BW213DH-3 _SERVICE TRAINING.pdf

Service Training

Single Drum Rollers BW 213 D/DH/PDH - 3 BW 214 DH/PDH-3 Deutz 2012C / 1013EC Partn-No. 008 099 77

3/2003

Service Training Foreword Reliable construction equipment is of greatest advantage for all parties involved in this business: • for the customer/user it is a basis for an exact calculation of utilization periods and the completion of projects as scheduled. • in the rental business it means that the equipment can be reliably used and planned without having to stock a large number of stand-by machines. • for the manufacturer it means that customers are satisfied, provides him with a good image and gives him a feeling of confidence. It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. However, it is the responsibility of the customer to have the daily routine maintenance work performed by his personnel. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine: • the location of components in the machine eases maintenance work, • the high quality standard of BOMAG is the basis for the considerable extension of the service and maintenance intervals, • the After Sales Service of BOMAG, including excellent operating and maintenance instruction manuals, high quality training courses and on-site machine demonstrations helps the customer to maintain their machines in good condition over a long period of time. Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service. This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses. This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses. The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high qualoity of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials . The structure of this training manual enables us to change or up-date individual chapters in case of major alterations to the machine.

BW 213 / 214 - 3 Deutz 2012/1013

- 1 A -

Service Training Documentation For the BOMAG machines described in this Service Training book the following documents are additionally available: Attention! Please draw the current P/N’s of the documents according to the serial number of the machine from the Doclist respectively Central Service page iin the BOMAG-Intranet or Extranet (BOMAG Secured Area).

1. Operating and mai ntenance instructions 2. Spare parts catalogue 3. Electric circuit diagram* 4. Hydraulic diagram * 5. Repair in structions 6. Service Inf ormation * The at the date of publication current documents are part of this training manual.

BW 213 / 214 - 3 Deutz 2012/1013

- 2 A -

Service Training General Single drum rollers of generation 3 are self-propelled soil compaction machines, which are particularly suitable for heavy-duty compaction applications in earth construction. The product range of single drum rollers includes also the machines: • BW 213 (available in different versions) • BW 214 The machines are available with two different types of drums, whereby the correct selection of the drum depends on the type of material to be compacted. The smooth drum is particularly suitable for the compaction of mixed soils, sand, gravel and rock, whereas the padfoot drum shows its advantages on cohesive soils. The use of a machine with padfoot drum on sand and gravel is not recommended. The BW 213 D-3 model 2003 is powered by a water cooled 4-cylinder Deutz engine of series BF4M 2012C. All other models of the product range BW 213 DH/PDH-3 and BW 214DH/PDH-3 are powered by a water cooled 4-cylinder Deutz engine of series BF4M 1013EC. Engine driven pumps transfer the output power of the engine via hydrostatic circuits to the drum, the rear wheels and the steering cylinder. These hydrostatic drives guarantee lowest possible power losses and high efficiency. Front and rear frames are connected by an oscillating articulated joint. The amply dimensioned oscillation angle makes sure that drum and wheels are always in ground contact. The rear axle is fitted with multi-disc brakes in the planetary drives. These brakes have the function of parking brakes. When starting the diesel engine the brakes are released by the increasing charge pressure. When shutting the engine down they are closed again by spring pressure. The brakes can also be applied while the engine is running. This requires only the actuation of the respective brake control valve. However, this feature should only be used if the machine is to be parked for a short while with the engine running. This parking brake must never be used as a service brake, because the deceleration effect is very high and the brake discs would be damaged. All machines of this family work with hydraulic travel systems for rear wheels and drum. The actual compaction tool, the drum, is fitted with a vibrator shaft. This shaft runs in cylinder roller bearings. The vibrator shaft is driven by a hydraulic motor via a Bowex coupling. Vibration of the drum is generated by the centrifugal forces caused by the revolving eccentric weights on the vibrator shaft.

BW 213 / 214 - 3 Deutz 2012/1013

- 3 A -

Service Training The sense of rotation of the vibrator shaft can be reversed. Changing the sense of rotation changes also the position of the change-over weights inside the eccentric weights on the vibrator shaft. This changes also the centrifugal force and the amplitude. The vibrator shaft speed is different to both directions of rotation. This means, that the vibration frequency will also change. In combination with the hydraulic vibration circuit the change-over weights inside the eccentric weights are arranged in such a way, that the high amplitude works with low frequency and vice versa. The combination of high amplitude and low frequency is particularly suitable for compaction applications in heavy earth construction and for pre-compaction work. Low amplitude with high frequency should be used for final compaction during the last passes. The individual machine functions like travel system, vibration and steering circuit are described in detail in the corresponding chapters.

BW 213 / 214 - 3 Deutz 2012/1013

- 4 A -

Service Training List of components 1

2

3 4

5

7 11

8

9

8

6

12 10

20

18

16

17

13 15

14

19

Position of the most important maintenance points 1

Drum

2

Drumdrivemotor

12

Vibrationpump

3

Front frame

13

Travel pump

4

Articulatedjoint

5

Operator’sstand

6

Hydraulicoilcooler

7

Radiator/Chargeaircooler

8

Fuelfilter

9

Lubricationoilfilter

10

Dieselengine

BW 213 / 214 - 3 Deutz 2012/1013

11

14 15 16 17 18 19 20

Steering pump

Handpumpforenginehood Wheels(withaxleandaxledrivemotor) Coolingblower Driver

’s seat

Steeringwheelwithsteeringvalve Vibrationmotor Hydraulicoilfilter

- 1 B -

Service Training Technical data and adjustment values The following pages contain technical data valid at the date of printing (see front page of this manual). Attention! The currently valid technical data and adjustment values can be taken from the BOMAG Intranet or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.

BW 213 / 214 - 3 Deutz 2012/1013

- 2 B -

BOMAGCentralService

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BOMAG Central Service - Technical data and adjustment values Status: 2003-03-10

Producttype: Type No.: Serial numbers from:

BW213D-3 581 42 101 581 42 1001

Engine: Manufacturer: Deutz Type: BF4M2012C Combustion principle: 4-stroke-Diesel Cooling: Water Numberofcylinders: 4 Power acc. to ISO 9249: 98 kW Power data at nominal speed of: 2300 1/min Lowidlespeed: 900+/-2001/min Highidlespeed: 2430+/-501/min Spec. fuel consumption: 225 g/kWh Valve clearance,inlet: 0,3mm Valve clearance, outlet: 0,5 mm Opening pressure, injection valves: 220 bar Startervoltage: 12V Starterpower: 3,1kW Travel pump: Manufacturer: Type: System: Max. displacement: Max.flowratio: High pressure limitation: Charge pressure, high idle:

Sauer-Danfoss 90R 075 Axialpiston-swashplate 75 cm3/U 172,9l/min 435 +/-15 bar 25+/-1 bar

Travel motor, rear: Manufacturer: Type: System: Max. displacement (stage 1): Min. displacement (stage 2): Perm. leak oil quantity:

Sauer-Danfoss 51D110 Axialpiston-bentaxle 110 cm3/U 65,9 cm3/U 2 l/min

Drum drive: Manufacturer: Type: System: Displacement stage 1: Displacement stage 2: Perm. leak oil quantity:

Poclain MSE 18 2CX Radialpiston 2800 cm3/U 1400 cm3/U 2 l/min

Vibration pump: Manufacturer:

Sauer-Danfoss

.../search_components_result.asp?Type=Prod&Text=213&OrderBy=SNsVon%5D%2C+%5B 10.03.03

BOMAGCentralService

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Type: 42R 041 System: Axialpiston-swashplate Max. displacement: 41 cm3/U Startingpressure: 350+/-50bar Operating pressure, soil dependent: ca.100 bar

Vibration motor: Manufacturer: Type: System: Displacement:

Hydromatik A10FM 45 Axialpiston-swashplate 45 cm3/U

Frequency: Amplitude:

30/36Hz 1,8/0,9 mm

Steering and charge pump: Manufacturer: Bosch Type: HY/ZFS11/22,5 System: Gear pump Displacement: 22,5 cm3/U Max. steering pressure: 190+/-10 bar Steering valve: Manufacturer: Type: System:

Sauer-Danfoss OSPC 500 ON Rotaryvalve

Rear axle: Manufacturer: Type: Differential: Degreeoflocking: Reductionratio:

Dana CHC 192/51HD No-Spin 100% 43,72

Filling capacities: Engine coolant:

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) Engineoil: 10l(SAE15W-40,APISJ/CF) Hydraulicoil: 60l(HVLP46VI150) Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF) Rearaxle: 11l(SAE90EP,APIGL5) Rear axle wheel hubs: 2,9 l (SAE 90 EP, API GL 5) AC refrigerant: 1100 g (R 134a) Compressor oil (filling the system): 100 ml (PAG Öl)

.../search_components_result.asp?Type=Prod&Text=213&OrderBy=SNsVon%5D%2C+%510.03.03

BOMAGCentralService

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BW213DH-3 581 43 101 581 43 1001

Engine: Manufacturer: Deutz Type: BF4M1013EC Combustion principle: 4-stroke-Diesel Cooling: Water Numberofcylinders: 4 Power acc. to ISO 9249: 114 kW Power data at nominal speed of: 2200 1/min Lowidlespeed: 900+/-2001/min Highidlespeed: 2430+/-501/min Spec. fuel consumption: 235 g/kWh Valve clearance,inlet: 0,3mm Valve clearance, outlet: 0,5 mm Opening pressure, injection valves: 275 bar Startervoltage: 12V Starterpower: 3,1kW Travel pump: Manufacturer: Type: System: Max. displacement: Max.flowratio: High pressure limitation: Charge pressure, high idle:


Reduction gear, drum: Manufacturer: Type: Transmissionratio:

Sauer-Danfoss CR 31 45,6



Drum drive: Manufacturer: Type: System: Displacement stage 1:

Sauer-Danfoss 51C 110 Axialpiston-swashplate 110 cm3/U


BOMAGCentralService

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31,4 cm3/U 2 l/min

Displacement stage 2: Perm. leak oil quantity:

Vibration pump: Manufacturer: Sauer-Danfoss Type: 42R 041 System: Axialpiston-swashplate Max. displacement: 41 cm3/U Startingpressure: 350+/-50bar Operating pressure, soil dependent: ca.100 bar Vibration motor: Manufacturer: Type: System: Displacement: Frequency: Amplitude:

Hydromatik A10FM 45 Axialpiston-swashplate 45 cm3/U 30/36Hz 1,8/0,9 mm




Dana CHC 193/66LD No-Spin 100% 65,08

Filling capacities: Engine coolant: Engineoil: Hydraulicoil:

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 10l(SAE15W-40,APISJ/CF) 60l(HVLP46VI150)

Vibration bearing housing: Rearaxle: Rear axle wheel hubs: Rear axle, transmission: Reduction gear, drum: AC refrigerant: Compressor oil (filling the system):

2x 0,8 l (SAE 15W-40, API SJ/CF) 1,8l(SAE90EP,APIGL5) 1,85 l (SAE 90 EP, API GL 5) 9,5 l (SAE 90 EP, API GL 5) 2,8 l (SAE 90 EP, API GL 5) 1100 g (R 134a) 100 ml (PAG Öl)


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BW213PDH-3 581 44 101 581 44 1001










BOMAGCentralService

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31,4 cm3/U 2 l/min













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BW213DH-3BVC 581 45 101 581 45 1001










BOMAGCentralService


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31,4 cm3/U 2 l/min


Hydromatik A2FM 45 Axialpiston-bentaxle 80 cm3/U 28 Hz 2,4 mm



Swashing motor, VARIO: Manufacturer: Type: System:

Pleiger STF 1-000-21 piston-gearrack

Rear axle: Manufacturer: Type: Differential: Degreeoflocking: Reductionratio: Filling capacities: Engine coolant: Engineoil: Hydraulicoil: Vibration bearing housing: Drum filling VARIO: Gearbox VARIO: Rearaxle: Rear axle wheel hubs:


16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 10l(SAE15W-40,APISJ/CF) 60l(HVLP46VI150) 16,5 l (SAE 15W-40, API SJ/CF) 80 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 3,6 l (Hight temperature grease AUTOL Top 2000) 1,8l(SAE90EP,APIGL5) 1 85 l SAE 90 EP A PI GL 5


BOMAGCentralService

Rear axle, transmission: Reduction gear, drum: AC refrigerant: Compressor oil (filling the system):

Seite3von3

9,5 l (SAE 90 EP, API GL 5) 2,8 l (SAE 90 EP, API GL 5) 1100 g (R 134a) 100 ml (PAG Öl)


BOMAGCentralService

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Product type: Type No.: Serial numbers from:

BW 213 DH-3 BVC mit Platten 581 41 101 581 41 1001










BOMAGCentralService


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27,5 cm3/U 2 l/min


Hydromatik A2FM 45 Axialpiston-bentaxle 80 cm3/U 28 Hz 2,4 mm

Vibration motor, plates: Manufacturer: Type: System: Displacement: Frequency:

Hydromatik A2FM16 Axialpiston-bentaxle 16 cm3/U 35-65/45-85Hz

Additional pump, plates: Manufacturer: Type: System: Max. displacement: Startingpressure: Charge pressure, high idle:

Sauer-Danfoss 42R 041 Axialpiston-swashplate 41 cm3/U 370+/-10bar 20+/-2 bar



Swashing motor, VARIO: Manufacturer: Type: System:

Pleiger STF 1-000-21 piston-gearrack

Rear axle: Manufacturer:

Dana


BOMAGCentralService

Differential: Degreeoflocking: Reductionratio:

Filling capacities: Engine coolant: Engineoil: Hydraulicoil: Vibration bearing housing: Drum filling VARIO:

Seite3von3

No-Spin 100% 65,08

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 10l(SAE15W-40,APISJ/CF) 60l(HVLP46VI150) 16,5 l (SAE 15W-40, API SJ/CF) 80 l (50% Water, 50% Anti-freeze agent on

Ethane-diol-basis) Gearbox VARIO: 3,6 l (Hight temperature grease AUTOL Top 2000) Rearaxle: 11l(SAE90EP,APIGL5) Rear axle wheel hubs: 2,9 l (SAE 90 EP, API GL 5) Rear axle, transmission: 1,9 l (SAE 90 EP, API GL 5) Reduction gear, drum: 2,8 l (SAE 90 EP, API GL 5) AC refrigerant: 1100 g (R 134a) Compressor oil (filling the system): 100 ml (PAG Öl)


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BW214DH-3 581 46 101 581 46 1001









.../search_components_result.asp?Type=Prod&Text=214&OrderBy=Maschinentyp%5D%2C10.03.03

BOMAGCentralService

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27,5 cm3/U 2 l/min












.../search_components_result.asp?Type=Prod&Text=214&OrderBy=Maschinentyp%5D%2 10.03.03

Service Training Maintenance Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth construction. To be able to meet these demands these machines must always be ready to be loaded up to their limits. Furthermore, all guards and safety installations must always be fully functional. Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably higher functional safety, but also prolongs the lifetime of the machine and of important components. The time required for thorough maintenance is only minor when being compared with the malfunctions and faults that may occur if these instructions are not observed. The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance interval all the work for shorter preceding intervals must also be performed. During the 2000 hours interval you must also perform the work described for the service intervals after 250, 500 and 1000 hours. It should also be clear that with the 2500 hour interval only the work for the 10, 250 and 500 hours intervals must be performed. During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and lubricants (oils, fuels, grease etc.). This training manual is handed out together with the presently valid operation and maintenance manual. For the individual maintenance intervals and the description of the maintenance work involved please refer to these maintenance instructions.

