corresponds with the neutral setting of the pump. > Tighten the counter nut again
Service Training If the bores are in line check the mechanical neutral position. > Join both control chambers of the travel pump (X1 and X2) Note: The resulting condition of equilibrium must bring the machine to standstill. If the neutral position is reached by this measure replace or repair the servo control on the machine.
Service Training If the neutral position is not reached it is necessary to adjust the mechanical neutral position. > Connect 600 bar pressure gauges to MA and MB. > Block the drum or disconnect the cable from the brake valve. > Run the engine with max. speed. > Read the pressure gauges. > Adjust the mechanical 0-position until the pressure readings are identical on both sides If the neutral position is not reached, replace or repair the travel pump.
Service Training Vibration The vibration drive is an open hydraulic circuit and consists mainly of the vibration pump, the control valve and the vibration motors. Circuit diagram AD-machine
8 cm³
8 cm³
110+10 110+10 bar
Service Training The vibration pump is directly driven by the timing gear side of the diesel engine. Vibration pump and steering/charge pump are joined together to a tandem pump unit. The gear pump delivers the hydraulic oil out of the hydraulic oil tank to the vibration control valve. If the vibration is switched off the hydraulic oil flows directly back to the t ank. When the vibration is switched on, the control valve directs the oil flow to the in line connected vibration motors (BW 100/120 AD-4), or to the vibration motor on the drum (BW 100/120 AC-4). The vibration motors (gear motors) drive the vibrator shafts in the drums with constant speed via Bowex couplings. The rotation of the exciter shafts with the attached eccentric masses generates the vibration of the drums, which are suspended in rubber elements. From the second vibration motor the oil flows back through the control valve block to the tank (open circuit). The standard equipment of the AD-machine includes a shut-off valve for the rear drum vibration. When operating a ball valve the oil flow is directly returned to the tank after the first motor (front drum) via the control valve block
Service Training Vibration pump The vibration pump is a directly driven gear pump.
Fig 21: The drive gear is connected with the auxiliary drive of the diesel engine via a pinion. Drive
Service Training Vibration control valve With the vibration control valve the vibration is electrically switched on and off. The valve consists of the solenoid operated valve piston, the pressure relief valve for the vibration circuit and the brake valve to brake the exciter shafts when switching the vibration off. When switching the vibration on the direct return flow to the hydraulic oil tank is interrupted and the hydraulic oil is guided to the vibration motors. The high pressure (starting pressure) in the vibration circuit generated by the resistance of the resting exciter shafts is limited to 210 bar by a pressure relief valve inside the control valve block. When operating the control valve the valve spool opens also a direct connection between the outlet of the second vibration motor and the oil tank. When switching the vibration off this direct connection is interrupted. The hydraulic oil, which is now displaced to the control valve by the still rotating vibration motors is applied to 110 bar pressure relief valve (brake valve). This valve brakes the rotation of the exciter shafts within the shortest possible time.
Service Training Vibration motor On the machines of series BW 100/120 AD-4 and BW 100/120 AC-4 the exciter shafts inside the drums are directly driven by vibration motors. These vibration motors are gear motors which are directly connected with the exciter shafts via Bowex couplings. The design of these vibration motors is almost identical with the design of the vibration pump. A more detailed detailed description of of the design is therefore therefore not required. required. On the BW 100/120 AD-4 the vibration motors are connected in series. The standard equipment of the machine includes a shut-off valve for the rear drum vibration. When operating a ball valve the oil flow is directly returned via the control valve block to the tank after the first motor.
Service Training Trouble shooting vibration
Vibration frequency too low If the specified exciter shaft speed is not reached, the engine speed must be checked first. Check the engine speed with a vibration reed frequency meter.
Nominal value:
2700 rpm (with throttle control in stage II)
If the nominal speed is not reached perform trouble shooting on the engine.
Various instruments or methods may be used to check the engine speed. (e.g. vibration reed frequency meter, optical speedometer etc.)
Service Training If the engine speed is correct, check the pressures in the vibration circuit. > Stand both drums on an elastic base (rubber (rubber tires). > Connect a 600 600 bar pressure pressure gauge to vibration pressure pressure test port. port. > Run the engine engine with full full speed and and switch the vibration on. on. Nominal value :
Starting pressure approx. 210 bar (for approx. 3 - 6 seconds) Operating pressure (one vibrating drum): approx. 60 bar Operating pressure (two vibrating vibrating drums): approx.: 100 bar
Service Training If the starting pressure is not reached check the control valve block. > Disconnect the high pressure pressure hoses from from the valve block (A and and B). > Close ports ports A and B on the valve block. > Switch the vibration on. Nominal value :
approx. 210 bar
Service Training If the pressure value is not reached subject the vibration pump to a high pressure check. > Install a 200 bar pressure relief relief valve with a 600 bar pressure gauge between between vibration pump and vibration valve. > Start the engine engine and and switch on the vibration Nominal value :
approx. 200 bar
If the pressure is reached replace the vibration valve block. If the pressure value is not reached replace the vibration pump.
Service Training If the pressure is reached during the pressure test described in Fig. 5, check the leak oil rate of the vibration motors. For this purpose stand the machine on rubber tires. > Disconnect the leak oil line line and hold hold it into a measuring vessel. > Switch the vibration on. Nominal value: max. 1.0 l/min Replace the motor with too high leak oil rate.
Service Training If the operating pressure is too high, high, the bearings for both vibrator shafts must be checked. > Check end float and moveability moveability of the exciter shafts shafts (front and rear). Nominal values:
min 0.5 mm max. 2.00 mm
Service Training No vibration If the vibration does not work at all you should first check the voltage supply for the vibration control valve. > Switch the vibration vibration on and check whether whether voltage is applied to the plug. plug. Nominal value:
12 Volt
If no voltage is applied, perform trouble shooting in the electric system.
Vibration solenoid valve
Service Training Steering The steering system is an open hydraulic circuit and consists mainly of the steering/charge pump, the steering valve, the steering cylinder and the connecting pressure resistant hoses.
Service Training The steering pump delivers the hydraulic oil from the tank to the steering valve and the connected steering cylinder. When the steering is not operated the complete oil flow is guided through the fine filter to the charge ports on the travel pump and further via the cooler to the tank. When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side of the steering cylinder. A measuring pump in the steering unit measures the exact oil quantity corresponding to the turning angle of the steering wheel and delivers this oil to the steering cylinder. The steering cylinder extends or retracts and articulates the machine. The steering unit is fitted with an integrated pressure relief valve. This valve limits the steering pressure to 140 bar. Since the hydraulic oil flowing out of the steering system is used as charge oil for the closed travel circuit, the charge pressure value must be added. When testing the pressure a value of 160 bar would therefore be measured.
Service Training Steering valve The steering valve block consists mainly of distributor valve, measuring pump, steering pressure relief valve and the shock valves. When turning the steering wheel the oil flow from the pump is directed through the distributor valve to the measuring pump. The measuring pump, in turn, directs the oil flow through the distributor valve to the corresponding side of the steering cylinder. The machine is fitted with a so-called “Open Centre” steering valve, i.e. in neutral position of the valve the incoming oil flows through the tank return bore directly to the charge ports for the closed travel circuit. 1 2 9
3
4
5
Service Training The rating pump determines the exact oil quantity in dependence on the turning angle of the steering wheel. The oil quantity directed to the steering cylinder articulates and steers the machine. The high pressure relief valve in the steering unit limits the pressure in the steering system to 140 bar. Since the oil leaving the steering system is used to charge the closed travel circuit, this charge pressure value must obviously be added when checking the steering pressure. The steering unit is fitted with so-called shock valves in each pressure side to the steering cylinder. These valves are adjusted to an opening pressure of 200 bar. The valves compensate extreme pressure peaks which may occur, e.g. when driving over obstructions, and protect the system against overloads. Each of these shock valves has its additional anti-cavitation anti-cavitation valve. This anti-cavitation valves prevent the appearance of cavitation, which may be caused by the response of the shock valves. A check valve near the inlet port of the steering unit makes sure that no hydraulic oil will flow back to the steering pump if the machine is articulated by sudden external forces. In such a case the steering cylinders would act as pumps and press the oil back to the pump.
Service Training Trouble shooting steering Steering function faulty Note: The steering pump works also as charge pump. In case of a fault in the steering system the steering/charge pump must be checked first. > Connect a 600 600 bar pressure pressure gauge gauge to steering pressure test port (M1). > Turn the steering against an end stop. > Read the pressure gauge. Nominal value:
approx. 170 bar
If the steering pressure is reached check the moveability of articulated joint and steering cylinder.
Service Training If the nominal value is not reached check the steering cylinder.
Disconnect the hydraulic hoses from ports L and R on the steering orbitrol orbitrol and close the orbitol with plugs. Due to the installation position the test is conducted on the orbitrol valve and not directly on the steering cylinder.
> Run the engine and turn the steering wheel. Nominal value:
approx. 160 to 190 bar
If the nominal value is reached replace the steering cylinder.
If the nominal value is not reached check the steering/charge pump. > Close the pump pump outlet with with a 200 bar pressure relief valve. > Repeat the pressure test. Nominal value:
approx. 200 bar
If the nominal value is not reached replace the steering/charge pump.
Service Training Electric circuit diagrams Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do not contain any information on the type of wiring, their purpose is solely the clarification of control logics. Circuit diagrams are of help when performing trouble shooting and enable the fault free connection during modifications or changes to the electric equipment of the machine.
Structure: 1. Table of contents 2. Function groups 3. List of components
1.
Table of contents
The table of contents lists all function groups and component lists of the machine. The arrangement of all sheets in a sequence results in the total wiring diagram.
Example: Function group ”brake”, drawing number 880,100 51 is found on sheet 4
Service Training 2.
Function groups
Electric circuits with a function oriented interrelationship are combined on individual sheets (sheet-no.: 1, 2, ...) in function groups (brake, warning systems ...) and subdivided into 20 current paths (along the bottom end of the page). This allows easy tracking of functional interrelationships interrelationships of the electric circuits. Arrangement Arrangement of of current current paths paths The individual current paths must be read as follows: > from top (plus potential) to bottom (minus potential) > from left to right (current path 1 to 20, along the bottom of the page, Fig.1)
Fig.: 1: > from function group (sheet-no.) to function group (sheet-no.) > via cross references for potentials and relays
Service Training Reference lines, frames Components and connections that apply only for special versions of machines (accessories, retrofit kits or optional designs, Fig. 3) are drawn with thin dash – dot – line and specially marked with bilingual text.