BW 213 / 214 - 3 Deutz 2012/1013

- 1 C -

Service Training Maintenance table

Maintenancework

.t c e p s n i n i g n i

) s r u o h . p n o u 0 5 R (

Remark

Changetheengineoil filter

X

Tighten all bolted connections on the machine

X

Retighten the wheel studs

s r u o h . r e p o

o p 0 1

o p 0 5

o 0 5 2

o 0 0 5

0 0 0 1

0 0 0 2

X

Changetheoilintheplanetarydrives Change the oil in the axle reduction gear

X not BW 213 D-3

Change the oil in the drum drive reduction gear

not BW 213 D-3

Change the oil in the vibrator housings drives

see note

X X X

X

Dipstickmark

Check the water separator approx. 340l

X

X

X

X

X

X

X

X

X

X

X

X

X X

X 1.1 bar

X

X

Inspectionglass

Check the coolant level

BW 213 / 214 - 3 Deutz 2012/1013

s r u o h . r e p o

X

Change the oil in the axle

Check the tire pressure Adjust the scrapers

s r u o h .r e p

X

Tighten all bolted connections on air intake, exhaust, oil sump and engine mounts

Checkthehydraulicoillevel

s r u o h .r e p

X

Check,adjustthevalveclearance

Checkthefuel level

s r u o h . r e

X

Change the engine oil

Checktheengineoillevel

s r u o h . r e

X X

X

X X

X

X

X X

X X

X

X

X X X X X X X X X X

- 2 C -

X

d e r i u q e r s a

Service Training

Remark

Maintenance work

.t c e p s ) in s r u n i- o g h . in p n o n u 0 5 R (

s r u o h . r e p o 0 1

s r u o h . r e p o 0 5 2

s r u o h . r e p o 0 5

Clean the cooling fins on radiator, charge air cooler and hydraulic oil cooler

not BW 213 D-3

Checktheoillevelintheplanetarydrives

X X

X

X

X

X

X

X

X

X

Check the oil level in the drum drive reduction gear

Check V-belt and tension, change V-Belt if necessary Changeengineoilandoilfilter

not BW 213 D-3

X

min.1xperyear

Darin the sludge from the fuel tank

X

Batterymaintenance

X

X

X

X

X

X

X

X

X

X

X

Greasethepoles min.1xperyear

Changetheoilintheplanetarydrives

X

min. 1 x per year, not BW 213 D-3

Change the oil in the drum drive reduction gear

not BW 213 D-3

X

X

X X

X

1 X year; 0.8 l/side

Check the engine mounts

X

X

X

X

X

BW 213 / 214 - 3 Deutz 2012/1013

X

X

X

X

Check the fastening of the axle on the frame

ROPS Check the

X XX

Changethefuelfilterandprefiltercartridge Change the oil in the vibrator housings drives

X

X

X

min.1xperyear

Change the oil in the intermediate gear of the axle

Tighten the wheel nuts

X

XXXX

Check the oil level in the vibrator housings

Changetheoilintheaxle

s r u o h .r e p o 0 0 0 2

XXXX

Check the oil level in the axle Check the oil level in the intermediate gear of the axle

s r u o h .r e p o 0 0 0 1

s r u o h . r e p o 0 0 5

X X

X X

- 3 C -

d e r i u q e r s a

Service Training

Maintenance work

Remark

Check V-belt and tension, change V-Belt if necessary

only BW 213 D-3

Checking and adjusting the valve clearance (on cold engine) DEUTZ

Inlet = 0,3 mm exhaust = 0,5 mm

Check Change / fuel leakage lines Changehydraulicoilandbreatherfilter Change the hydraulic oil filter

Change the coolant Clean, replace the dry air filter element

.t c e p s ) in s r u n i- o g h . in p n o n u 0 5 R (

s r u o h . r e p o 0 1

s r u o h . r e p o 0 5

s r u o h . r e p o 0 5 2

s r u o h . r e p o 0 0 5

X

X

s r u o h .r e p o 0 0 0 1

X

X

d e r i u q e r s a

X

X

min.every2years

X

X

min. every 2 years and after repairs in the hydraulic system min. every years 2

s r u o h .r e p o 0 0 0 2

X

X

X

X

min. 1 x year, safety cartridge min. every 2 years

X

Adjust the parking brake

X

Bleed system fuel the

X

Change tires the

X

Change the fresh air filter for the cabin

X

Tighten all bolted connections

Observe the tightening torques!

X

Engineconservation

Beforelonger periods of standstill

X

Additionally every 12.000 hours: engine service: • Replace the Injection valves • Replace the coolant pump • Replace the pressure retaining valve • Replace the c rankcase ventilation valve

BW 213 / 214 - 3 Deutz 2012/1013

- 4 C -

Service Training Note: When changing filters use only the srcinal filters specified in the operating and maintenance instructions for this machine. The installation of incorrect filters (e.g. insufficient pressure resistance) can lead to severe damage on engine or hydraulic components. The coolant for the water cooled engine must always be mixed with 40 to 50% anti-freeze additive (even under hot environmental conditions) as a preventive measure against corrosion and cavitation. However, the additive proportion must not exceed 60%, since this would have an adverse effect on the cooling ability of the coolant. Oil change intervals in the vibrator housings: after 50 h, after 500 h, after 1000 h and then every 1000 h.

BW 213 / 214 - 3 Deutz 2012/1013

- 5 C -

Service Training Deutz diesel engine Single drum rollers of series BW 213 D-3 are from model 2003 powered by a Deutz diesel engine of product range BF4M 2012 C. All other Models of series BW 213/214 DH-3/PDH-3 are from model 2003 powered by a Deutz diesel engine of product range BF4M 1013 C. This automotive engine is characterized by the following features: • short and compact design, • low noise level, • almost vibration-free running, • low fuel consumption, • low exhaust emissions (EPA II), • high power reserves and • good access to all service points. Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and ensures high wear resistance. The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These weights compensate manufacturing tolerances with respect to weight and centre of gravity. The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the middle at its side walls are inclined for 10 ° towards the inside. All pistons are fitted with three piston rings and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist. The forged crankshaft is equipped with integrated counterweights. The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of high-grade steel and are also shrink fitted.

BW 213-3 2012C/1013EC

- 1D -

Service Training Service side 3

4

2

5

1

6

14

7

13

11

12

10

9

8

Fig. 1: Service side BFM 2012/1013 1

Oil filler neck

2

Valve, boost fuel supply (not BOMAG)

9

3

Enginesolenoid

10

Fuelfilter

4

Oilpressureswitch

11

Lubricationoilfilter

5

Coolingairblower

6 7

Coolantpump V-beltpulley

BW 213-3 2012C/1013EC

8

Fuel pump

12 13 14

Engine mounting

Oilsump Dipstick Steering/chargepump

- 2D -

Service Training Starter side

6

5 4 3 1 2

Fig. 2: Starter side 1

Flywheel

2

Ground cable

3

Starter

4

Turbo charger

5

Generator

6

Coolant temperature switch

BW 213-3 2012C/1013EC

- 3D -

Service Training Lubrication oil circuit 3

4

2

5

6

1

7

8

22

21

9

10

11

20

12

19

18

13

14

17

15

16

Fig. 3: Lubrication oil circuit 1

Oilsump

12 Pistoncoolingnozzle

2

Return flow turbo charger to crankcase

13 Camshaft bearing

3

Turbocharger

4

Oillinetoturbocharger

15 Lubricationoilcooler

5

Line to mass balance wheel (2 x)

16 Lubrication oil pump

6

Oilpressuresensor

7

Valve with pulse lubrication

18 Leak oil return line

8

Push rod, oil supply to rocker arms

19 Lubrication oil filter

9

Linetospraynozzles

10R ockerarm 11 Returnflowtooilsump

BW 213-3 2012C/1013EC

14 Mainoilchannel

17 Pressurereliefvalve

20 Suctionline 21 Crankshaftbearing 22 Conrodbearing

- 4D -

Service Training Lubrication oil circuit

8 7

6 1

3

2

5

4

Fig. 4: Lubrication oil circuit 1

Cooler

2

To cooler

3

From cooler

4

Coolant pump

5

Lubrication oil cooler

6

Cylinder c ooling

7

Cylinder head cooling

8

Ventilation connection between cylinder head and heat exchanger

BW 213-3 2012C/1013EC

- 5D -

Service Training Fuelsystem 7

6

4

1c

1b

1a

Fig. 5: Fuel system BW 213-3 2012C/1013EC

- 6D -

Service Training Legend Fig. 6: 1a

Fuel tank

1b

Manual fuel pump with integrated check valve

1c

Fuel pre-filter / w ater separator

2

Feed to fuel lift pump

3

Fuel lift pump

4 5

Connecting line lift pump – main filter ( fuel pre-pressure up to 10 bar ) Main fuel filter ( pressure resistant)

6

Connecting line main filter – supply for injection pump

7

Single injection pump

8

High pressure line

9

Injection nozzle

10

Leakage l ine

11

Pressure retaining valve - 5 bar

12

Return flow to tank

BW 213-3 2012C/1013EC

- 7D -

Service Training Fuel pre-filter / water separator (SEPAR-Filter)

1

6

2

5

3

4

Fig. 6: Fuel filter / water separator 1

Filter element

2

Sealkit

3

Drain valve

4

Discharge from drain valve

5

Electric connection for water level sensor

The fuel pre-filter / wate rseparator consists mainly of:

• the centrifugal water separator • the dirt / water sediment bowl with water level warning sensor • and the filter element

BW 213-3 2012C/1013EC

- 8D -

Service Training Function: The fuel is drawn by the fuel lift pump into the filter through inlet port B (Fig.8) . Inlet A is closed

closed

closed

Fig. 7: SEPAR-Filter Phase1: The fuel flows from the inlet to the centrifuge. The centrifuge itself does not rotate. Rotation of the fuel is caused by the geometry of the centrifuge. Phase 2: The fuel coming out of the centrifuge flows against the outside wall of the collecting vessel. Here the velocity of the fuel is braked. Due to the inertia of the heavier dirt and water particles these are pressed to the outside so that they drop down into the collecting bowl by their gravity. Phase 3: Fuel now flow up along the outside of the centrifuge while it is still rotating inside the vessel. In this phase smaller dirt and water particles move to the middle of the vessel, where the water particles accumulate to larger drops. There they are picked up by the middle bigger wing of the centrifuge,

BW 213-3 2012C/1013EC

- 9D -

Service Training from where they drop down. This is caused by the fact that the lowest pressure in vessel is at the lowest point of the centrifuge. Phase 4: Even directly in front of the filter element the fuel is still in rotation. This causes further dirt and water particles to settle and drop down into the vessel. Phase 5: The water resistant filter element retains remaining smaller dirt and water particles.

Once the water level reaches the height of the warning connections, the warning light H 70 in the dashboard will light up.

Draining of water/fuel / regeneration of the filter element: To open the drain valve keep the actuating button depressed and turn it. If the filter element is clogged before a service is due (indicated by e.g. a power drop), the filter may be regenerated as follows to keep up operation of the engine:

• Open the bleeding screw (this applies atmospheric pressure to the filter element and releases bigger dirt particles from the bottom side of the filter, which will then sink down.

• Open the drain valve and let approx. 0.5 l of fuel run out. The fuel above the filter element presses through the filter element and cleans the underside of the filter element from dirt.

• Close the drain valve. • Bleed the system with the manual fuel pump and then tighten the bleeding screw.

Main fuel filter Attention! The main fuel filter is subjected to approx. 10 bar fuel pre-pressure from the fuel lift pump. This pressure is considerably higher than on other engines. For this reason only srcinal filter elements must be used. Filter elements of similar design or with adequate dimensions are not necessarily pressure resistant! A filter element of insufficient pressure resistance will be damaged by the high pressure and will disintegrate. This causes severe damage to the injection system!

BW 213-3 2012C/1013EC

10 -D-

Service Training Checking and adjusting the valve clearance Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the intervals specified in the operating and maintenance instructions. Note: The valve clearance must be checked and adjusted when the engine is cold. Intake v alve: = 0.3 mm Exhaust valve= 0.5 mm

• Turn the crankshaft until both valves on cylinder 1 are overlapping (the exhaust valve is not yet closed, the intake valve starts to open).

Flywheel side

1

2

3

4

Fig. 8: Crankshaft position 1

• Check and adjust the valve clearance by following the black marking in the adjustment schematics. For control purposes mark the respective rocker arm with chalk.

Flywheel side

1

2

3

4

Fig. 9: Crankshaft position 2

BW 213-3 2012C/1013EC

11 -D-

Service Training • Turn the crankshaft one full turn (360°) further. • Check and adjust the valve clearance by following the black marking in the adjustment schematics.

BW 213-3 2012C/1013EC

12 -D-

Service Training Explanation of pictograms During the following work the following pictograms are used for the reason of simplicity:

BW 213-3 2012C/1013EC

13 -D-

Service Training plug-in injection pump Deutz diesel engines of product range 2012/1013 are equipped with plug-in injection pumps of series PF 33 from Bosch. The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in combination with a low fuel consumption. Plug-in fuel injection pumps have the following plunger dimensions:

• Stroke

12mm

• Diameter

9mm

Cavitation in the injection lines and injection overrun, which is normally associated with high pressures, is prevented by a return flow nozzle arranged after the pressure valve Das The constant volume relief is 50 mm ³.

Assembling the plug-type injection pumps The adjustment of the injection pump timing (FB) affects:

• the fuel consumption, • the power • the exhaust emission of the engine. On engines of series 2012/1013 the start of delivery is adjusted without tolerance. The start of delivery is enered in degree of crank angle measured from the top dead centre of the piston and depends on application, power and speed setting of the engine. The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply bore in the plunger sleeve.

BW 213-3 2012C/1013EC

14 -D-

Service Training On engines with inline injection pumps the engine drive is turned to start of delivery position and closing of the fuel supply bore is determined by means of a high pressure pump. Occurring tolerances are compensated in the coupling of the injection pump drive, whereby the injection pump camshaft is turned to start of delivery position against the fixed engine drive. The injection pump cams of engine series 2012/1013 are arranged on the camshaft of the engine. For this reason the conventional adjustment method for the start of delivery cannot be used. The start of delivery of the injection pump must be adjusted using the new method. For this the conventional adjustment method is subdivided into length measurements of individual engine parts and calculations. The permissible manufacturing tolerances for the components

• cylinder crankcase, • camshaft, • plunger • plug-in injection pump are measured and eliminated by the adjustment of the start of delivery. However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but individual injection pumps will be replaced. Crankcase, camshaft and plunger remain unchanged. This results in a certain installation measurement for the engine drive, which is stamped on the engine type plate. In column „EP“ iit is stamped as „CODE“ for each cylinder. Note: If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and nozzle must also be replaced.. 1. Remove crankcase ventilation and cylinder head cover.

Fig. 10:

BW 213-3 2012C/1013EC

15 -D-

Service Training 2. Remove the engine solenoid

Fig. 11: 3. Insert the pressing device WILBÄR No. 100 830 carefully into the groove of the governor rod and fasten it.

Fig. 12: 4. Turn the knurled fastening screw to press the governor rod to stop position. Note: Tighten the knurled fastening screw by hand.

Fig. 13:

BW 213-3 2012C/1013EC

16 -D-

Service Training 5. Set the cylinder of the injection pump to be replaced to ignition top dead centre (valves overlapping). Then turn the cr ankshaft approx. 120° against the sense of rotation.

Firing TDC

Note: View on flywheel

Fig. 14: 6. Remove injection line and injection pump.

Fig. 15: 7. Take the compensation shim carefully out with the rod magnet.

Fig. 16: Determine the thickness of the new compensation shim:

BW 213-3 2012C/1013EC

17 -D-

Service Training Determination of the compensation shim thickness when replacing plug-in fuel injection pumps On the engine type plate column - EP – contains a code for the plug-in fuel injection pump for each cylinder.

295

Each line represents 1 cylinder e.g. 1st line = cylinder 1 2. line = cylinder 2 etc.

Fig. 17: Injection pump code BFM 2012/1013

The EP-code is used to determine the installation measurement to be corrected „Ek“ from table 1.

BW 213-3 2012C/1013EC

18 -D-

Service Training

EK (mm)

EP code

EK (mm)

EP code

EK (mm)

EP code

EK (mm)

EP code

119,250

230

119,850

254

120,450

278

121,050

302

119,275

231

119,875

255

120,475

279

121,075

303

119,300

232

119,900

256

120,500

280

121,100

304

119,325

233

119,925

257

120,525

281

121,125

305

119,350

234

119,950

258

120,550

282

121,150

306

119,375

235

119,975

259

120,575

283

121,175

307

119,400

236

120,000

260

120,600

284

121,200

308

119,425

237

120,025

261

120,625

285

121,225

309

119,450

238

120,050

262

120,650

286

121,250

310

119,475

239

121,075

263

120,675

287

121,275

311

119,500

240

120,100

264

120,700

288

121,300

312

119,525

241

120,125

265

120,725

289

121,325

313

119,550

242

120,150

266

120,750

290

121,350

314

119,575

243

120,175

267

120,775

291

121,375

315

119,600

244

120,200

268

120,800

292

119,625

245

120,225

269

120,825

293

119,650

246

120,250

270

120,850

294

119,675

247

120,275

271

120,875

295

119,700

248

120,300

272

120,900

296

119,725

249

120,325

273

120,925

297

119,750

250

120,350

274

120,950

298

119,775

251

120,375

275

120,975

299

119,800

252

120,400

276

121,000

300

119,825

253

120,425

277

121,025

301

Fig. 18: Injection pump code table BFM 2012

BW 213-3 2012C/1013EC

19 -D-

Service Training

EK (mm)

EP code

EK (mm)

EP code

EK (mm)

EP code

EK (mm)

EP code

145.7

349

146.3

373

146.9

397

145.725

350

146.325

374

146.925

398

145.75

351

146.35

375

146.95

399

145.775

352

146.375

376

146.975

400

145.8

353

146.4

377

147.0

401

145.825

354

146.425

378

147.025

402

145.85

355

146.45

379

147.05

403

145.875

356

146.475

380

147.075

404

145.9

357

146.5

381

147.1

405

145.925

358

146.525

382

147.125

406

145.35

335

145.95

359

146.55

383

147.15

407

145.375

336

145.975

360

146.575

384

147.175

408

145.4

337

146.0

361

146.6

385

147.2

409

145.425

338

146.025

362

146.625

386

147.225

410

145.45

339

146.05

363

146.65

387

147.25

411

145.475 145.5

340 341

146.075 146.1

364 365

146.675 146.7

388 389

147.275 147.3

412 413

145.525

342

146.125

366

146.725

390

147.325

414

145.55

343

146.15

367

146.75

391

147.35

415

145.575

344

146.175

368

146.775

392

147.375

416

145.6

345

146.2

369

146.8

393

147.4

417

145.625

346

146.225

370

146.825

394

147.425

418

145.65

347

146.25

371

146.85

395

147.45

419

145.675

348

146.275

372

146.875

396

Fig. 19: Injection pump code table BFM 1013

Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from table 1.