Fig. 3:
Service Training Potential cross references Example potential 15: 5:1 ---------> direction arrow (cross reference to sheet 5 current path 1) Potentials stretching over a longer distance in the circuit diagram may be interrupted for the reason of clarity. In this case only the beginning and end of the potential is shown. The interrelationship of these cut-off points is represented by cross-references. Potential crossreferences therefore enable tracking of signals transferred from one function group (sheetno.) to another function group (sheet-no).
Example 1 (Fig. 4): Potential ”15" on sheet no. 6 continues to the left on sheet-no. 4 in current path ”10" and to the right on sheet-no 8 in current path ”1". To the right it ends at the nodal point (without arrow) on sheet-no. 8 in current path ”3".
Service Training Relay cross reference in developed presentation Switching symbols of parts of electric components (relays, switches ...) are drawn separately and arranged in such a way, that every current path can be easily tracked. The spatial relationship of individual contacts is of no importance. A straight and clear presentation without any crossing of the individual current paths is of highest importance. Relay cross references can therefore be used to trace signals which have to be followed on components with dependent contacts. Apart from this there is a contact plan under each relay coil providing information about the contact types of a relay and where these appear in the wiring diagram. Example 2 (Fig. 4): 4): On sheet no. 8 the coil of relay (K99) is located in current path ”6". The contact sketch under the relay informs that a throw-over contact with the contact types 30, 87 and 87a is triggered. On sheet no. 8 this double-throw contact is located in current path ”3".
3.
List of components
This list contains all components used in alphabetical order, related to their component abbreviation (A01, A02....).
Service Training Electric system Table of potentials
Potentials 30 31 M15
Meaning Battery positive Vehicle ground battery negative control elements Battery minus is supplied when ignition is ON
Explanations to the electric circuit diagram: Start the engine: To start the diesel engine the following conditions must be fulfilled: - Emergency stop switch not operated - Travel lever in neutral position (switch B08) B08 triggers triggers relay K05 - Voltage on ignition switch output 50a Driving the machine:
Service Training Descrip tion o f the modules The machine is equipped with two control/monitoring modules. These modules are fitted with control lamps on the inputs/outputs, which are used to monitor the applied signals. Module travel lever monitoring (part number 880 255 02)
a bc 1
2 3
D E L
D D E E L L
Service Training Description of hardware: The inputs are designed in such a way, that the following table is valid: Input
Performance Remark
Input PIN12
HIGH-active
LED lights when applying when applying positive voltage!
Input PIN13
LOW-active
LED lights when applying when applying ground potential!
Input PIN14
HIGH-active
LED lights when applying when applying positive voltage!
Input PIN15
HIGH-active
LED lights when applying when applying positive voltage!
Input PIN16
HIGH-active
LED lights when applying when applying positive voltage!
Pin assignment digital inputs Signal Name Initiator for brake
Module Pin 12
Button vibration on
13
Switch position vibration auto / manual
14
Description Active-HIGH = Travel lever in braking position LED on LOW =T =Tra rave vell leve leverr not not in brak brake e posi positi tion on LED LED off Active-LOW = Momentary contact function LED on HIGH = Normal status LED off Active-HIGH = autom. vibr. no nominal on on, LED on LED off LOW = manual vibr. nominal on
Service Training Signal level:
a bc 1 D E L
1
2
3
4
5
6
2 D E L
7
8
3 D E L
9
0 1
1 1
2 1
3 1
4 1
6 1
Service Training Description of function Switching off If operating voltage is applied to the module (PIN1/2 UB, PIN10/11 ground), LED1 will light as a control light. LED 2 flashes as Stay-Alive-Indicator („Live Sign of Module“), but with a flashing frequency which depends on the current on input PIN 8 (analogue input 1).
Angle sensor: The machine is equipped with an angle sensor under the driver’s seat, mounted to the switch guide plate of the travel lever. The angle sensor reports the travel lever position back to the module. The sensor works with an output current of 4-20 mA.
Ang le s sensor
Service Training Neutral position of angle sensor The zero point of the angle sensor is automatically adjusted via the module. Once the travel lever is in neutral position the brake initiator (on the travel lever) (Pin 12) is actuated. The zero position is thereby recognized. Should the brake initiator be defective or a cable is broken the last value is set as default for the zero point. If LED2 (on the module) flashes in intervals of one second and LED3 lights permanently, the zero point is reached.
In it iator f f o r B Br ake
Service Training Defect on angle sensor The current of the functional angle sensor is in the range from 4mA to 20mA. A current flow of <2mA or >22mA on Pin 8 of the module indicates a sensor fault (sensor defective, short circuit, or sensor not connected, etc.). LED2 and LED3 are then used as indicators. LED2 flashes fast (with 80 Hz), LED3 shows permanent light. 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, if the voltage is too low. This always takes place in case of a low voltage level on Pin 9. This may be caused by a too low supply voltage for the module (with U B < 9,5V the voltage of 8,5V can no longer be maintained on PIN 9) or by a defect of the module. The complete module works from a minimum voltage of UB = 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.
The following functions are influenced by the angle sensor: -
Automatic vibration ON/OFF
Service Training Vibration control Manual vibration If no voltage is applied to PIN 14 (manual (manual vibration on), on), vibration can be switched on via button input (vibration (vibration on) on) on PIN 13. Vibration is always switched on or off when a clear ground potential is detected on Pin 13. If vibration is switched on, the LED on Pin 5 lights up. If the vibration button is actuated again, vibration is switched off. In case of a bridge (Active-HIGH-Signal) on PIN 16 vibration switched off at a speed higher than 6 km/h and on again at a speed below 6 km/h. Without a bridge on PIN 16 the vibration is not switched off above 6 km/h.