BW 213-3 2012C/1013EC

20 -D-

Service Training During the manufacture of the plug-in fuel injection pump the high pressure method is used to determine the wear in the fuel supply bore. In this position – injection pump plunger in start of fuel delivery positio n - the distance between pump contact face and plunger foot contact face is measured. Measurement "A" in 1/100 mm has been written on the pump with an electric marker.

64

Fig. 20: Plunger code inscription

BW 213-3 2012C/1013EC

21 -D-

Service Training

A=XXX

Fig. 21: Individual injection pump

BW 213-3 2012C/1013EC

22 -D-

Service Training Measurement "A" specifies by how many 1/100 mm the gap between contact area on cylinder crankcase and plunger foot is longer than the hydraulic base measurement L o.

Lo A = XX

A/100

Fig. 22: Presentation of measurement „A“

• Lo = 117,5 mm - BFM 2012 • Lo = 143 mm - BFM 1013

BW 213-3 2012C/1013EC

23 -D-

Service Training

Ek

Lo+A/100

Z Ts

Fig. 23: Drive in start of delivery position after determination of „Ts“ The plug-in fuel injection pump is now positively connected with the drive, which has been set to start of delivery by inserting a compensation shim "Z" of calibrated thickness.. The illustration explains that according to calculation: (Ek) - (Lo + A/100) there is a gap „Ts“ between injection pump plunger foot and roller plunger. This gap has to be compensated with a compensation shim "Z" of appropriate (calculated) thickness.

BW 213-3 2012C/1013EC

24 -D-

Service Training

Theoretical thickness „Ts“

Compensation shim thickness „Ss“ (mm)

(mm)

Theoretical thickness „Ts“

Compensation shim thickness „Ss“ (mm)

(mm)

0.95 - 1.049 1.05 - 1.149

1.0 1.1

2.45 - 2.549 2.55 - 2.649

2.5 2.6

1.15 - 1.249

1.2

2.65 - 2.749

2.7

1.25 - 1.349

1.3

2.75 - 2.849

2.8

1.35 - 1.449

1.4

2.85 - 2.949

2.9

1.45 - 1.549

1.5

2.95 - 3.049

3.0

1.55 - 1.649

1.6

3.05 - 3.149

3.1

1.65 - 1.749

1.7

3.15 - 3.249

3.2

1.75 - 1.849

1.8

3.25 - 3.349

3.3

1.85 - 1.949

1.9

3.35 - 3.449

3.4

1.95 - 2.049

2.0

3.45 - 3.549

3.5

2.05 - 2.149

2.1

3.55 - 3.649

3.6

2.15 - 2.249

2.2

3.65 - 3.749

3.7

2.25 - 2.349

2.3

3.75 - 3.850

3.8

2.35 - 2.449

2.4

Table 1: Shim thicknesses 2012/1013 For the determination of the theoretical shim thickness „Ts“ it is also necessary to determine measurement Lo + A/100 of the new fuel injection pump, which must then be subtracted from the corrected injection pump measurement Ek. Ts = Ek - (L o + A/100) [mm] The real compensation shim thickness „Ss“ is determined with the help of table 2.

BW 213-3 2012C/1013EC

25 -D-

Service Training Exemplary calculation for BFM 2012 EP-code read off engine type plate: 295

• see table 1 corrected injection pump measurement „Ek“: 120,875 mm Lo = 117,5 mm (fixed measurement) Value for A/100 read off new injection pump A/100 = 42

• Ts = Ek - (Lo + A/100) Ts = 120,875 mm - (117,5 + 42/100 mm) Ts = 2.995 mm

• see also table 1 Ts = 3,0 mm Exemplary calculation for BFM 1013 EP-code read off engine type plate: 397

• see table 1 corrected injection pump measurement „Ek“: 146.9 mm Lo = 143 mm (fixed measurement) Value for A/100 read off new injection pump A/100 = 133

• Ts = Ek - (Lo + A/100) Ts = 146,9 mm - (143 + 133/100 mm) Ts = 2.57 mm

• see also table 1 Ts = 2,6 mm

BW 213-3 2012C/1013EC

26 -D-

Service Training 8. Place the new calculated compensation shim on the roller plunger.

Fig. 24: 9. Turn the injection pump control lever to approx. middle position.

Fig. 25: 10. Apply some oil to the locating bore in the crankcase and the O-rings on the injection pump. Carefully insert the injection pump control lever into the governor rod.

Fig. 26:

BW 213-3 2012C/1013EC

27 -D-

Service Training 11. Attach the flange. Note: The chamfer must face towards the injection pump body

Fig. 27: 12. Slightly oil the screws and tighten them evenly with 5Nm.

Fig. 28: 13. Loosen the screws again for 60 ° .

Fig. 29:

BW 213-3 2012C/1013EC

28 -D-

Service Training 14. Carefully turn the injection pump with and open end spanner in anti-clockwise direction against the noticeable stop

Fig. 30: 15. Tighten the screws again for 60° and continue in stages with tightening torques of 7 Nm, 10 Nm and 30 Nm. Note: Start with the outer screw, viewed from the flywheel. (see arrow).

Fig. 31: 16. Back out the knurled screw of the pressing device, remove the pressing device. 17. Reinstall the engine solenoid with a new Oring. 18. Reinstall the cylinder head cover. Tightening torque: 9 +/-1 Nm. Note: If necessary replace the gasket. Fig. 32: 19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening torque 9 +/- 1Nm Note:

BW 213-3 2012C/1013EC

29 -D-

Service Training If necessary replace the gasket.

Tools The following tools can be ordered from the respective supplier (in brackets) under the stated partnumber. For tools from Hazet and Bosch you should consult your nearest representative, orders to Wilbär should be addressed to: Co. Wilbär P.O. box 140580 D - 42826 Remscheid

Fig. 33

• Pressing device for governor rod

BW 213-3 2012C/1013EC

100 830 (Wilb

ä r)

30 -D-

Service Training Electrical components and measuring point on the engine

4 2 1

3

Fig. 34: Diesel engine, right

Pos.

Designation

Pos. in wiring diagram

1

2

Heating flange module A 13 High current relay for heating flange 14 K

3

Oilpressureswitch

4

Enginesolenoid

B06

Y13

Pos. in hydraulic diagram

Measuring values

0/12 V pressureless closed, 0,8 bar 0/12V,approx.4 Ω

BW 213-3 2012C/1013EC

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Service Training

1

2

Fig. 35: Top view of diesel engine

Pos.

Designation

1

Heatingflange

2

Pressure differential switch for air filter

BW 213-3 2012C/1013EC


R19

B 03


Measuring values

0/12V,167A, approx. 0,07 Ω pressureless open, 50 mbar

32 -D-

Service Training

1

2

3

Fig. 36: Rear view of diesel engine

Pos.

1

2 3

Designation

Boostfuelvalve Coolant temperature switch for warning light Coolant temperature flange for heating flange

BW 213-3 2012C/1013EC


Y01

B53 B113


Measuring values

0/12V cold open, on ca. 110°C Ω at approx. 2 20 C

33 -D-

Service Training d e e p s m ro f

e lv a v e g n ra

9

A

vela v eg n ra de e p S

B

6 . 0 ø .6 0 ø

L

8

e v l a v e k ra b m rfo

vel av g inh su l F

7 8 9

3 M

0 11 D 1 5 eru a

3 T

4 M

7

6 2 M

5

p m u p n o ti ra ib v o t e r u s s re p e rg a h C

4

3

i t u c r i c l e v a r T

r a b 5 2

2 8 . 0 5 M 4 M

ø

1 .8 0 ø

1

r e iltf il o c li u ra d y h m o fr re u s s e r p e rg a h C

-3 D 31 2 W B m et s syl ev rat m graa id ic ula r dy H :1 .g i F

BW 213 / 214 - 3 Deutz 2012C 1013EC /

X C 2 81 E S M ni lac o P rot o m vrei d m ur D

- 1E -

e lvav no it ncu itfl u M

le ax ra e R

rto S o m veir d lex A

4 5 6

5 70 R 09 r e au S p m up elv ra T

lo rt onc ov re S

ev l vfa leei r reu sse rp eg arh C

1 2 3

Service Training 2 1 1 M

2 M

)r too m ev ir

3 T

1 1

0 1 9

A

B

8

3 M

6 3 T

4 M

7

5

4

3

2

r a b 5 2

1

-3 H D P / H D 6 21 W B / 3H D /P H D 41 2 W B / 3H D P / H D 31 2 W B it ciur c evl a trm rag iad luci rda y :2H . ig F

dm ur d( vel va g in suh l F

r)o t o m ev ir d m u (dr vel av eg na r de e p S

13 R C eru a S aer g n tioc u de R

9 01 11 21

lex a ra e R

01 1 D 15 er au S r ot o m vrei d lex A

ev la v e nga r de ep S

ev l va gn ih s lu F

5 6 7 8

57 0 R 0 eur9 a S p m u lpe avr T

vel av f lo r not c o rve S

reli er us s re p e rg ah C

ev l va n iot c n fui tl u M

1 2 3 4

BW 213 / 214 - 3 Deutz 2012C 1013EC /

)0 11 C 15 er au(S r too m ev i dr m ru D

- 2E -

Service Training The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of: • travel pump with control and safety elements, • drum drive motor with integrated multi-disc brake (BW 213 D-3), • drum drive motor with reduction gear (all DH/PDH-3 versions), • axle drive motor, • charge pump (also for vibration circuit), • hydraulic oil filter (in charge circuit), • hydraulic oil cooler with thermostat • hydraulic lines. Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral part of the vibration pump. The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine. The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function valves in the pump limit the pressure in the closed circuit to 425 bar (∆p = 400 bar between low and high pressure sides). A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain oil quantity out of the closed circuit when the machine is driving (∆p between the two sides of the closed circuit). Leakage in the individual components of the circuit are replaced by the charge circuit through the boost check valves in the travel pump. The charge pump inside the vibration pump draws hydraulic oil out of the tank and delivers it through the hydraulic oil filter to the boost check valves in travel and vibration pump. The return flow from the steering system flows also through the hydraulic oil filter and is then available for the charge circuit. The charge circuit provides the oil for the control functions in the closed circuits for travel and vibration drive, as well as to release the parking brakes and to change the travel speed ranges. Both travel motors are designed with variable displacement. The operator has the possibility to choose from two fixed displacements and thereby from two different travel speed ranges.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 3E -

Service Training Travel pump The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable for applications in hydrostatic drives with closed circuit. M4

M5

2

A from/to travel motor

25 bar

4 3

1

from/to travel motor

B Charge pressure to vibration pump Charge pressure from hydraulic oil filter

Fig. 3: Hydraulic diagram of travel pump 1

Pumpdrive

3

Chargepressurereliefvalve

2

Servocontrol

4

Multi-functionvalves

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 4E -

Service Training The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing angle of swash plate) of the pump.

7

1

2 3

4

6

5

Fig. 4: Travel pump 1

Controllever

5

Cylinderblock

2

Drive shaft

6

Valve plate

3

Swashplatebearing

7

Controlpiston

4

Pistons with slipper pads

With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both maximum displacement positions. When altering the swash plate position through the neutral position, the oil flow will be reversed and the machine will drive to the opposite direction. All valves as well as the safety and control elements needed for operation in a closed circuit, are integrated in the pump. Note: The charge pump is inside the vibration pump.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 5E -

Service Training Cross-sectional view of travel pump

2 4 5

1

3 6 7

9

10

8

11 Fig. 5: Cross-sectional view of travel pump 1

Retainerforswashplate

2

Slidingblock

8

Swashplateguide

3

Control piston

9

Swashplate

4 5

Servo arm Servovalve

10 11

Swashing lever Chargepump(onlyinvibrationpump)

6

Feedback device

BW 213 / 214 - 3 Deutz 2012C 1013EC /

7

Swashplatebearing

- 6E -

Service Training View of the rotating group 1 2

5

4

3

Fig. 6: Travel pump, view of the rotating group 1

Working pistons

2

Slipper pad

3

Pre-tensioning spring

4

Cylinder block

5

Drive shaft

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 7E -

Service Training Description of function

2

4

3

5

6

1

8

6

7

Fig. 7: Function of travel pump 1

Driveshaft

5

Cylinderblock

2

Driveshaftbearing

6

Multi-functionvalves

3

Swashplate

4

Pistonswithslipperpads

7 8

Chargepump(onlyinvibrationpump) Valveplate

The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly connected cylinder block (5). With the roation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper pads of the working pistons abut against the swash plate (3).

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 8E -

Service Training When moving the swash plate out of neutral position, the working pistons will perform a stroke movement with every rotation of the cylinder block. The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle by a retaining device. During a full rotation of the cylinder block each working piston will move through the bottom and top dead centre back to the initial position. During this movement each piston performs a complete stroke. During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the hydraulic circuit and presses it out into the high pressure side.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 9E -

Service Training Tandem pump, connections and adjustment points

38

Thermostat housing

Fig. 8: Connections and adjustment points

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-10 E-

Service Training 1

Control solenoid, high frequency (vibration pump)

2

Control solenoid, low frequency (vibration pump)

3

Multi-function valve 425 bar (charging and pressure limitation), travel system

4

Charge pressure to so lenoid valve for brakes and speed range selector, charging vibration

5

Multi-function valve 425 bar (charging and pressure limitation), travel system

6

Adjustment screw, mechanical neutral position

7

Port L, leak oil to vibration pump

8

Travel lever

9

Pressure test port, pilot pressure

10

High pressure port B, high pressure reverse

11

Charge pressure relief valve, 25 bar

12

Adjustment screw, low frequency

13

Port L2, leak oil to tank

14

Pressure test port MB, high frequency

15

Pressure test port MA, low frequency

16

High pressure port A, low frequency

17

High pressure port B, high frequency

18

Charge pump (only in vibration pump)

19

Port L2, to drum drive motor 51 C 110 (flushing)

20 21

Adjustment screw, high frequency Port D, charge pressure to filter

22

Multi-function valve 370 bar (charging and pressure limitation), vibration high frequency

23

Port S, suction line between hydraulic oil tank and charge pump

24

Multi-function valve 370 bar (charging and pressure limitation), vibration low frequency

25

Charge pressure relief valve, vibration pump (blocked)

26

Port E, charge oil from travel pump

27

Port L1, leak oil port to travel pump

28

Pressure test port MB, high pressure reverse

29

Charge oil from filter

30

Pressure test port MA, high pressure forward

31

High pressure port A, high pressure forward

32

Port C, from solenoid valve for brake/speed range selection

33

Leak oil port D, leak oil from axle drive motor

34

Leak oil port A, leak oil from travel pump

35

Leak oil port G, leak oil from drum drive motor

36

Leak oil port F, leak oil from vibration motor

37

Leak oil port B, leak oil to oil cooler

38

Adjustment screw for m echanical neutral position, vibration

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-11 E-

Service Training Servo control The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal of the pump control lever into a position controlling output signal. This position controlling signal determines the swashing angle of the swash plate (the displacement of the pump), as well as the swashing direction (flow direction of the pressure fluid). The flow quantity delivered by the variable displacement pump is proportional to the value of the mechanical input signal. A mechanical feedback device ensures the fixed correlation between the mechanical input signal and the swashing angle of the swash pl ate (displacement of pump). Servo cylinder

Control piston

Sliding block

Servo arm

Fig. 9: Control piston

A mechanical damage to thesafety servo device control.(spring) makes sure that a too fast lever movement will not cause any The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel control cable. This requires only very little manual forces and only a slight movement of the lever.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-12 E-

Service Training Since the control is spring centred, the swash plate will automatically return to neutral position under the following conditions, thereby interrupting the oil flow and braking the machine: • when shutting the engine down, • if the external control cable comes loose, • if the pressure in the charge circuit drops below a certain value.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-13 E-

Service Training Multi-function valves High pressure limitation Pumps of series 90 are equipped with a follower valve, which activates a pressure override and a pressure relief valve, one after the other.

1

2

7 3 A

6

5

B 4 7

2 Fig. 10: Multi-function valves 1

tothecontrol

2

Multi-functionvalve

6 7

Driveshaft tothecontrolpiston

3

Chargepump

8

tothecontrolpiston

4

Chargepressurereliefvalve

A

PortA

5

Pilotpressurereliefvalve

B

PortB

If the adjusted pressure is reached, the pressure override will move the swash plate quickly back towards neutral position, thereby limiting the system pressure. The average response time is less than 90 ms.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

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Service Training In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the high pressure relief valve is higher than the pressure level of the pressure override. The high pressure relief valves will only respond if the pressure override is not able to swash the pump back quick enough in case of sudden pressure peaks.

2

3

4

5

1

6 9 10

7 8

11

Fig. 11: Multi-function valve, details 1

Reducingfitting

7

2

Hydraulicby-passpiston

8

3

Spring plate

4

Spring

5

Highpressurereliefvalve

6

Valve seat

Checkvalve Pressurelimitation

9

Spring 10

10

By-pass housing By-passsleeve

Pressure override and high pressure relief valve are both parts of the multi-function valve, which is screwed into the pump. With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure override makes sure that the high pressure relief valves will only respond in exceptional cases. This protects the hydraulic circuit against overheating and reduces the load on the diesel engine. Note: The multi function valves must be tightened with a torque of 89 Nm!

BW 213 / 214 - 3 Deutz 2012C 1013EC /

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Service Training Charge pressure relief valve The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted value (25 bar). The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits and provides the necessary pressure to control the travel and vibration pumps, the speed range selection and to operate the multi-disc brakes in the travel drives. Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the pressure in the low pressure side is almost identical with the pressure in the charge circuit. When parking the machine on level ground with the engine running, the pressures in both sides of the closed circuit are identical (charge pressure).

BW 213 / 214 - 3 Deutz 2012C 1013EC /

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Service Training Flushing valve 2

1 Fig. 12 Cross-section of flushing valve 1 Flushing spool 2 Flushing pressure relief valve The flushing valves are integrated in the axle drive motor, or on DH/PDH machines, also in the drum drive motor. In case of a pressure increase in one of the two sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the low pressure side. The valve is operated by the pressure difference between the two sides of the closed circuit (A and B). If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows through a thermostat valve back to the tank. The flushed out oil quantity is immediately replaced by oil entering from the charge circuit through the corresponding boost check valve (part of the multi-function valve). In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature household of the hydraulic system is maintained at a permissible level.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

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Service Training Axle drive motor The axle drive motor is a swash plate controlled Sauer-Sundstrand axial piston motor (series 51 D 110) with variable displacement.

5

8

7

6

9

1

11 4

2

10

3 Fig. 13: Axle drive motor,

1 2

Controlpiston Flushingvalve

3

Control

4

Spindlewithball

5

Qmin-screw

6

Valve plate

BW 213 / 214 - 3 Deutz 2012C 1013EC /

7 8 9 10 11

Cylinderblock Universaljoint Output shaft Outputshaftbearing Workingpiston

-18 E-

Service Training The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle between cylinder block and output shaft. With a large angle position the motor works with maximum displacement, slow speed and high torque. When changing the swash plate position to minimal angle the motor works with minimum displacment, high speed and low torque. The displacement is changed by a control piston, which is tightly connected with the valve segment. Changing of the displacement is accomplished by pressurizing the corresponding control piston side with pressure oil from the charge circuit via a 4/2-way solenoid valve. Function The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows under high pressure through the corresponding port to the back of the working pistons. Since the working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a stroke movement, thereby causing a rotation of the output shaft. Once the respective piston has passed its dead centre (max. extended position), it will change to the low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is thereby displaced out of the cylinder chamber through the low pressure side back to the pump. The synchronizing shaft with roll surfaces ensures uniform rotation of output shaft and cylinder block. The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the connection between output shaft and pistons no other parts are required. The output shaft runs in two tapered roller bearings.

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Service Training Manual releasing of brake on axle drive For manual releasing of the brakes on the rear axle you should proceed as follows:

Fig. 14: Manual releasing of rear axle brakes • Slacken the counter nut (Pos. 1, Fig. 14) and turn the counter nut approx. 8 mm back, until the brake is released. • Turn the brake realeasing screws (Pos.2) completety in against the end stop. • From this stop turn the screw max. another turn in to release the brake. Attention! Turn the screws in evenly on both sides! (alternately 1/4 turn on each side) • Repeat this measure on the opposite wheel side

BW 213 / 214 - 3 Deutz 2012C 1013EC /

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Service Training Drum drive motor Poclain MSE 18 2 CX On single drum rollers of series BW 213 D-3 the drum is driven by a hydraulic radial piston motor. These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the working pistons and the output shaft.

2

3

4 1

43090070

8

7

6

5

Fig. 15: Drum drive motor 1

Drive shaft with output flange

2

Piston with roller

3

Oil distributor

4

Brake piston

5 6

Multi-disc brake Cylinder block

7

Camring

8

Bearing plate

The housing consists of:

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-21 E-

Service Training • bearing section (drive shaft b earings), • torque section (cam race) and • oil distributor. Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure oil presses the working pistons with the rollers against the cam race of the torque section and forces the rollers to roll along the cam race. This transforms the axial movement of the pistons to a radial movement of the cylinder block. The cylinder block transfers this rotation via a spline connection to the output shaft. The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc and the rubber elements to the drum. The function of the radial piston motor is described hereunder. The piston positions described in this explanation can be seen in the related illustration. The movement of a piston along the cam race must be examined in several phases during a full rotation: 5

1 4

2 3

Fig. 16: Function of the radial piston motor

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-22 E-

Service Training Piston position 1: The oil enters into the oil distributor under pressure, flows through the distributor and presses against the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the roller along the cam and causes a rotation of the cylinder block. Piston position 2: At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The piston continues his travel along the cam race towards the valley between two cams. As the movement continues, the opening cross-section for the oil supply decreases. Piston position 3: Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first piston out of the dead centre. Piston position 4: Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now connected with the low pressure side and the reverse movement of the piston presses the oil back to the pump. Piston position 5: The pumping movement of the motor back to the pump comes to an end, the connecting bore between cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre position. This point is the start of a new working cycle. Reversing the oil flow reverses also the rotation of the motor. The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc and the rubber elements to the drum.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-23 E-

Service Training Manual releasing of the brake in the Poclain motor For manual releasing of the brake in the Poclain motor (drum drive) you should proceed as follows:

Fig. 17: Manual releasing of the brake in the Poclain motor • Remove the plug 1 (Fig. 17). • Lay the U-bar (5) across the brake housing (2) and turn the screw (4) into the tapped bore (3) until it bottoms. • Turn the nut (6) down and tighten it for approx. one turn. The drum must turn freely.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-24 E-

Service Training Drum drive motor 51 C 110 with reduction gear CR 31 The drums on the DH-3 and PDH-3 versions are driven by a swash plate operated Sauer axial piston motor 51 C 110. This motor is almost identical with the rear axle motor. Another detailed description at this point is therefore not necessary. 2 1

3

4

5

6

7

8

10 9 Fig. 18: Reduction gear CR 31 1

Travel motor

6

Sun gear

2

Taperedrollerbearing

7

Planetcarrier

3

Spur wheel

8

Brake discs

4 5

Hollowwheel Planetwheel

9 10

Mechanicalseal Brakepiston

This motor is a fast rotating hydraulic motor. Since the output speed of this motor is much too high to drive the drum, a reduction gear reduces the output speed to the actually required drum drive speed.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-25 E-

Service Training Brake control During operation the closed hydrostatic travel circuit has the function of a service brake. When moving the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill. However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause creeping of the machine when it is parked on a slope with the engine running, the machine is additionally equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever in neutral position the multi-disc brakes will close and the machine can be parked on slopes with the engine running and without the risk of creeping. However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is interrupted and the oil from the brake housings flows as leak oil back into the tank. If the brake solenoid valve is supplied with current while the engine is running and the brake is open, the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake discs. Manual releasing of the brake in the drum drive reduction gear

Brake releasing device in operation position

Brake releasing device in position “brake manually released”

Fig. 19 Manual brake releasing device

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-26 E-

Service Training

Fig. 20: Manual releasing of the brake in the drum drive CR31

• clockwise Turn both direction, screws (Fig. releasing the brakefreely. in the drum drive reduction gear evenly in until20) thefordrum can be turned

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-27 E-

Service Training Travel circuit with Poclain motor (position of components)

2 3

1

4

8

6

1

7 5

Tr High pressure Low pressure Charge pressure

el av

re di

io ct

n 1 2 3 4 5 6 7 8

Travel pump Vibration pump Travel lever Hydraulic oil filter Rear axle Axle drive motor Drum drive motor Hydraulic oil tank

Leak oil (case pressure)

Fig. 21: BW 213 D-3, travel circuit, routing of hoses

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-28 E-

Service Training Travel circuit with drum drive motor 51 C 110 and CR 31 (position of components)

2

9

1

3 8

4 7

5

6 T

High pressure Low pressure Charge pressure Leak oil

i ld ve ra

on c ti re

1 2 3 4 5 6 7 8 9

Travel pump Vibration pump Hydraulic oil filter Rear axle Axle drive motor Reduction gear Drum drive motor Hydraulic oil tank Travel lever

Fig. 22: Travel circuit with 51 C 110 and CR 31

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-29 E-

Service Training Brake control BW 213 - 3 (with Poclain motor)

Brake valve

Leak oil from drum drive motor to brake valve Brake releasing pressure Charge pressure Leak oil from brake valve to hydraulic oil tank

Fig. 23: Brake circuit

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-30 E-

Service Training Brake control BW 213 - 3 (with Sauer motor 51 C 110 and CR 31)

Brake valve

Charge pressure Brake releasing pressure Leak oil

Fig. 24: Brake circuit

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-31 E-

Service Training Trouble shooting travel circuit The following description of trouble shooting steps contains a small selection of possible faults, which may occur during operation of the machine. This list is by no means complete, however, the description should help you to become acquainted with a systematic trouble shooting procedure. The problems and trouble shooting steps described in this training manual are identical with the problems and trouble shooting steps in the operating and maintenance instructions for this machine. However, in this manual we have tried to describe the individual steps in more detail, in order to explain why certain trouble shooting steps should be applied and why certain preparations must be made before certain tests or measurements can be performed. After this training session the persons attending the course should be able to apply the correct trouble shooting steps, even if the actual problem is not described in this manual.

3

-214/213 BW

-

1ETr-

Service Training The machine moves with the travel lever in “NEUTRAL”

Check neutral position Fig. F1

OK ?

no

Adjust the travel cable Fig. F2

no

Adjust mechanical 0-position Fig. F4

no

Replace the servo control

yes Check mechanical 0-position Fig. F3

OK ?

yes Check the servo control Fig. F5

OK ?

yes Replace the travel pump

3

-214/213 BW

-

2ETr-

Service Training The machine does not drive (to either direction) Check the control cable (torn / detached)

nein no

OK ?

Replace / attach the control cable

yes Check the charge pressure Fig. F6

no

OK ?

Check steering for function and movability

yes Check high pressure Fig. F9

Replace steering/ charge pump

no

OK ?

yes no

OK ?

yes Check the coil of the brake solenoid valve Fig. F10

Check the charge pressure relief valve Fig. F7

no

Replace the charge pressure relief valve

no OK ?

Perform trouble shooting in electric system

yes Check brake releasing pressure Fig. F11

no

OK ?

OK ?

yes Check the leakage of the brake Fig. F8

OK ?

no

Replace the brake valve yes

Repair the component after the disconnection of which the charge pressure value was OK

yes

Mechanical fault in axle, drum

3

-214/213 BW

-

3ETr-

Service Training Checking of individual components Check drum drive motor Fig. F12

yes

Pressures OK ?

Check flushing valve on drum drive motor (axial piston motor), Fig. F14

no Check axle drive motor/ travel pump Fig. F13

Check axle drive motor flushing valve, Fig. F14

no OK ?

yes

yes

Pressures OK ? Repair/replace the drum drive motor

no no OK ?

yes

Check the servo Fig. F5 control

Replace the flushing valve Replace the servo control

no OK ?

Replace, repair the flushing valve

yes Replace/repair the travel pump

3

-214/213 BW

Replace the flushing valve

-

4ETr-

Service Training Insufficient travel power, max. speed is not reached Check the engine speed Fig. F15

OK ?

no

Perform trouble shooting on the diesel engine

yes Check travel cable for play / wear

OK ?

no

Adjust / replace the travel cable

yes Continue trouble shooting with „Machine does not drive“, from „Check charge pressure“

3

-214/213 BW

-

5ETr-

Service Training Hydraulic oil overheating (> 90 °C)

Check the thermostat valve Fig. F16

Thermostat opens ?

no

Replace the thermostat

yes Check the multi-function valves Fig. F17

Heating of valves ?

no

Check hoses for buckling / components for excessive development of heat

yes Clean / replace the multifunction valve

3

-214/213 BW

-

6ETr-

Service Training Fig. F1: Checking the neutral position With the travel lever in neutral position the machine must not move, even when the engine is running. In this condition the travel pump is centred in neutral position and both sides of the closed circuit have identical pressure (charge pressure). If the machine moves in this condition on flat ground you should perform trouble shooting by applying the following steps. • Shift the travel lever to ”Ne utral” position • Disconnect the travel cable from the pump • Start the engine (if the machine is fre e of faults the machine will now stop) • Check, whether bores in ball soc ket and pump control lever are in lin e

3

-214/213 BW

-

7ETr-

Service Training Fig. F2: Adjusting the travel cable • Slacken the co unter nut on the tra vel cable bracket to adjust the tr avel control cable • Turn the adjustment nut, until the correct neutral position (bores in line) is reached • Tighten the counter nut again

3

-214/213 BW

-

8ETr-

Service Training Fig. F3: Checking the mechanical neutral position The mechanical neutral position determines the mechanical position of the pump control piston. This piston is connected with the swash plate and its position determines the position of the swash plate. If the piston is out of neutral position the swash plate actuates the working pistons, whereby oil is being pumped to the travel motors. • Connect both control chambers on the pump control with a suitable hose • Start the engine • If the mechanical neutral position is correctly adjusted the machine will not move.

3

-214/213 BW

-

9ETr-

Service Training Fig. F4: Adjusting the mechanical neutral position If the machine still moves after connecting both control chambers, the mechanical neutral position of the travel pump needs to be adjusted: • Connect 600 bar pressure gauges to the high pressure test ports • Pull the plug off the brake solenoid valve and block the drum • Start the engine and run it with max. speed • Read the pressure gauges and adjust the mechanical neutral position on the adjustment screw of he spring pack on the control cylinder (see illustration), until identical pressure (charge pressure) is reached on both sides. For higher accuracy repeat the testing and adjustment procedure with two 60 bar pressure gauges.

3 -214213 /BW

- 10 ETr-

Service Training Fig. F5: Checking the servo control: • Disassemble the servo control • Check piston and linkages for moveability and wear • Check the nozzles, clean if necessary replace a defective servo control immediately.

3 -214213 /BW

- 11 ETr-

Service Training Fig. F6: Checking the charge pressure • Connect a 60 bar pressure gauge to the charge pressure test port • Start the engine and run it with max. speed Nominal value: 25 +/-1 bar

3 -214213 /BW

- 12 ETr-

Service Training Fig. F7: Checking the charge pressure relief valve • Unscrew the valve and check for dirt and damage Replace a defective charge pressure relief valve immediately.

3 -214213 /BW

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Service Training Fig. F8: Checking the leakage of the brake A leakage in the brake housings can cause a drop in charge pressure, the brake cannot be released. • Release the brake by shifting the travel lever out of braking position • Disconnect the brake lines one after the other from drum drive and wheel drive motor and perform charge pressure tests always after disconnecting a hose Repair the motor after the disconnection of which the charge pressure was found correct.