Auto Vibration ON
Travel lever
Manuell Vibration
Service Training Automatic vibration control (optional) If a positive voltage is applied to PIN 14 (automatic ( automatic vibration on) on) the LED on PIN 14 lights up and the vibration (PIN 5) is switched on and off in dependence on the travel lever position. With a bridge (Active-HIGH-Signal) on PIN 16 the vibration (output, PIN 5) is switched off with the travel lever in a position <1 km/h and >6 km/h. Without the bridge (LOW-Signal) on PIN 16 the vibration (output, PIN 5) is only switched off at a speed < 1 km/h.
Auto Vibration ON
Travel lever
Service Training 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.
Sprinkling stages for pressurized sprinkler system
St uf uf e 12 Stufe 11 Stufe 9 Stufe 8
12-Step switch
Stufe 7 Stufe 6 Stufe 5 Stufe 4 Stufe 2 Stufe 1
Travel lever
Stufe 3
Stufe 10
S tu tu fe fe 12 Stufe 11 Stufe 10
Service Training After stopping the machine (travel lever in neutral, evaluation of analogue signal on PIN 8) sprinkling continues with the set interval for another 30 seconds (pressure sprinkling). After this time sprinkling will only be resumed after moving the travel lever out of neutral. If the switch is in stage 12 (permanent sprinkling), sprinkling will continue after the 30 seconds, without any temporal limitation! Should be used for inspection with the machine stopped to check nozzles, pump etc. Gravity feed sprinkler system If no 12-stage switch is connected, but the gravity sprinkler switch (S05 on output PIN 4) instead, the output will permanently switch a High signal. The sprinkling system is triggered via this switch. With the machine stopped (travel lever in neutral position, evaluation of analogue signal on PIN 8) the HIGH-signal will still be emitted at PIN4 for another 30 seconds, after this it will be set to LOW-signal, until the travel lever is moved out of neutral again.
12-Step switch
12 step switch not connected
Service Training Descrip tion o f the seat contact m odu le (part-no.: (part-no.: 88003 88003042 042) )
RS 232
2 D E L
5 D E L
-
+
OUT
30
Pin assignment:
4 3 D D E E L L
4
3
1 D E L
2
1
Service Training Descrip tion o f hardw are The inputs are designed in such a way, that the following table is valid: In p u t
P e r f o r m an c e R e m a r k
Inpu Inputt PIN1 IN1
LOWLOW-ac acti tive ve
LED LED lights when hen app applying gro ground poten tentia tial!
Inpu Inputt PIN2 IN2
LOWLOW-ac acti tive ve
LED LED lights when hen app applying gro ground poten tentia tial!
Inpu Inputt PIN3 IN3
HIGH-ac -active
LED LED ligh lights ts when when appl applyi yin ng posi positi tive ve vol voltage tage!!
Inpu Inputt PIN4 IN4
HIGH-ac -active
LED LED ligh lights ts when when appl applyi yin ng posi positi tive ve vol voltage tage!!
Pin assignment digital inputs
Signal Name Seat contact switch Seat contact switch (is presently not evaluated) Sensor Travel lever neutral position Engine – oil pressure
Module Pin 1
Description Active-LOW = Driver seated HIGH = Driver standing Active-LOW = Driver standing HIGH = Driver Driver seated
LED on LED off LED on LED off
3
Active-HIGH = Brake released LOW = Brake applied
LED on LED off
4
Active-HIGH = Oil pressure present
LED on
2
Service Training Descripti Descrip tion on of o f func f unc tion tion
Travel lever in brake lock and driver standing
Travel lever is actuated
Engine emmidiately OFF
Driver seated
Travel lever is actuated
Druíver gets up during
Engine shuts OFF after 2
Driver sits down within 2 seconds and oil pressure
Service Training Descripti Descrip tion on of o f func f unc tion tion Switch ignition on and start the engine engine • •
Stay-Alive-(Live Signs) LED flashes in one second intervals. Engine running
Shut dow n the engine imm ediately ediately •
•
If the driver seat is not occupied (PIN 2 has HIGH–Signal) and the travel lever is actuated (PIN 3 has Active–HIGH–Signal), the module will simulate a oil pressure fault. Relay (PIN 30 + 87) switches immediately for half a second and LED6 lights for half a second. The holding winding of the engine solenoid is not not energized for half a second and the engine is shut down.
Engine shut down with time delay • •
• •
The driver's seat is occupied (PIN 2 has Active–LOW–Signal) and the travel lever is in neutral position (PIN 3 has LOW–Signal). When leaving the driver’s seat (PIN 2 has LOW–Signal) after shifting the travel lever out of neutral (PIN 3 has Active–HIGH–Signal), the warning buzzer is activated. After 2 seconds the relay (PIN 30 + 87) is switched on for half a second and LED6 lights for half a second. The holding winding of the engine solenoid is not not energized for half a second and the engine is shut down.