3 -214213 /BW

- 14 ETr-

Service Training Fig. F9: Checking high pressure • Connect 600 bar pressure gauges to the high pressure test ports • Connect a 60 bar pressure gauge to the charge pressure test port • Pull the plug off the brake solenoid valve and block the drum • Start the engine and run it with max. speed • Drive the machine against the closed brake, for this purpose actuate the travel lever for a moment and read the pressure gauges Nominal values: High pressure 435 +/-15 bar, charge pressure 25 +/- 1 bar

3 -214213 /BW

- 15 ETr-

Service Training Fig. F10: Checking the magnetic coil of the brake valve • Start the engine and release the brake (disengage the travel lever from the braking position) • use an appropriate meter to measure the voltage and current draw on the magnetic coil of the solenoid valve Nominal values: D-versions: 12 V / 1.8 A; DH/PDH-versions: 12 V / 1.8 A;

3 -214213 /BW

- 16 ETr-

Service Training Fig. F11: Checking the brake releasing pressure If the brake valve does not open, no oil from the charge circuit will be guided to the brakes and the brake discs cannot open. • Install a pressure test port with a 60 bar pressure gauge to the brake releasing line • Start the engine and release the brake (disengage the travel lever from the braking position) • Read the pressure gauge, Nominal value: 25 +/- 1 bar (charge pressure)

D - version

3 -214213 /BW

DH-/PDH-versions

- 17 ETr-

Service Training Fig. F12: Checking the drum drive motor • Unscrew the high pressure hoses from the drum drive motor and close them with suitable plugs • Perform a high pressure test (Fig. F9) If the specified pressure values are reached after disconnecting the drum drive motor, whereas they have not been reached while the motor was still connected, the drum drive motor is defective. If the specified pressures are not reached, the axle drive motor or the travel pump must be defective

D - version

3 -214213 /BW

DH-/PDH-versions

- 18 ETr-

Service Training Fig. F13: Checking axle drive motor / travel pump • Disconnect the high pressure hoses from the travel pump • Close the pump port with pressure resistant plugs • Perform a high pressure test (Fig. F9) If the specified pressure values are now reached and the drum drive motor is OK, the fault must be in the axle drive motor. If the high pressure values are not reached, the fault must be in the travel pump.

3 -214213 /BW

- 19 ETr-

Service Training Fig. F14: Checking the flushing valves on axle drive and drum drive motor (only axial piston motor) In case of a failure on one of the flushing valves a too high oil quantity may be flushed out and the charge circuit may not be able to replace this quantity. The charge pressure will drop and important machine functions will no longer be available. • Pull the valve spool out of the flushing valve • Check for moveability and damage replace a defective flushing valve.

3 -214213 /BW

- 20 ETr-

Service Training Fig. F15: Checking the engine speed • Start the engine and run it with max. speed • Measure the engine speed with a suitable RPM-meter (e.g. digital optical RPM-meter) Nominal value: 2300 min -1 (high idle)

3 -214213 /BW

- 21 ETr-

Service Training Fig. F16: Checking the thermostat valve If the hydraulic oil heats up to a too high temperature it will loose its lubrication properties, which may cause damage to important components in the hydraulic system. In case of a too high hydraulic oil temperature shut the engine down immediately, let the system cool down and perform trouble shooting. Do not start to operate the machine unless the fault has been corrected. First check the function of the thermostat valve. Up to a temperature of 60 °C all leak oil, flushing and return flow quantities flow directly back into the tank. At 60°C the thermostat valve should start to open and guide the hydraulic oil through the hydraulic oil cooler back to the tank. • Feel with your hand if the hose to the hydraulic oil cooler starts to become warm after a hydraulic oil temperature of 60°C is reached. • If the thermostat valve does not open it must be replaced immediately.

3 -214213 /BW

- 22 ETr-

Service Training Fig. F17: Checking the multi-function valves The opening cross-sections of the high pressure relief valves, which are part of the multi-function valves, are very small. Hydraulic oil escaping from the high pressure side through the h igh pressure relief valves (e.g. in case ofa defective pressure override, which is also part of the multi-function valve) will cause very quick overheating of the hydraulic oil. • Pull the plug off the brake solenoid valve • Block drum and wheels with chocks • Start the engine and run it with max. speed • Actuate the travel lever to both directions and check the multi function valves for heat development. • If one of the valves develops excessive heat, it must be immediately replaced Attention! Tightening torque for multi-function valves 89 Nm

3 -214213 /BW

- 23 ETr-

Service Training Vibration system The vibration system of the single drum rollers BW 213 - 214 of generation 3 works with two frequencies and two amplitudes. This enables perfect adaptation of the machine to various types of soil and different applications. The vibration drive is a closed hydraulic circuit. The circuit consists of: • the vibration pump, • the vibration motor and • the pressure resistant connecting hoses.

to release the brake

from charge pump via travel pump D

L2

M3

E

Charge oil vibration pump

N

A

M1

M2 S

1

B

2

M4

M5

Fig. 1: Vibration circuit 1

Vibration pump

2

Vibration motor

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 1F -

Service Training Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly driven by the diesel engine. When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to one of the two control piston sides. The swash plate inside the pump will swash to the corresponding side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the vibrator shaft inside the drum. When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will change its direction and the vibration motor will change its sense of rotation. Since the end stops for the swash plate are set to different swashing angles to both directions, the angle for the piston stroke is also different to both sides. This angle influences the length of the piston stroke and thereby the actual displacement of the pump. • Large angle = high displacement = high vibrator shaft speed (frequency) • Small angle = low displacement = slow vibrator shaft speed (frequency) The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights. This results in the following constellations: • Basic weight + change-over weight = high amplitude • Basic weight - change-over weight = low amplitude In order to achieve effective compaction results the vibration system is designed in such a way, that high amplitude is coupled with low frequency and low amplitude with high frequency.

Fig. 2:

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 2F -

Service Training Vibration pump Similar to the travel pump the vibration pump is also a swash plate operated Sauer-Sundstrand axial piston pump with variable displacement for operation in a closed circuit. The displacement of the pump is proportional to the engine speed and the chosen displacment. When actuating the swash plate out of neutral position the flow quantity to the chosen direction will increase from ”0” to the maximum value. When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will change its direction and the vibration motor will change its sense of rotation. All valves and safety elements for operation in a closed circuit are integrated in the pump. Releasing the brake

from charge pump via travel pump

Charge oil Vibration pump

L2

1 2 3 4

N 5

Vibration pump Charge pump High pressure limitation 4/3-way solenoid valve

A 3

1

M1 2 M2 3 B

M4

M5

4

Fig. 3: Hydraulic diagram vibration pump

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 3F -

Service Training Function

1

2

6

4

5

3

Fig. 4 Cross-section of vibration pump 1

Servo piston

2

Working pistons

3

Charge pump

4

Valve plate

5

Roller bearing

6

Swash plate

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 4F -

Service Training 1

2

5

4

3

Fig. 5 Cross-section of vibration pump 1

Control

2

Servo piston

3

Friction free swash plate bearing

4

Attachment plate

5

Spool valve

The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons. The slipper pads rest against the sliding surface of the swash plate and are at the same time held on the sliding surface by a retaining device. During each rotation the piston pass through their upper and lower dead centre back to their initial position. Between both dead centres each piston performs a full working stroke. During this stroke movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the length of the working stroke.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 5F -

Service Training During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he closed circuit.

Control The electro-hydraulic displacement control)with converts the electric inputbut signal a load controlling output signal. Since the control pump is(remote not equipped a proportional control, a 12toVolt solenoid valve, the pump is always actuated to one of the two end stop positions.

High pressure relief valves As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted with pressure relief valves.

1 2

3

Fig. 6 Pressure relief valve

1 2

From the charge pump Closed circuit

3

High pressure relief valve with integrated boost check valve

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 6F -

Service Training Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this phase. The high pressure relief valve reduces these pressure peaks to a value of max. 374 bar (pressure difference between high and low pressure side = 345 bar + charge pressure = 29 bar). The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the closed vibration circuit. The function of these valves has already been described in the chapter “travel system”.

Charge pump The charge pump for travel circuit and vibration works also as steering pump The pump is an internal gear pump with fixed displacement. The oil flow generated by the charge pump is joined together with the return flow from the steering valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration pump.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 7F -

Service Training Vibration motor The vibration motor is a swash plate type axial piston motor with fixed displacement of series A10FM 45 from Bosch-Rexroth (Hydromatik). Since the motor can be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits. The output speed of the motor depends on the oil quantity supplied by the vibration pump.

2

3 4

5

1

6

10

9

8

7

Fig. 7 Cross-section of vibration motor 1

Flushing valve block

2

Flushing valve

3

Working pistons with slipper pads

4

Roller bearing for output shaft

5

Radial seal

6

Output shaft

7

swash plate

8

Retaining plate

9

Pre-tensioning spring

10

Flushing pressure relief valve

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 8F -

Service Training The output torque raises with increasing pressure difference between low and high pressure side in the closed circuit. Changing the flow direction of the oil will also change the sense of rotation of the vibration motor. When switching the vibration on the motor must first start to move the resting vibration shaft. This resistance causes a hydraulic starting pressure, which is limited to 365 bar by the corresponding high pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly depends on the condition of the ground (degree of compaction, material etc.). • Hard ground = High operating pressure • Loose ground = Low operating pressure

MA

A 2

3

B

1

MB

Fig. 8 Circuit diagram of vibration motor 1

Vibration motor

2

Flushing valve

3


BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 9F -

Service Training The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a pressure difference will appear between the two sides of the closed circuit. The higher pressure moves the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low pressure side.

1 A

2 B

Fig. 9 Flushing valve 1

Flushing spool

2


The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only a certain quantity of hydraulic oil is flushed out of the low pressure side. This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately replaced with fresh and filtered oil through the corresponding boost check valve.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

-10 F-

Service Training Drum

4

14 5

9

2

13

7

6

10 3

8

11

12

1

Fig. 10 Cross-section of drum 1

Drumshell

2

Vibrationbearing

3

Basicweight

4

Vibratorhousing

5

Cooling fan

12

Rubber buffer

6

Vibratorshaft

13

Vibrationmotor

7

Elastic coupling between shafts

14

Flanged bearing housing

BW 213 / 214 - 3 Deutz 2012C 1013EC /

8 9 10 11

Change-overweight Couplingvibr.-motor–vibratorshaft Travelbearing Travelbearinghousing

-11 F-

Service Training Trouble shooting vibration circuit The following description of trouble shooting steps contains a small selection of possible faults, which may occur during operation of the machine. This list is by no means complete, however, the description should help you to become acquainted with a systematic trouble shooting procedure. The problems and trouble shooting steps described in this training manual are identical with the problems and trouble shooting steps in the operating and maintenance instructions for this machine. However, in this manual we have tried to describe the individual steps in more detail, in order to explain why certain trouble shooting steps should be applied and why certain preparations must be made before certain tests or measurements can be performed. After this training session the persons attending the course should be able to apply the correct trouble shooting steps, even if the actual problem is not described in this manual.

3

-214/213 BW

-

1FTr-

Service Training No vibration (travel system o.k.)

Check vibration pressures Fig. V1 Charge pres. OK Starting pres. too

Charge pres. OK Starting pres. zero

Check solenoid coil on vibration valve Fig. V4

low

Check coupling on vibration motor Fig. V2

OK ?

Charge pres. / stating pres. too low Voltage/ current OK ? yes

no

Check vibration pump Fig. V3

Perform trouble shooting in the electric system

OK ?

no

Replace/repair the vibration pump

no

Replace the flushing valve

yes Check or replace the

Check vibration motor

solenoid valve

flushing valve, Fig. V7

OK ?

yes Replace/repair the vibration motor

3

-214/213 BW

-

2FTr-

Service Training Vibration works only with high or low amplitude

Check the magnetic coil on the vibration valve Fig. V4

Voltage / current OK ?

no

Perform trouble shooting in the electric system

yes

Check the solenoid valve

OK ?

no

Replace the solenoid valve

yes Check, clean or replace the high pressure relief valve for the faulty amplitude

3

-214/213 BW

-

3FTr-

Service Training Too low vibration frequency (travel system o.k.)

Check engine speed Fig. F15

no

Perform trouble shooting on

OK ?

the diesel engine

yes Speed drop > 10%?

no

Adjust the speed for high or low frequency Fig. V5

yes Check the vibration pressures Fig. V1

OK ?

Charge pres. OK Operating pres. too high Check/replace the vibrator shaft bearings Fig. V6

all pressures too low Check the vibration pump Fig. V3

OK ?

no

Replace/repair the vibration pump

no

Replace the flushing

yes Check vibration motor flushing valve Fig. V7

OK ?

valve yes Replace/repair the vibration motor

3

-214/213 BW

-

4FTr-

Service Training Fig. V1 Checking the vibration pressures A too low charge pressure is an early indicator for a fault (leakage) in the closed vibration circuit (if travel system is OK). The pump cannot be operated correctl y. A too low starting pressure is an indicator for extreme leaks in the closed circuit or a defective vibration motor coupling. A too high operating pressure is an indicator for damaged vibration bearings or overfilling of the vibration bearing housing. • Connect 600 bar pressure gauges to the high pressure test ports • Connect a 60 b ar pressure gauge to the charge pressure test port • Drive the drum on old rubber tires • Start the engine and run it with max. speed • Switch the vibration on and read the pressure gauges Nominal values: charge pressure 25 +/- 1 bar starting pressure 350 +/- 50 bar Operating pressure

3

-214/213 BW

low amplitude approx. 90 +/- 15 bar high amplitude approx. 110 +/- 15 bar

-

5FTr-

Service Training Fig. V2: Checking the coupling on the vibration motor • Disassemble the vibration motor • Check the coupling parts between motor and shaft • Replace defective parts

3

-214/213 BW

-

6FTr-

Service Training Fig. V3: Checking the vibration pump • Close the high pressure ports on the vibration pump with plugs • Check the vibration pressures, see Fig. V2 If the pressure values are now reached whereas they were not reached while the vibration motor was connected, the vibration motor must be faulty. If the high pressure values are not reached, the fault must be in the pump.

3

-214/213 BW

-

7FTr-

Service Training Fig. V4: Checking the magnetic coil of the vibration valve • Switch the ignition on • Switch the vibration on with high or low frequency • Measure the voltage applied to the magnetic coil and the current draw with an appropriate meter Nominal values: 12V / 2,5 A

3

-214/213 BW

-

8FTr-

Service Training Fig. V5: Adjusting high and low frequency If the engine speed is correct and the drop in vibrator shaft speed is less than 10%, the corresponding frequency can be adjusted on the vibration pump. • Slacken the counter nut on the respective adjustment screw • Turn the adjustment screw, until the required vibrator shaft speed is reached (the adjustment screw for high amplitude protrudes further than the adjustment screw for low amplitude). • Retighten the counter nut.

3

-214/213 BW

-

9FTr-

Service Training Fig. V6; Checking the vibrator shaft bearings • Disassemble the vibration motor • Check the moveability of the vibration bearings • Replace defective parts

3 -214213 /BW

- 10 FTr-

Service Training Fig. V7: Checking the flushing valve on the vibration motor •

Unscrew the flushing valve from the vibration motor

•

Check the flushing spool for damage and moveability

•

Replace a defective flushing valve

3 -214213 /BW

- 11 FTr-

Service Training Steering The single drum rollers BW 213 D-3 / DH/PDH-3 and BW 214 DH/PDH-3 are equipped with a hydraulically operated oscillating articulated steering. The steering system consists mainly of: • the steering/charge pump, • the steering valve, • the steering cylinders and • the pressure resistant connecting hoses. The steering pump delivers the hydraulic oil from the hydraulic oil tank to the steering valve and the connected steering unit. If the steering is not operated, the complete oil flow will flow through a fine filter to the charge ports for the travel and vibration circuits.

210 bar

8

6

7 3

1

210 bar

2

4 5

Fig. 1: Hydraulic diagram of steering system 1

Rating pump

5

Check valve

2

Distributorvalve

6

Shockvalves

3

Anti-cavitationvalve

7

4

Highpressurereliefvalve

BW 213 / 214 - 3 Deutz 2012C 1013EC /

8

Anti-cavitationvalves Steeringcylinder

- 1G -

Service Training When turning the steering wheel the distributor valve guides the oil flow to the corresponding steering cylinder sides. A rating pump inside the steering unit measures the exact oil quantity corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders. The steering cylinders extend or retract and articulate the machine. The steering valve contains also a pressure relief valve. This valve limits the steering pressure to 175 bar. Since the oil is available for the charge circuit after it as left the steering unit, the charge pressure of 25 bar must be added to this value. The maximum steering pressure is therefore approx. 200 bar.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 2G -

Service Training Steering/charge pump The steering/charge pump is a gear pump with constant displacement. It is driven by the auxiliary drive of the diesel engine and draws the hydraulic oil directly out of the oil tank. The oil flows then through the steering valve and the fine filter to the charge ports in the travel and vibration circuits, or, when turning the steering wheel, to the steering cylinders. 9

9

6

1

7

9

3 8 2 5

4 Fig. 2: Steering pump 1

Housing

4,5 Bearingplates

2

Flange

6

3

Shaft

7, 8P inions

9

Seals

Cover

Function of he gear pump The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of both gears mesh with minimum clearance when rotating. The displacement chambers are formed between the tooth flanks, the inside wall of the housing and the faces of the bearing plates. The chambers transport the hydraulic oil from the suction side to the pressure side. This generates a vacuum in the suction line, which draws the hydraulic oil out of the tank. These tooth chambers transport the hydraulic oil along the inside wall of the housing from the suction side to the pressure side, from where it is pressed to the consumers. To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic fluid can be transported from the suction side to the pressure side without any losses. Outer gear pumps are provided with gap seals. This results in pressure level dependent fluid losses from the pressure side to the suction side. An axial pressure field presses the bearing plate on the cover side against the front face of the gears, making sure that only a very little quantity of oil will leak from the pressure side to the suction side when the pressure increases during operation. The pressure field is always under system pressure.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 3G -

Service Training Steering valve The steering valve consists mainly of: • the distributor valve, • the rating pump, • the steering pressure relief valve and • the shock valves. 1 2 9

3

4

5

8

6

7 Fig. 3: Steering unit 1

Neutralsettingsprings

2

Housing

3

Inner spool

8

Check valve

4

Outerspool

9

Pressurereliefvalve

5

Universal shaft

BW 213 / 214 - 3 Deutz 2012C 1013EC /

6

Ringgear 7

Gear

- 4G -

Service Training When turning the steering wheel the oil flow from the pump is guided through the distributor valve to the rating pump and from there to the respective sides of the steering cylinders. The rating pump determines the exact oil quantity in dependence on the turning angle of the steering wheel. The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar + charge pressure. The steering unit is equipped with so-called shock valves for both pressure sides to the steering cylinder. These valves are adjusted to 200 bar. They compensate extreme pressure peaks, which can be introduced from outside, e.g. when driving over obstacles. The system is thereby protected against overloads. Each of these shock valves is fitted with an additional anti-cavitation valve. These anti-cavitation valves protect the system against cavitation which could be caused by the reaction of the shock valves. A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump if forces are introduced from outside. In such a case the steering cylinders would act as pumps and press the oil back to the pump.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 5G -

Service Training Articulated joint The articulated joint is the connecting link between the front frame with the drum and the rear frame with operator’s stand, diesel engine and drive wheels.