Inhaltsverzeichnis: table of contents: Blatt Nr.: sheet no.: 001 002 003 004 005 006 007 009 101
BW 100 AD/AC−4, BW 120 AD/AC−4 BW 100 AD/AC−4, BW 120 AD/AC−4
Zeichnungsnummer drawing − no. 8 80 100 5 1 8 80 100 5 1 8 80 100 5 1 880 100 51 8 80 100 5 1 880 100 51 8 80 100 5 1 8 80 100 5 1 8 80 100 5 1
Funktionsgruppe
function unit
Stromlaufplan Versorgung, Motor, Starten, Not−Aus Vibration, Berieselung Sitzkontakt
Circuit Diagram supply, engine, starting unit, emergancy shut off vibration, sprinkler system brake, flow divider, rotary beacon, edge cutter switch seat contact
Arbeitsbeleuchtung, Arbeitsbeleuchtung, Blinkbegrenzung, Blinkbegrenzung, Arbeitsbeleuchtung Arbeitsbeleuchtung
working head lights, flash and position illum., working head lights
Wetterschutzkabine
cabin, weather protection
Zentralelektrik Bauteilliste
cross − bonding − box component listing
Bremse, Mengenteiler, Mengenteiler, Rundumkennleuchte, Rundumkennleuchte, Kantenschneidg.
2 2
B : 5 2 X
30 P01
Zündstartschalter ignition switch
A : 5 2 X
2 C Box A F04 F119 2:11 3 1
1
R09
V43 V43 (A3) (A3) 2 1 R21 1
2
X1:1
X12:2 IG
X12:1 L
V43 2:11
H08
H49
X6:17
X6:16
D+
G02 B Generator generator F141
2
−
B 2:18
X1:3 B53
_t
Batterie − battery
Sicherung Generator fuse, generator
2:4 3
X1:4 B06
H(−)
4
6 : 1 1 X
4 : 1 1 X
5 : 1 1 X
K37 X11:3
G 4:3
X6:10
X6:2 1
2 M− 2:12
B BOX A F139 2 30 K22 5:19
1
P −
X6:6
P01 − H(−)
X11:2 Glühüberwachung indicator light, glowing
X1:5 R03 option
2
21
11
22
12
2:16 1
87a
3:2
K05 3:2
H
X6:1
2 0 R
87 K96 2:13 30 UPM4 5:2
X2:4
X1:6
X10:2
X10:1
K05 K053:12 2:19
A15 Überwachungsmodul monitoring module
2 0 R
2 0 R
2 : 2 X
3 : 2 X
3X8A
2 0 R
Glühkerze Header plug ) 0 5 ( T S
) 0 3 ( B
2:3 B
M01 −
M− 4:3
Hubmagnet Motor shut off solenoid engine
Temperaturgeber Kuehlmittel temperature switch, collant Druckschalter Motoröl pressure switch, engine oil
Geber Kraftstofftank sender, level gauge
2:16
1 : 2 X
HW
2:9 M−
Betriebsstundenzähler engine hour meter
BOX A F48
2:15 K05
2 0 R
AW Y13
87
2:19
1 0 S
F139 4:9 option Sitzkontakt seatswitch 87
87a
8
(A4) V44
2:16 87a
50a
30
UPM15 3:1
2 30 BOX A
19 17 17
2 : 4
1 0 S
K05 2:18
+
V45 V45 (A5) (A5) H(−) 2:6
G01 7:2
1 V45 2:11
e g u a g l e v e l
4
Not−Aus−Schalter emergancy shut off V45 5:12
H52 e g i e z n a f f o t s t f a r K
D
1 5 54 58 2 15 6:1 15 BOX A 3:1
S01
2:8 V43 X6:20
H09
P00
X25:C 31 Hauptsicherung fuse, main
86 K96 85
K32 7:2
X6:14
X1:2
+
2:9 F119
2:7 V45
2
F00
BOX A F119
Meldeleuchte Ladekontrolle indicator light, charge control Meldeleuchte Motorüberhitzung indicator light, engine overheating Meldeleuchte Motoröldruck indicator light, engine oil pressure
V41 (A1)
2
G01
P0123 S00
30 3:1
31 3:1 Starter starter
2:9 30
30 6:1 2
2:14 30 BOX A 2:19 15 BOX A
15 BOX A 4:1
2:17 UPM15 X3:3
UPM15 5:1
2:20 K05
Intervallschalter interval switch Druckberieselung press. water sprink sys.
Initiator Bremse proximity switch, brake B08
A
2 K05 5:1
1
V48 V48 (A8) (A8) F45 4:12
5
X14:1 N B / R B
BOX A F03
E
Aufnehmer Fahrhebel transducer travel lever
1
BOX A F68
Vibrationsschalter man./autom. switch, vibration, man./autom.