Fig. 4 Articulated joint The rear console is tightly bolted to the rear frame. The front console is fastened with screws to the rear cross-member of the front frame. Due to the use of rocker bearings between front and rear console, both frames can oscillate to each other for +/- 12°. This ensures that the machine is always in ground contact, even under extremely difficult soil conditions. The front console is connected with the rear console by two vertical bolts. These bolts are mounted in rocker bearings.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 6G -

Service Training The front console is additionally fitted with the welded on bearings eyelets for the steering cylinders. When turning the steering wheel the steering will extend or retract. The piston rods swivel the front console around the vertical bolts. The machine articulates and steers. All bearing points on the articulated joint are maintenance free, lubrication is not required.

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 7G -

Service Training Steering circuit, position of components

Steering pump

Steering valve

Hydr. oil filter

Hydraulic oil tank

Steering cylinder

High pressure Low pressure Charge pressure Suction line

Fig. 5: Steering circuit, position of components

BW 213 / 214 - 3 Deutz 2012C 1013EC /

- 8G -

Service Training Electrics, single drum rollers of generation 3 The new single drum rollers of generation 3 are fitted with two easy to change logic modules.

1

2

8

3 4 5 6 7

13

11

9

10 12

Fig. 1: Electric junction box

1 Relay K06 (rear head lights) 2 Relay K26n (backup alarm) 3 RelayK22(enginesolenoid)

6 Relay K05 (start current) 7 Relay K11 (terminal 30 -> 15) 8

Fusebox

4 Relay K48 (travel lever ”0”)

9

Relay K04 (vibration)

5 RelayK36(brakecontrol)

10

Relay K32 (cabin)

11 Generator module A23 12 Didode module 13 TerminalstripX1:

The electric junction box contains the following module: • Generator module (A23), Simple trouble shooting by easy bridging of input and output potentials. The generator module is able to convert the different signals of various generator manufacturers to a D+ signal. This allows to use different engines from various manufacturers without having to change the electric system. • Diode module In the speed range selection logic the diode module is used to change to different speed ranges. The optionally available Anti Spin Control (ASC) provides optimal traction for drum and wheels. This enables safe driving on difficult soil and increases the gradability of the machine.

Power supply (Fig. 2)

BW 213 / 214 - 3 -H1-

Service Training Battery When the engine is stopped the power supply for the vehicle electrics is assured by two parallel connected rechargeable and maintenance free 12 Volt batteries. The minus pole of the battery (G01:05,11) is connected with vehicle ground (potential 31). The plus pole of the battery (G01:02,08) is connected with potential 30 via the main fuse (F00:02). There is a direct connection between battery (+), • terminal B+ on generator (G02:15), • starter (M01:05) (Fig. 3) terminal 30. The minus pole (-) of the battery is connected with potential 31. Note: Potentials 30, 31 and B+ are always directly connected with the battery. The current can only be interrupted by fully discharging or disconnecting the battery.

Generator When the engine is running a 14 V generator (G02:16) supplies the vehicle electrics via terminals B+ (to potential 30) and B- (to potential 31) with current. Terminal D+ supplies the generator module (A23:23) with a (+) or (-) signal. When the engine is not running terminal D+ is negative (ground potential). The charge control light in the monitoring board (A15) (Fig. 3) lights up. Refer also to the chapter “Monitoring board”.

Sockets The machines are equipped with two sockets (XS:36/XS:39). These are connected to potential 30 and secured by fuse (F05).

Fig. 2:

BW 213 / 214 - 3 -H2-

Service Training 1 0 : 2 0 0 3

g3 in -5 n i .22 ra ..2 T1 e 2 c i W B v r e S

44

1 3

34 24 14

V S 2 X 1

04 93

+ 0 :1 1 X

5 0 F

83

V S 1 X 2

73 63

+

53 43 33

1 :0 3 0 C : 4 2 F

1 :0 3 0 : + 6 D 3 M K

5 0 : 2 0 + B

23 13

1 0 M

03 92 82 72

1

3 2 A

45/ 51

+DM

6 0 4 6 6 7 5 0

8 :2 1 X

2 3

45/ 51

0 0 P

9 :2 1 X

h

7 :3 1 X

4 5 3 :1 1 X :3 -1 7 1 X

:2 1 8 1 X

7 3 : 1 X

2 1 : 1 X

1 : 1 8 1 X

:4 1 7 1 X

22 12

B

+ D

81 71

W

2 0 G

61 51

+ B

41 31 21

_

11

5 : 1 X

1 0 G

+

90

70

3 9 1 2 .. . 3 1 2 W B

60

_

3 : 1 X

1 : 1 X

01

80

:4 1 X

:2 1 X

w o P

02 91

G W

ly p ply u sp ru e p ws or Pe

42 32

+D

G

62 52

50

0 0 F

+

1 0 G

40 30 20 10

I A . 1 0 _ 3 1 2 W B

BW 213 / 214 - 3 -H3-

Service Training Ignition and starter circuit (Fig. 3) Ignition switch (S00) in position "0" (ignition off) The ignition switch (S00:04) is permanently supplied with current from the battery (G01) (Fig. 2) via main fuse (F00) (potential 30) and fuse (F13:05). In this position the connection to the coil of relay (K11:28) is interrupted and the relay drops off. The solenoid valve (Y58:32) for interrupting the fuel supply or the shut-down solenoid (Y13:37) (depending on type of engine) is no longer supplied with current and the engine will stop.

Ignition switch (S00) in position "1" (ignition on) with the engine at rest In this position the coil of relay (K11:26) is supplied with current. Relay (K11) switches potential 30 to potential K11 (15/54). Fault monitoring unit (A15) (Fig. 3) supplies the coil of relay (K22:40) with current, the relay switches. Current flows • from potential K11, • via fuse (F14:37), • the closed emergency stop switch (S01:37), • the closed contacts of relay (K22:37) • to the solenoid valve (Y58:32) for interrupting the fuel supply or the engine shut-down solenoid (Y13:37). The engine is now ready for starting.

Ignition switch (S00) in position "3" (starting) Note: Position "2" is not used. In this switching condition current flows from terminal 50a on ignition switch (S00:06) to the contact of relay (K05:07). When the travel lever is in "0" - and brake position the contact of proximity switch (B13:15) opens, the coil of relay (K48:15) is no longer excited and the contact switches over.

BW 213 / 214 - 3 -H4-

Service Training Current flows • from potential K11, • via relay (K48:17), • to the coil of relay (K05:09). The contact closes and current can now flow to the starter (M01:05) terminal 50. The magnetic switch of the starter is excited and the starter cranks the diesel engine. Note: The starter (M01) is supplied with current directly from potentials B+ and 31. When releasing the ignition switch it will automatically return to position “1”. During the starting process a 50a signal is transferred to the monitoring board (A15) (Fig. 4). During the starting process this signal avoids sounding of the warning buzzer and activation of the automatic engine shut-down (see description of the fault monitoring unit). To repeat the stating process the ignition must first be switched off and on again (start repetition interlock).

Ignition switch (S00) in position "1" (ignition on) with the engine running When the engine is running the generator (G02) (Fig. 2) produces electric current. This current flows from terminal D+ to the generator module (A23). The output signal MD+ delivers the voltage for the operating hour meter (P00). The MD+ signal is additionally fed into the monitoring board (A15) (Fig. 4) and into the brake control relay (K36) (Fig. 6). The internal logic of the fault monitoring unit switches the charge control light off. In case of a fault the automatic shut-down system in the monitoring board (A15) is activated and the warning buzzer will sound.

BW 213 / 214 - 3 -H5-

Service Training 0 3

1 :0 3 1 0 1 K

44

1 0 : 3 0 4 :2 1 X

5 1 A

1 :4 1 X

1 3

68

2 2 K 03

0 4 : 1 X

5 0 :1 1 X

58

34 24 14 04

a78

g in -35 n i 22 ra --T2 e 21 ic W v r B e S

93 83

78

73

4 1 F

6 :1 1 X

1 0 S

:7 1 8 1 X

:6 -1 7 1 X

3 1 Y

63 53 43 33 23

8 8 5 5 Y : 1 X

6 4 : 1 X 03

a78

1 1 K

03 92

5 0 V

78

13

1 3 : 1 X

82 72 62

68

58

3 3 " :4 0 " 0 0 T /3 U E 6 3 N K

:8 1 X

52 42 32 22 12 02 91

g in t

gr a in tt rS a t S

81 78

03

68

5 2 F

a 0 /5 5 1 A

3 1 B

71

8 4 K

a78

61 51

58

41

1 5 : :0 7 -2 3 :1 8 0 1 1 X X

:8 2 7 1 X

1 0 Y

31 21 11 01

68

5 0 4 /5 5 1

8 : 1 X 3 1 F

0 3

a 0 5

:9 1 X

0K 3

58

90 a78

:1 2 6 : 8 1 1 X X

78

0 3

3 2 1 0 P

+ B

8 5

0 0 S

:4 2 7 1 X 0 5

+ B 0 3 : 1 0

80 70 60

M

50

1 0 M

30

40

20 10

S P E . 2 0 _ 3 1 2 W B

: 3 . g i F

BW 213 / 214 - 3 -H6-

Service Training Monitoring board (Fig. 4) Ignition on, engine not running When switching the ignition on the program is reset to a defined initial condition. As a self-test function all warning and control lights light up for a moment. If a fault is detected already at this point, the corresponding control light will stay on. Warning buzzer (H07:22) and shut-down relay (K22:40) (Fig. 3) remain deactivated, because the pressure has not yet built up. If the time span between “Ignition On ” and “Start” is to long, starting is not possible.

Engine running The monitoring board is active, warning buzzer and shut-down relay are at stand-by. Within a predetermined period of time all sending signals for the corresponding potential must change to “OK”. If this is not true, the following control lights will light: • the signal fields, • the warning buzzer is activated • and the shut-off relay is switched after a predetermined time.

Engine stalled, ignition on The monitoring board remains activated, warning buzzer and shut-down relay will be activated after a predetermined period of time. In order to achieve a clearly defined initial condition, the ignition must first be switched off for a moment.

BW 213 / 214 - 3 -H7-

Service Training 1 0 : 4 0 1 1 K

1 0 : 4 0

+ D M

r o rr E C S A

44

1 3

34 24

8 2 : 1 X 0 2 : 1 X

G : 6 0 B 9 1 : 1 X

:5 -1 8 1 X

3 0 B

P

14 04

:8 -1 7 1 X

g in in 3a r 12 T2 eW c i B v r e S

93 83 73

6 0 B

P

63 53

5 1 H

9 0 H

3 2 H

43

+ D M

33

5 :2 1 X

23 13

Q

5 5 B

03

0 3 : 1 X

4 2 F

1 3 : 1 X

92 82 72

P

7 :1 1 X

4 :3 1 X

1 2 B

62 52

:1 5

:2 5

2 :3 1

X

7 X 0 H

X

42 32 22 12 02

2 2 : 1 X

91

1 3 : 1 X

81

w e n , d r aw oe bn g, n d ri r ino to a b og mn tl ir uo a it Fn

o M

71 61 51

1 0 : 4 0 8 2 H

6 0 H

5 0 H

1 2 0 0 H A

3 2 : 1 X

1 0 H

41

4 1 S

31 21 11 01 90 80 70 60

3 5 B C : 4 2 F

1 1 K 4 4 : 2 0

+ D M

A 0 5 0 :3 1 0

2 :1 2 0

0 3 : 1 0

2 2 K 4 4 : 2 0

8 1 : 1 X

4 : -1 8 1 X

50

:1 -1 7 1 X

40 30

3 5 B

20 10

S P .E b 3 0 2 1 2

W B

: 4 . ig F

BW 213 / 214 - 3 -H8-

Service Training Engine shut down by shut-down relay The fault, that has led to the shut down of the engine, is saved and displayed. The warning buzzer remains active. Other indicators, that were triggered by the shut down of the engine, are no longer displayed. The operator can rectify the fault. After this the ignition switch must be switched off to deactivate the shut-down relay, in order to enable a new starting attempt.

Function group Hydraulicoilfilter(B21) Coolanttemperature(B53)

Colour of indic ation

red

Coolantlevel(B55)

red

Chargecontrol(MD+)

2minutes

red

Engineoilpressure(B06) Brakeapplied(H01)

Shut down time

red

red

2minutes 10seconds 10seconds -

yellow

-

Air filter (B03)

yellow

-

Hazard light (H06)

red

-

Indicatoron(H05)

green

-

AntiSpinControlASC

yellow

-

BW 213 / 214 - 3 -H9-

Service Training Brakes (Fig. 6) With the engine at standstill no hydraulic pressure is available, the brake discs cannot be relieved, the brake is automatically closed. Travel lever in “brake”-position with the engine running When the engine is running and the generator is fully functional, the generator (G02:15) (Fig. 2) delivers a D+ signal or the generator module (A23:24) (Fig. 2) a MD+ signal to the brake relay (K36:33). If the travel lever is in “brake”-position, the coil of relay (K48:05) is not supplied with current. Current flows • from potential K11, • via fuse (F25) • and the contacts of relay (K48:07) • to the coil of relay (K05:09) (Fig. 3). Starting is now possible. Current flows also • from potential K11, • via fuse (F25) • and the contacts of relay (K48:05) • to the monitoring board (A15:17) (Fig. 4). The control light “Brake applied” (H01) lights up.

Travel lever operated When operating the travel lever • proximity switch (B13:05) will close, • relay (K48) switches over • and the current flow to relay (K05:09) (starting) (Fig. 3) is interrupted. The engine cannot be started.

BW 213 / 214 - 3 - H 10 -

Service Training If the engine is running and the generator is fully functional • the coil of relay (K36:34) is supplied with current, • the contact closes. Current flows • from potential K11, • via the contacts of relay (K48:07), • and the contacts of relay (K36:33) • to solenoid valve (Y04:34), when the emergency stop switch (S01:34) is closed. The brake opens. If the V-belt has snapped, the generator is defective or if the engine has stalled when driving up a gradient and no MD+ signal is present, the coil of relay (K36:34) is no longer supplied with current. Contact (K36) will open and interrupt the current flow to solenoid valve (Y04:34). The brake closes. To be able to drive the machine for a short while, even with a snapped V-belt or a defective generator, the contacts 30-87 of relay (K36:34) must be bridged to open the brake.

BW 213 / 214 - 3 - H 11 -

Service Training 1 1 K

1 0 : 5 0

g in -3 in 252 a r ... T 2 e 12 c i W v r B e S

44

1 3

34 24 14 04

2 3 : 1 X

93 83 73

5 8

6 8

3 :4 1 X

7 8

a 7 8

6 3 K

2 :4 1 X

1 :9 1 X

2 :9 1 X

53 43

1 0 S

0 3

63

33

4 0 Y

23 13 03 92 82 72 62 52 42 32 22 12 02 91 81 71

e k a r B e k a r B

61 51 41 31 21 11 01 90

5 2 F

6 0 :1 1 X

:4 7 X

:3 6 X

8 0 1 : 1 X

78

03

8 4 K

a78

80 70

1 3 : 1 X

60 50

68

58

40

1 1 K

4 :4 3 0

+ 4 D 4 : M3 0

3 1 B

1 0 H

7 1 : 3 0

5 0 K 9 0 : 2 0

30 20

1 3

10

S P .E 4 0 _ 3 1 2 W B

: 5 . ig F

BW 213 / 214 - 3 - H 12 -

Service Training Travel speed range selector (Fig. 7) Reverse travel When moving the travel lever to reverse while driving on level ground, the coil of relay (K26:05) is not supplied with current. Current flows • from potential K11, • via fuse (F26:23), • through the closed contact (K26:07) • to the back-up alarm buzzer (H14:11). The back-up alarm will sound. Forward travel In this position the proximity switch (B14:05) closes. Current flows • from potential K11, • via fuse (F25:05), • the closed proximity switch (B14:05), • to the coil of relay (K26:05). The relay switches over, the current supply for the warning buzzer (H14:11) is interrupted. Current flows also • from potential K11, • via fuse (F26:23), • to the travel speed range selector (S42:24).

BW 213 / 214 - 3 - H 13 -

Service Training Travel speed ranges Depending on the position of the travel speed range (S42:23) the solenoid valves (Y30:19, Y31:29) • for both travel motors (drum and axle), • only for the front travel motor (drum), • only for the rear travel motor (axle), • or for none of the motors are supplied with current. This enables the operator to influence the gradability of the machine by changing the displacement of the travel motors. The motor of the slipping axle is switched over to low displacement. If the travel speed range selector switch (S42:23) is in position 1 ”turtle”, none of the solenoid valves (Y30:11/Y31:18) is supplied with current. In this switch position all motors for drum and axle work with high displacement. The machine drives with low travel speed range (working speed). In switch position 2 current flows • from potential K11, • via fuse (F26:23), • switch (S42:23) • to solenoid valve (Y30:19). The drum drive motor switches to low displacement. The current flow to solenoid valve (Y31:29) is avoided by diode (V02:22). In switch position 3 current flows • from potential K11, • via fuse (F26:23), • switch (S42:23) • to solenoid valve (Y31:29). The axle drive motor switches to low displacement. The current flow to solenoid valve (Y30:19) is avoided by diode (V03:27). If the travel speed range selector switch (S42:23) is in position 4 ”rabbit” both solenoid valves (Y30:11/ Y31:18) are supplied with current. In this switching condition both motors for drum and axle are switched to low displacement. The machine drives with high speed range (transport speed).

BW 213 / 214 - 3 - H 14 -

Service Training In this switch position current flows • from potential K11, • via fuse (F26:23), • switch (S42:23) • to both diodes (V02:22 and V03:27) • to both solenoid valves (Y30:19 and Y31:29). Drum drive motor and axle drive motor change to low displacement.

BW 213 / 214 - 3 - H 15 -

Service Training 1 0 : 6 1 0 1 K

44

1 3

34 24 14 04

g n i in a r T e c i v r e S

3 5 2 2 .. . 2 1 2 W B

93 83 73 63 53 43 33 23 13 03 92

1 3 Y

3 0 V

4 :4 1 X

6 2 F

2 0 V

52

Q Q = = 1 0

42 32

1

4 3 2 1

72 62

x n i a m m

3 7 5

2

82

2 0 V

22 12

2 4 S

02 91 81

0 3 Y

71

r to c le e rs o te cn g le era s ed ge ne p ras dl ee ev pa SrT

61 51 41

3 :3 1 X

6 3 : 1 X

:1 9 X

4 1 H

31

2 : 9 X

2 3 : 1 X

21 11 01 90 80

R

5 2 F

1 1 K

4 :4 4 0

6 0 1 : 1 X

78

5 : 7 X

3 : 7 X

4 1 B

03

7 0 1 : 1 X

a78

70

6 2 K

60 50

68

58

40 30 20

1 3

10

S P E . 5 0 _ 3 1 2 W B

: 6 . ig F

BW 213 / 214 - 3 - H 16 -

Service Training Anti Spin Control ASC On extreme inclinations and on slippery soil the Anti Spin Control (ASC) provides optimal traction and avoids spinning of drum and wheels. However, if the physical limits are reached, even the ASC cannot improve the traction of the machine any further. The following machines are generally equipped with the ASC Anti-Spin-Control (Fig. 9): • BW 213 DH-3/PDH-3 • BW 214 DH-3/PDH-3 • BW 216 DH-3/PDH-3 • BW 219 DH-3/PDH-3 • BW 225 D-3/PD-3 The machines with Anti Spin Control (ASC) in the travel system are equipped with the following sensors: • analogue inclination sensor (B57) • analogue travel lever sensor • sensors for speed and detection of sense of rotation (B59/B60). For safety reasons the following assembly groups (hardware) are electronically monitored: • area monitoring of inclination sensor • area monitoring of travel lever sensor • fault monitoring of speed sensor • fault monitoring of solenoid valves • fault monitoring of internal 5V voltage supply for the sensors. Additional monitoring of (software): • checking of signal for sense of rotation • checking of signal for neutral start position • checking of version of operating system. If a fault is found, e.g. cable breakage or short circuit, the ASC-system is deactivated and an error message will be displayed (monitoring board).

BW 213 / 214 - 3 - H 17 -

Service Training Voltage on analogue input of plug (X1:52) on inclination sensor Inclinatio n

Positionofdrum

-45° (100%)

uphill

Voltage(V) 0,5

-5,7° (10%)

downhill

2,15

0°

levelground

2,5

+5,7° (

10%)

uphill

2,75

+45° (

100%)

uphill

4,5

BW 213 / 214 - 3 - H 18 -

Service Training Vibration (Fig. 11) Switching the vibration on Current flows: • from potential K11, • via fuse (F03:05) • to toggle relay (K04:05). When pressing the push button (S13:05) the toggle relay switches and the contact of toggle relay (K04:05) closes. Current flows to the selector switch for high / low amplitude (S35:29). Depending on the switch position current flows to the solenoid valve (Y07:29) for high amplitude or (Y08:34) for low amplitude. The selected vibration starts.

BW 213 / 214 - 3 - H 19 -

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44

1 1 K

1 3

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93 83 73 63

5 9 : 1 X

53 43

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8 0 Y

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5 3 S

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7 0 Y

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0 2 :1 1 X

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3 0 F

8 3 : 1 X

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1 1 K 4 :4 5 0

b 6 5

80

6 5

4 0 1 : 1 X

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2 : 8 X

3 0 :1 1 X

50

S 4 0 K

70 60

40

3 1 S

30 20

1 3

10

S P E . 6 0 _ 3 1 2 W B

: 7 . ig F

BW 213 / 214 - 3 - H 20 -

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HL,t norf r ot aci dni r uot noc sk nil enr ov et hc uel ßi r mU 1

1 4 E

3 2 3 5 S

0 3 6 1 K

4 2 8 :9 1 X a 7 8 7 8 8 2 9 1 : : 4 1 1 X

st hgil daeh gni kr o w, hcti ws gnut hc uel ebsti ebr Ar etl ahc S 1 : 3 2 X 1 : 2 2 X

A81, 0

A6, 4

HRt hgil daeh st hc er r ef r e wni ehc S

A6, 4

HLt hgil daeh sk nil r ef r e wni ehc S

6 8 6 0 K 1 7 1 E 1 6 1 E

n tio a n i m u ll

B e O Z vt S A Z

i O Z vt S n tio p o

5 8331: 1 X

HR, r aer r ot aci dni r uot noc st hc er net ni h et hc uel ßi r mU 1

4 4 E 1 3 4 E 1 5 1 E 1 4 1 E 1 2 1 E 1 3 1 E 1 2 4 E

g n tu ch u le

2 : 4 1

A24, 0

A24, 0

2 2 2 2 2

:3 7 2 X 1 : 6 2 X 1 : 5 2 X 3 : 4 2 X

2 0 0 2 . 6 s 0 . i 7 e 1 S

A24, 0

2 A24, 0

5 8 8 :5 1 X

:5 5 1

2 2

:2 3 2 X :2 2 2 X

1 3 0 :2 3 1

2 0 0 2 . 6 0 . 7 1

r e n r e W

1 4 :2 0 3 1 ro t a ry b e a c o n

W1 S 1 7 e 7 e 0 . rn . is 0 6 e 6 .2 2 r .0 0 0 0 2 2

ro C t o a ry n n b e e ic t a o c n o h n e wa it d h li Rg O th Ps S/

R u n d u m k e n n le u c h te

b wA e e n i r s Rf c O re h P / lu SRß u A − n A d rb u u e fb m i t s a l s u e c u c h h e i te n −

2

2

E 8 2 1 Arbeitsscheinwerfer hinten rechts

2

E 2 3 1 Arbeitsscheinwerfer vorne links

2

E 2 5 1 Arbeitsscheinwerfer vorne rechts

4,6A

X 1 :7 6

working head lights, front rh.

2

2

E 4 5 1 Bel. Öldruckanzeige

3 0 A

2

E 2 2 1 Bel. Hydrauliköltemperatur

2

E 0 2 1 Bel. Temperaturanzeige

2

E 0 3 1 Bel. Drehzahlmesser

2

E 4 6 1 Bel. Voltmeter

2

E 0 5 1 Bel. Frequenzanzeige

2

E 5 4 1 Bel. Vektoranzeige

2

E 6 3 1 Bel. E−Vib Anzeige

3 0 A

0.166A

0.166A

0.166A

0.166A

X 2 :5

X 2 : 4 4

0.166A

0.166A

X :2 1 0 8 1

1

3 1 1 6 :1

0.166A

2

5 BF o 2 A2 x

B o x F A1 9

D

1 2 :1 7 B E L 1

illumin. speedometer

S T V 2 1 6 :1 5

S T V 1 1 6 :1 5

wCb it o e i h n K c n a e a b b c in tio in e n h e a d lig h ts

illumination level gauge X

0.166A

0 1 5

E

working head lights, front lh.

E 0 1 1 Bel. Tankanzeige

0.166A

X 1 :7 7

1 4 : 8 3 K 7 0 6 3 0 8 7 a

working head lights, rear rh.

E 0 4 1 Bel. Gesch.−Anzeige

0.166A

5 8 2 7 0 0 8 9

working head lights, rear lh.

2

0.166A

X 1 :2 0 0

2 3

E 2 7 1 Arbeitsscheinwerfer hinten links

4,6A

h ts , r o t a ry b e a c o n

S 3 8 2 4

+

4,6A

In s tr . B e le u c h tu n g , A r b e it s b e l. , R n u d u m k e n n le u c h te

X 1 :2 0 1

−

4,6A

in s tr . ill u m i n a ito n , w o rk in g h e a d lg i

Schalter Rundumkennleuchte switch, rotary beacon

E 3 2

X 1 : 2 0 2

1 1 4 4 :2 :6 0 R U 3 K 0

1 :3 5

illumin. oil pressure indicator

3 0 A

F

4

A n s c h lu ß A r b e it s s c h e i n w e rf e r

B o x A2 F 1 6

illumin. hydraulic oil temperature

illumin. temperature indicator

illumination RPM meter

illumin. voltmeter

illumin. frequency meter

X 2 : 4 3

X 2 : 5 1

illumin. vector indicator

illumin. E−Vib indicator

E 0 4 1 Bel. Gesch. Anzeige

illumin. speedometer

X :2 1 0 7

o n l y V a ri

N u r b e i V c a o rio n c t o ro l n t w ro l tih o o h u n t e T T e e rr r a ra mm e e te t r e r

3 0

1

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1F02:1

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8 3 S

2:17

2 0 F

F

+

n o ti Ap Zo

1 o i io d a d R ra

1 3 − −

1

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2 A6, 4

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1

1: 2/ 92 X

4: 1/ 92 X

3: 33 X

2: 2/ 92 X

3: 1/ 92 X

1: 33 X

6: 2/ 92 X

7: 1/ 92 X

1: 13 X

2: 2/ 82 X

3: 1/ 82 X

M

5 E

5

2 1 0

A6, 4

2 A6, 4

2 : 3 3 X

A2, 41

9 0 M

3

1 3 F

n r e t a n i e r h , r st e rf ih e g l wd n i a e e h csh g tis kin e ro b r Aw

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6: 1/ 92 X

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5: 2/ 92 X

8: 1/ 92 X

4: 13 X

7: 2/ 82 X

6: 1/ 82 X

1: 03 X

5: 2/ 82 X

8: 1/ 82 X

8: 2/ 82 X

5: 1/ 82 X

3: 03 X

6: 2/ 82 X

7: 1/ 82 X

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M

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4 0 M

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t n e tsm u j d a . p o r p

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2: 51 X

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s e t la p n i to a r vib ti n u g lin b m se s a

n te t a l p s n o ti ra ib V u a b n A

6 1 :1 1 X

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9 6 :1 1 X

2

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1

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2 1 :1 1 X

4 2 1 Y

2 4 1 V

7 0 3 5 : 8 K 7 1

4

2

s te la p n w o d t le

g n r t e lu a vo ch s h tc mi Uw s lik lic u u ra a r d d y y Hh

e tz ü L

A5. 2

0 8 1 : 1 X

E ß u l h cs n A / C x o B / 3 0 F

3 2 1 Y

3 1 V

1 7 : 1 X

0 1 1 5 5 7 5 0

0 3 1 S

2

2

9 0 V

3 2

S 0 H

1

A5. 2

n ke n e s n e tt la P

e tz ü L

7 1 0

9 8 0 0 7 2 8 5

6 8 A81, 0

A81, 0

5 8

3 0 K

6 8 7 6 K

0 :1 7 1

5 8 3 1 : 7 1 1 3 0 :2 6 1

2 0 0 2 . 6 s 0 . i 7 e 1 S

2 0 0 2 . 6 0 . 7 1

r e n r e W

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2

c o m p o n e n t il tin s g

B a u te ill is te

1

1 0

1 0 1

5 8 2 7 0 0 8 9

Bl. 014 007 007 012 016 004 006 007 002 012 013 010 011 012 011 005 007 017 013 009

Pf. 14 9 4 18 17 14 13 15 8 12 14 2 11 4 2 3 17 6 18 12

Benennung

A02 A05 A06 A08 A12 A13 A15 A16 A23 A33 A35 A36 A37 A44 A46 A48 A51 A54 A64 A68 B03 B06 B11 B11 B13 B14 B16 B21 B29 B51 B51 B53 B54 B55 B57 B59 B60 B60 B61 B62 B62 B62 B62 B62 B75 B88 B113 B113 B114

006 006 006 006 008 008 007 006 016 016 016 006 003 006 010 010 010 012 011 011 011 012 013 013 016 005 004 005 005

19 15 1 3 2 4 3 18 5 17L 18L 16 7 19 9 11 12 2 7 9 10 18 14 17 5 5 14 12 6

UnterdruckschalterLuftfilter DruckschalterMotoroel Signalhorn Signalhorn NaeherungsinitiatorFahrhebellinks NaeherungsinitiatorFahrhebelrechts AufnehmerVibrationsfrequenzvorne DifferenzdruckschalterHydr.−Oelfilter Raumthermostat autsprecher Radio autsprecher Radio TemperaturgeberKuehlmittel TemperaturgeberStarthilfe KuehlmittelstandAusgleichsbehaelter NeigungssensorStufenumschaltung AufnehmerBandagengeschwindigkeit AufnehmerAchsgeschwindigkeit AufnehmerAchsgeschwindigkeit AufnehmerVerstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Beschleunigungsaufnehmer Beschleunigungsaufnehmer Beschleunigungsaufnehmer Kuehlmitteldruck DruckgeberMotoroel EMRTemperaturgeberKuehlmittel EMRTemperaturgeberKuehlmittel EMRAufnehmer,Motordrehzahl

B115 B126

005 10 005 14

E01 E02 E03 E04 E04 E04 E05 E05 E07 E07 E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E22 E23 E23 E25 E25 E27

015 015 015 013 015 015 013 015 012 013 014 014 014 014 0146 0145 0146 0147 0142 0142 015 015 016 015 016 015

10 BeleuchtungTankanzeige 13 BeleuchtungTemperaturanzeige 13 BeleuchtungDrehzahlmesser 11 BeleuchtungGeschwindigkeitsanzeige 10 BeleuchtungGeschwindigkeitsanzeige 17 BeleuchtungGeschwindigkeitsanzeige 10 BeleuchtungFrequenzanzeigevorne 15 BeleuchtungFrequenzanzeigevorne 17 BeleuchtungOmegameter 9 BeleuchtungOmegameter 17 Blinkleuchtevornelinks 18 Blinkleuchtehintenlinks 19 Blinkleuchtevornerechts 19 Blinkleuchtehintenrechts Parkleuchte links Schlussleuchte links Parkleuchte rechts Schlussleuchte rechts Scheinwerfer links Scheinwerfer rechts 12 BeleuchtungTemperaturanzeigeHydr.−oel 6 Arbeitsscheinwerfervornelinks 16 Arbeitsscheinwerfervornelinks 7 Arbeitsscheinwerfervornerechts 17 Arbeitsscheinwerfervornerechts 5 Arbeitsscheinwerferhintenlinks