3
B39 2
1
K B / W S
U B / L B
2 : 1 : 3 : 8 8 8 1 1 1 X X X
2 : 4 1 X
X14:3
0−11
X13:2
X13:1
X13:3
X3:1
X3:6
X3:2
13
X22:1
14
S164
S08
A01
8 0 B
X3:4
3
1
3:2 9 (8,5V)
7
11 (GND)
8
1 (15/54)
14
16 15
A03 Modul Vibration modile vibration
12
X22:2 S164 4:13
A03 4:1 3
3:2 K05
86
85
8 0 B
13 A03:12 5:2 X7:1
X20:1 option S12
S13
A15
3
Taster Vibration switch vibration
10 (GND)
K117 X19:3 X8:1
2 + H14
X8:2 X19:8
−
Warnsummer warning buzzer
1
V42 5:6
g n u n l o i e t s a e t i r i v e a b r t g f , a r g k n r l e i k w n h i r c p S s
5
13 14
X7:1
X7:2 X5:4
S05
X6:9
4
2:20 31 2:19
4
V42 V42 (A2) (A2) 3 4
X20:2
6
X3:5 X7:1
. s y sK79 k n g i r n p u s l e r s e e t i r a e b w . k s c s u r e r D p
86
n n e e p p y y T t − − C C A A
X1:9
86
85
85
t ä r e g d i e n r h t c e s t n u c n t e o n e i t d p a g o K e
K78 3:16 87
1
K79 3:11 87
87a X19:5
86
+
85
−
1
87a
X15:1 +
Y06
M03
2
30
g n . u s l e y s s e k i r n r e i b p k s c r u e r t D a w . s s e r p
X19:6
X16:1 K78
Y71
30
g n n u i o l e t a s t e i i r v e a r b g t f , a g r i n k r l e k n i w r h p c s S
M02
X16:2 X19:8
V02
2
−
X15:2 31 4:1
Überwachungsmodul 3:20 monitoring module Berieselungsschalter switch sprinkler system
4:17
3:17 Magnetventil Vibration solenoid valve, vibration
Emulsionspumpe emulsion pump Fußschalter switch, foot
Berieselungspumpe sprinkler pump
Berieselungsventil solenoid valve sprinkler
3:17 15 BOX A 3:15 A03 BOX A F23
G
option
7
Schalter Rundumkennleuchte switch, rotary beacon
11 S01 2:16
2:14
F
BOX A F45
option
6
option 3:17 F45
F139
3:16 S164
12
30
K117 3:13
UMP3 5:2
87
87a
X5:3 Taster Signalhorn switch warning horn
Schalter Kantenschneidgerät switch, edge cutter
S03
13
S38
13
102 S34
14
14 K11
86
X6:11 85
13 0
14 30
K11 4:9 87
24
X24:A
X24:B V08
87a
1 X19:2
X1:8 2:10 H(−)
H(−) 5:5
Meldeleuchte Bremse indicator light brake
1
V09 2 Y48
X1:7
+ + −
X1:10 E32
1
Y20
−
B11
X4:2
Y04
2
1
1 2
X4:1
H01
23
X19:8 2
Y21
2 Y90
1 2
1 2
2:20 M−
X24:C X5:4
3:20 31 Bremsventil solenoid valve, brake
31 5:1 Signalhorn warning horn
4:10
Mengenteiler flow divider Rundumkennleuchte rotary beacon
Magnetventil Hydr.−umsch. solenoid valve, hydr. switch over Kantenschneidgerät ab edge cutter, down
Kantenschneidgerät auf edge cutter, up
3:17 K05 3:8 UPM15 2:16 UPM4 3:3
A03:12 UMP3
4:5
K137
86
4
3
15/54
85 2 1 15/54
X5:1
X5:2
X23:2
X23:3
2
K137 5:3 87
3:8
1
Sitzkontaktschalter switch, seat contact
X21:1 + − X21:2
H20
4:20
X19:8 H(−)
H(−) 6:2
31
BTS
86
H82 K22
Warnsummer warning buzzer
85 2:15 V45
31 6:1 5:10
option
30
X19:4
X6:12
4:5
87a
87
X23:1 X5:4
A68 Modul Sitzkontakt modul seat contact
V42
3
S06
30
2:14 Meleleuchte Sitzkontakt indicator light,drivers seat contact
2:19 15
ZA/option StVZO Beleuchtung
2
3:20 30 BOX B F F07 6
C
A
BOX B F08
3 Schalter Blinker switch indicator S37
L0R
13
23
14
24
Beleuchtungsschalter STVZO switch, lighting STVZO S15
49L
12
Überwachungsmodul monitoring module R A15 X9:1
X6:19 X9:2
H06 5:8 H(−)
23
H(−) 6:8
X27:1
1
D
BOX B F10
4
H05
1
E08 2
23
14
24
1
X9:5
24
E09
2
X28:4 1
1
1
E11
ZA/option Arbeitsbeleuchtung
E13 2
2
E12
E14 2
X31:1 X30:1 1 E23 E25 1
1 2
1 E15 2
2 X30:2
2 X31:2
X32:1 X33:1 1 E27 E28 1 2
2 X32:2
5:19 31 Schalter Warnblinker switch, hazard light
23
X19:1
X1:11
X27:4
X28:3
6:3 H(−)
E10
2
X27:5
S53
E
X9:4
X27:3
X28:2
1
Meldeleuchte Warnblinker indicator light, hazard light
13 01
5
X9:3
V12
X27:2
X28:1
2
01
24
24 H06
S53
X6:18 V13
X6:7
BOX B F09 X6:8
S14 14
11 012
A02
L
01
012
49R
82
23
BOX B F12
Schalter Arbeitsbel. hinten switch, working head lights rear
Schalter Arbeitsbeleuchtung switch, working light
L0R
31
13
2
1
Blinkgeber flasher 30
B
BOX B F11
X28:5
Meldeleuchte Blinker indicator light, indicators
X33:2
X19:7
X9:6
Blinkleuchte VL Blinkleuchte VR indicator front, LH indicator front, RH Blinkleuchte HL Blinkleuchte HR indi indica cato torr rea rear, r, LH indi indica cato torr rea rear, r, RH
31 Parkleuchte links Scheinwerfer vorne links parking light, LH working head light front, LH Parkleuchte rechts Scheinwerfer vorne rechts parking light, RH working head light front, RH Schlußleuchte links Schlußleuchte rechts tail light, LH tail light, RH
Scheinwerfer hinten links working head light rear, LH Scheinwerfer hinten rechts working head light rear, RH
7:1
2:11 K32 2:3
G01
F39
1 Sicherung fuse 2 30
K32 7:14 87
87a
6 S20
012
S21 2
6 012
3
2
3
K32
+
M04
85
M − +
M06 M
+
M07 M
−
− +
M05 M
−
6:20 31
31 Scheibenwischer vorn Scheibenwischer hinten windsceen wiper motor, front windscreen wiper motor, rear Scheibenwascher vorn windscreen washer motor, front Scheibenwascher hinten windscreen washer motor, rear option
86
7:9
X6:1−20 9 8 7 6
3 6
X11:2−6
5 4 3 2 1
K37
2 5 4
201918 1716151413 121110 V41
A03
A15
3 0 4 6 6 7 5 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Zentralstecker Sammelanzeige (Ansicht von hinten) mainplug monitoring module (view from backside)
option Rundumkennleuchte rotary beacon
K22
86
K11
1
1
1
2
2
2
AC typen
K78
V42
K79
V43 V44 V45 V46 V47 V48 1 3
1
1 4
5
6
2
2
2
2
R09
1
2
R21
1
1
1
1 7 2
2
2
30
A02 49R 31 82
L
R 30 49L
30 30 30 87 87 87 87a 87 85 85 87a 86 85 87a 86 85 87a 86 30 30 30 30 85 86 87 87 87
8
87a 87
K05
K96
option Stvzo Beleuchtung
1 2
K117
option Kantenschneidgerät edge cutter
option Sitzkontakt seatswitch
K137 option Sitzkontakt seatswitch
Box B F11 F12 F08 F09 F10
A68
X10:1−2
85 87a 86 85 87a 87a 86 85 87a 87a 86
F07
Y13
Hubmanget Motor shut off solenoid, engine
BTS 4 3 2 30 87 87a 15/54
1
option Stvzo Beleuchtung StVZO lights Arbeitsscheinwerfer working lights
Box A F68 F139 F04 F119 F03 F45 F23 F48
Name
K n e i p
c o m p o n e n t l i s t i
B a u t e i l l i s t e
4 . 2 . 4
Bl.
Pf. Benennung
title
TYP
A01 A02 A03 A15 A15 A15 A15 A66 A67 A68
003 006 003 002 003 006 009 008 008 005
6 6 10 17 7 11 4 9 15 13
Intervallschalter Blinkrelais Modul Vibration Platine Ueberwachungsmodul Platine Ueberwachungsmodul Platine Ueberwachungsmodul Platine Ueberwachungsmodul Elektronik Steuereinheit Eingabeeinheit Mo Modul Sitzkontakt
interval switch indicator relay modul, vibration Printed circuit board, monitoring module Printed circuit board, monitoring module Printed circuit board, monitoring module Printed circuit board, monitoring module Electronic control unit Keyboard Modul seat contact
B06 B08 B11 B39 B53
002 003 004 003 002
6 2 7 10 5
Druckschalter Motoroel Naeherungsinitiator Fahrhebel ’0’−Stell. Signalhorn Aufnehmer Fahrhebel Temperaturgeber Kuehlmittel
Pressure switch, engine oil Proximity switch, travel lever ’0’ pos. Warning horn Transducer, travel lever Temperature switch, collant
E08 E09 E10 E11 E12 E13 E14 E15 E23 E25 E27 E28 E32
006 006 006 006 006 006 006 006 006 006 006 006 004
5 6 7 8 11 10 12 13 14 15 17 18 10
Blinkleuchte vorne links Blinkleuchte hinten links Blinkleuchte vorne rechts Blinkleuchte hinten rechts Pa Parkleuchte links Sc Schlussleuchte links Parkleuchte rechts Pa Schlussleuchte rechts Sc Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten rechts Kennleuchte
Indicator, front, lh. Indicator, rear, lh. Indicator, front, rh. Indicator, rear, rh. Parking light, lh. Tail light, lh. Parking light, rh. Tail light, rh. Working head light, front, lh. Working head light, front, rh. Working head light, rear, lh. Working head light, rear, rh. Warning light
21W 21W 21W 21W 10W 10W 10W 10W 55W 55W 55W 55W 5,5A
F00 F03 F04 F07 F08 F09 F10 F11 F12 F23 F39 F45 F48 F68 F119 F139 F141
002 003 002 006 006 006 006 006 006 004 007 004 002 003 002 002 002
1 11 10 3 6 11 13 14 17 7 9 17 19 17 16 14 2
Hauptsicherung Batterie Siicherung Vibration S Si Sicherung Instrumente Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Scheinwerfer rechts Sicherung Signalhorn Hauptsicherung Kabine Sicherung Kantenschneidgeraet Sicherung Gluehanlage Sicherung Potential 30 Sicherung Motor Sicherung Hubmagnet Motor Sicherung Hydraulikölkühler
Fuse, main, battery Fuse, vibration Fuse, gauges Fuse, hazard light Fuse, indicators a. work. head light Fuse, parking and tail light, lh. Fuse, parking and tail light, rh. Fuse, head light, lh. Fuse, head light, rh. Fuse, warning horn Main fuse, cab Fuse, edgecutter Fuse, glow plug system Fuse, potential 30 Fuse, motor Fuse, shut off solenoid, engine Fuse , cooling air blower
80A 10A 10A 15A 15A 15A 15A 15A 15A 10A 15A 10A 10A 20A 10A 30A 50A
G01 G02
002 1 002 2
Batterie Generator
Battery Generator
88 AH 50A
4X21WATT MAX1,5A MAX1,5A
MAX 300MA 4−20 mA
K n e i p
c o m p o n e n t l i s t i
B a u t e i l l i s t e
4 . 2 . 4
Name
Bl.
Pf. Benennung
title
S00 S01 S01 S03 S05 S06 S08 S12 S13 S14 S15 S20 S21 S34 S37 S38 S53 S53 S164
002 002 002 004 003 005 003 003 003 006 006 007 007 004 006 004 006 006 003
18 16 16 7 10 3 12 4 5 3 13 9 11 17 6 9 17 19 16
Startschalter Sc Schalter NOT AUS Sc Schalter NOT AUS Taster Signalhorn Berieselungsschalter Sitzkontaktschalter links Vibrationsschalter man./autom. Vibrationsschalter Fahrhebel links Vibrationsschalter Fahrhebel rechts Warnblinkschalter Beleuchtungsschalter StVZO Schalter Scheibenwischer vorne Schalter Scheibenwischer hinten Schalter Kantenschneidgeraet Schalter Blinker Schalter Kennleuchte Schalter Arbeitsbeleuchtung Schalter Arbeitsbeleuchtung Fusschalter
Starter switch Switch, emergency off Switch, emergency off Push button, warning horn Switch, sprinkler system Switch, seat contact, lh. Switch, vibration, man./autom. Switch, vibration, travel lever, lh. Switch, vibration, travel lever, rh. Switch, hazard light Switch, lighting StVZO Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, edge cutter Switch, indicator Switch, warning light Switch, working lights Switch, working lights Switch, foot
V02 V08 V09 V12 V13 V41 V42 V43 V44 V45 V48
003 004 004 006 006 002 003 002 002 002 003
18 17 19 9 8 3 8 4 16 6 16
Diode Diode Diode Diode Diode Diode (A1) Diode (A2) Diode (A3) Diode (A4) Diode (A5) Diode (A8)
Diode Diode Diode Diode Diode Diode (A1) Diode (A2) Diode (A3) Diode (A4) Diode (A5) Diode (A8)
X1:1 X1:2 X1:3 X1:4 X1:5 X1:6 X1:7 X1:8 X1:9 X1:10 X1:11 X2:1 X2:2 X2:3 X2:4 X3:1 X3:2 X3:3
002 002 002 002 002 002 004 004 003 004 006 002 002 002 002 003 003 003
3 2 5 6 10 16 7 2 14 13 14 20 20 19 15 9 10 2
FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND
Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform
TYP
MAX 2A STECKER FE5B FE5B
MR756 MR756 MR756 MR756 MR756 MR756
K n e i p
c o m p o n e n t l i s t i
B a u t e i l l i s t e
4 . 2 . 4
Name
Bl.
X11:3 X11:4 X11:5 X11:6 X12:1 X12:2 X13:1 X13:2 X13:3 X14:1 X14:2 X14:3 X15:1 X15:2 X16:1 X16:2 X18:1 X18:2 X18:3 X19:1 X19:2 X19:3 X19:4 X19:5 X19:6 X19:7 X19:8 X19:8 X19:8 X19:8 X20:1 X20:2 X21:1 X21:2 X22:1 X22:2 X23:1 X23:2 X23:3 X24:A X24:B X24:C X25:A X25:B X25:C X27:1 X27:2 X27:3 X27:4 X27:5 X28:1
002 002 002 002 002 002 003 003 003 003 003 003 003 003 003 003 003 003 003 006 004 003 005 003 003 006 003 003 004 005 003 003 005 005 003 003 005 005 005 004 004 004 002 002 002 006 006 006 006 006 006
Pf. Benennung 12 13 13 12 3 2 10 9 10 2 2 2 19 18 17 17 5 5 6 17 10 7 10 17 19 17 7 17 10 10 4 4 10 10 16 16 3 3 3 17 19 17 1 1 1 5 7 11 12 5 6
FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND GENERATOR GENERATOR SITZKONSOLE SITZKONSOLE SITZKONSOLE SITZKONSOLE SITZKONSOLE SITZKONSOLE BERIESELUNGSPUMPE BE BERIESELUNGSPUMPE BE EMULSIONSPUMPE EMULSIONSPUMPE ARMATURENPULT ARMATURENPULT ARMATURENPULT FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRHEBEL FAHRHEBEL FAHRERSTAND FAHRERSTAND FUßSCHALTER FUßSCHALTER Fahrersitz Fahrersitz Fahrersitz FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND FAHRERSTAND
title Operators platform Operators platform Operators platform Operators platform Generator Generator Seating unit Seating unit Seating unit Seating unit Seating unit Seating unit Sprinkler pump Sprinkler pump Emulsion sprinkler pump Emulsion sprinkler pump Instrument board Instrument board Instrument board Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Travel lever Travel lever Operators platform Operators platform Foot−switch Foot−switch Driver‘s seat Driver‘s seat Driver‘s seat Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform Operators platform
TYP
S15
S53
S38
S14
S08
A15 / X6 H08 H15 H09 H49
H23 H73 H52 H70 H06 H05
H20
S01
H01
P00 P01
S03
S37
S05 A01 X18 BOX A BOX B X11
S164
S00
S13
F00
G01
F141
R02 B53
Y13
M01
B53 Y20 Y21 Y48
Y90