E27 E28 E28 E29 E30 E32 E32 E41 E42 E43 E44 E45 E46 E54 E63 E63

016 015 016 0167 002 015 016 014 014 014 014 015 015 015 013 015

15 Arbeitsscheinwerferhinten 5 Arbeitsscheinwerfer hintenlinks rechts 16 Arbeitsscheinwerferhintenrechts Innenleuchte Kabine 12H eizgeraet 3K ennleuchte 20 Kennleuchte 4 Umrissleuchtevornelinks 4 Umrissleuchtehintenlinks 7 Umrissleuchtevornerechts 8 Umrissleuchtehintenrechts 11 BeleuchtungOeldruckanzeige 14 BeleuchtungVoltmeter 16 BeleuchtungVektoranzeige 11 BeleuchtungSteifigkeitsanzeige 16 BeleuchtungSteifigkeitsanzeige

F00 F02 F03

002 3 HauptsicherungBatterie 016 19 Ersatzsicherung 009 2 Sicherung Vibration

Blinkrelais Elektronik Geschwindigkeitsanzeige Elektronik Frequenzanzeige vorne Elektronik Omegameter Radio Steuergeraet Heizung Platine Ueberwachungsmodul Elektronik Tachograph Platine Generator Zentralplatine Kopplung Verdichtungskomponenten Versorgungsplatine Elektronik Antischlupfregelung Elektronik Variomatic Zusatzelektronik Modul Variomatik Elektronische Motorsteuerung Platine Frequenzanzeige Modul Pumpenansteuerung Modul Steifigkeitsanzeige Modul Sitzkontakt

GeberLadeluftdruck EMRTemperaturgeberKraftstoff

title

TYP

Indicator relay Electronic system, speedometer Electronic system, frequency meter, fr. Electronic system, Omegameter Radio Control unit, heating Printed circuit board, monitoring module Electronic system, tachograph Printed circuit,generator Connection dircuit board, compac. components Suppling circuit board Elektronic antispin control Elektronic variomatic Additional control unit Modul, variomatik Electronic engine management Circuit board,frequenzy meter Modul pump control Modul stiffnes indicator Modul seat contact Vacuumswitch,aircleaner Pressureswitch,engineoil Warning horn Warning horn Proximityswitch,travellever,lh. Proximityswitch,travellever,rh. Transducer,vibrationfrequency,front Pressurediff.switch,hydr.oilfilter Room thermostat Speaker radio Speaker radio Temperatureswitch,collant Temperatureswitch,startingassistance Coolantchargeexpansiontank Slopesensor,speedrangeselection Sensor,drumspeed Sensor,axlespeed Sensor,axlespeed Sensor,ajustablezylinder Accelerationsensor Accelerationsensor Accelerationsensor Accelerationsensor Accelerationsensor coolant pressure Sender,engineoilpressure EMRTemperatureswitch,collant EMRTemperatureswitch,collant EMRTrancducer,enginespeed

MODUL MODUL

MAX. 5A MAX. 5A

Sender,chargingairpressure EMRfueltemperaturesender Illumination,levelgauge Illumination,temperaturegauge Illumination,rpmmeter Illumination,speedometer Illumination,speedometer Illumination,speedometer Illumination,frequencygauge,front Illumination,frequencygauge,front Illumination,Omegameter Illumination,Omegameter Indicator,front,lh. Indicator,rear,lh. Indicator,front,rh. Indicator,rear,rh. Parking light, lh. Tail light, lh. Parking light, rh. Tail light, rh. Head light, lh. Head light, rh. Illumination,temp.gauge,hydraulicoil Workingheadlight,front,lh. Workingheadlight,front,lh. Workingheadlight,front,rh. Workingheadlight,front,rh. Workingheadlight,rear,lh. Working Workinghead headlight, light,rear, rear,lh. rh. Workingheadlight,rear,rh. Inside light, cabin Heating unit Warning light Warning light Contourilluminationfront,lh. Contourilluminationrear,lh. Contourilluminationfront,rh. Contourilluminationrear,rh. Illuminationoilpressureindicator Illuminationvoltmeter Illuminationvectorindicator Illuminationstiffnessindicator Illuminationstiffnessindicator Fuse,main,battery Fuse, spare Fuse, vibration

MAX.1,75A MAX.1,75A MAX.1,75A MAX.1,75A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 4,6A MAX. 4,6A MAX.4,6A 4,6A MAX.4,6A 4,6A MAX.4,6A 4,6A MAX.4,6A 4,6A 1,3A MAX.20A/NENN2A 5A MAX.0,42A MAX.0,42A MAX.0,42A MAX.0,42A

125A 30A

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

2

1 0

1 0 2

5 8 2 7 0 0 8 9

F05 F07 F08 F09 F10 F11 F13 F14 F17 F18 F19 F21 F22 F23 F24 F25 F26 F31 F40 F42 F43

Bl. 002 0141 014 014 014 014 0036 003 016 014 015 015 015 0062 006 008 008 016 002 016 016

Pf. Benennung 19S icherung Steckdose 2 Sicherung Warnblinker 13 SicherungBlinkeru.Arbeitsscheinw. 5 SicherungPark−u.Schlussl.links 7 SicherungPark−u.Schlussl.rechts 2 SicherungScheinwerferlinks Sicherung Startschalter 15 SicherungHubmagnetMotor 17 Sicherung Radio 4 VorsicherungArbeitsscheinw.vorne 7 SicherungArbeitsscheinw.vorneli. 11 SicherungInstrumentenbeleuchtung 5 SicherungArbeitsscheinwerferhinten Sicherung Signalhorn 14 SicherungUeberwachungsmodul 2 SicherungMagnetv.Fahrenu.Bremse 14 SicherungMagnetv.Fahrstufenumsch. 13 SicherungKabinenluefter 12 SicherungKabinenheizung 7 SicherungKabineninnenleuchte 8 SicherungWischermotorhinten

F44 F48 F51 F63 F67 F84 F124

016 002 010 010 011 011 004

11 4 2 16S 12 13 4

G01 G02 G03

002 3 002 5 002 4

Batterie Generator Batterie

H04 H07 H14 H34 H34 H56 H56 H57 H57 H69 H71 H74

011 006 008 004 005 011 013 011 013 004 013 005

MeldeleuchteBetriebsstoerung WarnsummerBetriebsstoerung WarnsummerRueckwaertsfahrt MeldeleuchteVorgluehen MeldeleuchteVorgluehen Meldeleuchte"Weiter" Meldeleuchte"Weiter" Meldeleuchte"Fertig" Meldeleuchte"Fertig" MeldeleuchteKraftstoffvorwärmung nzeige EVIB OK MeldeleuchteMotordiagnose

K04 K05 K06 K09

009 2 0086 014 3 002 9

2 14 9 14 7 14 8 15 9 3 17A 6

SicherungWischermotorvorn SicherungGluehanlage SicherungAntischlupfregelung icherung Lenkung SicherungSteuerung(Potential30) SicherungSteuerung(Klemme54) SicherungKraftstoffvorwärmung

SchrittrelaisVibration Relais Startstrom RelaisScheinwerferhinten RelaisKlimageraet

K11 003 K14 004 K16 014 K22 006 K26 008 K30 017 K32 003 K33 016 K34 009 K36 002 K48 008 K49 0164 K67 017 K134 004 K14(EMR)0 05

3 16 9 12 4 5 2 5 14 8 2

RelaisKlemme30auf15 RelaisVorgluehen RelaisScheinwerfervorne RelaisHubmagnetMotor RelaisRueckfahrwarneinrichtung RelaisUeberlastschutz Relais Kabine RelaisWarnsummerBetriebsstoerung RelaisSitzkontaktschalter RelaisBremskontrolle RelaisFahrhebel0−Stellung Relais Warnsummer 3 RelaisVibrationsabschaltung 2 RelaisKraftstoffvorwärmung 19 RelaisVorgluehen

M01 M04 M05 M06 M07 M09 M09

003 016 016 016 016 016 016

9 10 8 11 9 3 14K

P00 P01 P02 P03 P04

002 006 006 006 0071

10 Betriebsstundenzaehler 5T ankanzeige 6 TemperaturanzeigeHydraulikoel 7D rehzahlmesser 1G eschwindigkeitsanzeige

P04 P04 P05 P05 P07 P07 P09 P11 P11 P12 P13 P14 P15 P16 P26 P31

0131 0131 0075 013 012 013 007 011 013 006 006 006 013 011 0115 0131

4G 5G eschwindigkeitsanzeige eschwindigkeitsanzeige Frequenzanzeigevorne 13 Frequenzanzeigevorne 19 Omegameter 13 Omegameter 18 Frequenz−undGeschwindigkeitsanzeige 19 Drucker 3 Drucker 11 Voltmeter 8 AnzeigeMotoroeldruck 10 AnzeigeKuehlmitteltemperatur 17B CM 03 Bildschirm 19 FehleranzeigeVariomatic Anzeige Amplitude 6 Steifigkeitsanzeige

R02 R03 R04

003 8 0064 006 5

Starter Scheibenwischermotorvorne Scheibenwischermotorhinten Scheibenwaschermotorvorne Scheibenwaschermotorhinten Kabinenluefter abinenluefter

Gluehkerze Geber Tankanzeige GeberHydraulikoeltemperatur

title Fuse, socket Fuse, hazard light Fuse,indicatorsa.work.headlight Fuse,parkingandtaillight,lh. Fuse,parkingandtaillight,rh. Fuse,headlight,lh. Fuse, starter switch Fuse,shutoffsolenoid,engine Fuse, radio Primaryfuse,work.headlight,fr. Fuse,workingheadlight,front,lh. Fuse,illuminationofgauges Fuse,workingheadlights,rear Fuse, warning horn Fuse,monitoringmodule Fuse,sol.valve,travelandbrake Fuse,sol.valve,speedrangesel. Fuse,cabinventilator Fuse,heatingunitcab Fuse,insidelightcab Fuse,wipermotorrear Fuse,wipermotorfront Fuse,glowplugsystem Fuse,antispincontrol Fuse, steering Fuse,controller(pot.30) Fuse,controller(Pin54) Fuse,fuelpre−heating Battery Generator Battery Indicatorlight,breakdown Warningbuzzer,breakdown Back−upalarmbuzzer Indicatorlight,glowing Indicatorlight,glowing Indicatorlight,"continue" Indicatorlight,"continue" Indicatorlight,"ready" Indicator light,"ready" Indicatorlight,fuelpre−heating Indicator EVIB OK Indicatorlight,eng.diagnostics Togglerelay,vibration Relay, starting current Relay,headlights,rear Relay,airconditioning Relay,terminal30to15 Relay,glowplugsystem Relay,headlights,front Relay,shutoffsolenoid,engine Relay,backupalarm Relay,overloadprotection Relay, cabin Relay,warningbuzzer,failureindication Relay,switch,driversseat Relay,brakecontrol Relay,travellever0−position Relay, warning buzzer Relay,vibrationdeactivation Relay,fuelpre−heating Relais,glowplugnsystem Starter Windscreenwipermotor,front Windscreenwipermotor,rear Windscreenwashermotor,front Windscreenwashermotor,rear Cabin ventilator Cabin ventilator

TYP 30A 15A 15A 15A 15A 15A 30A 30A 30A 30A 30A 30A 30A 30A 30A 30A 25A

125A 30A 30A 15A 10A 30A AH 100 AH 100

VORGLÜHEN

EMRFEHLER BOSCHW BOSCHW BOSCHW BOSCHL BOSCHL BOSCHW BOSCHW BOSCHW BOSCHW BOSCHL BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHL 4,7A 2,9A MAX.3,8A MAX.3,8A 14,2A

Operatinghour meter Level gauge Temperaturegauge,hydraulicoil Rpm meter Speedometer Speedometer Speedometer Frequency meter, front Frequencymeter,front Omegameter Omegameter Frequency−andSpeedometer Printer Printer Volt meter Pressuregauge,engineoil Temperaturegauge,coolant BCM 03 terminal Faultindication,varimatic amplitude indicator Stiffness indicator Glow plug Sender, level gauge Sender,hydraulicoiltemp.

0,8A

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

3

1 0

1 0 3

5 8 2 7 0 0 8 9

R07 R10 R19 R23 R24 R25 R26 R79

Bl. 010 0058 004 011 011 011 011 0045

Pf. Benennung 8 PotentiometerGeschwindigkeitsk. Parallelwiderstand 17 Heizflansch 14 Widerstand 14 Widerstand 14 Widerstand 14 Widerstand Kraftstoffvorwärmung

S00 S01 S03 S06 S09 S13 S14 S15 S20 S21 S35 S36

003 0031 0062 009 011 009 0141 014 016 016 009 017

6

S37 S38 S38 S42 S42 S42 S44 S45 S53 S58 S65 S71 S102 S104 S106 S107 S118 S11:1−25 S127 S12:1−5 S130 S131 S131 S132 S132 S133 S133 S134 S134

014 0153 0162 008 008 010 016 016 014 004 011 010 016 0111 011 011 005 012 0054 012 017 011 013 011 013 011 013 011 013

16S chalter Blinker Schalter Kennleuchte 0 Schalter Kennleuchte 11 Stufenumschalterschnell−langsam 16 Stufenumschalterschnell−langsam 5 Stufenumschalterschnell−langsam 13 SchalterKabinenluefter 7 Kabineninnenleuchte 3 SchalterArbeitsbeleuchtung 7 SchalterAetherstartanlage 2 SchalterVibrationhorizontal/vertikal 17S chalter Lenkung 3 Schalter Klimaanlage 5 Schalter man./autom. 17 SchalterVerdichtungsenergie 16 SchalterAmplitutenverstellung 5 SchalterFehlerdiagnose 8 Schalter Motordrehzahl 8 16 SchalterPlattenHeben/Senken 16 Schalter Start 5 Schalter Start 16 Schalter Stop 6S chalter Stop 17 Schalter Drucken 6 Schalter Drucken 18S chalter Loeschen 7 Schalter Loeschen

S139 S140 S14:1−5 S152 S153 S157 S15:3 S15:4 S15:5 S15:7 S15:8 S16:1 S16:2 S16:3 S16:6 S16:7 S17:1−8 S18:1 S18:2 S18:5 S18:6 S18:7 S18:8 S19:1−6 S20:1−9 S21:1 S21:5 S21:6 S4:1

017 013 012 012 013 004 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012

6 7 7 8 7 2 10 10 11 11 12 8 9 9 9 10 8 12 12 13 13 14 13 13 9 7 6 7 6

S4:2 S4:3 S5:1 S5:2 S5:3 S5:4 S6:1 S6:2 S6:3 S6:4 S6:5 S6:6 S6:9 S7:1−15 S8:1−10 S9:1−5

012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012

7 7 12 12 12 13 9 10 10 10 11 11 11 8 8 7

V01 V02 V03

010 6 008 16 008 17

Startschalter Schalter NOT AUS Taster Signalhorn 13 Sitzkontaktschalterlinks 6 Vibrationsschaltervorne 2 VibrationsschalterFahrhebelrechts 2W arnblinkschalter 3 BeleuchtungsschalterStVZO 11 SchalterScheibenwischervorne 8 SchalterScheibenwischerhinten 5 Vibrationsschalterklein/gross 9 Vibrationsschalter 5

SchalterFrequenzverstellung SchalterTestNormal / Schalter PD−D Papiervorschub SchalterKraftstoffvorwärmung

title Potentiometerspeedcontrol Parallel resistor heater flange Resistor Resistor Resistor Resistor fuel pre−heater Starter switch Switch, emergency off Push button, warning horn Switch,seatcontact,lh. Switch,vibration,front Switch,vibration,travellever,rh. Switch, hazard light Switch,lightingStVZO Switch,windscreenwiper,front Switch,windscreenwiper,rear Switch,vibrationlow/high Switch, vibration Switch, indicator Switch, warning light Switch, warning light Speedrangeselector,fast−slow Speedrangeselector,fast−slow Speedrangeselector,fast−slow Switch,cabinventilator Switch,cabininsidelight Switch,workinglights Pushbutton,etherstartingunit Switch,vibrationhorizontal/vertical Switch, steering Switchairconditioning Switch man./autom. Switch,compactionenergy Switch,amplit.adjustment Switch,faultdiagnosis

TYP EMR DIAGNOSE 1KOHM 1KOHM 1KOHM 1KOHM

NOTAUSH

EMRDIAGNOSE TERRAMETER

Switch, engine rpm TERRAMETER Switch,plateslift/letdown Switch, start Switch, start Switch, stop Switch, stop Switch, print Switch, print Switch, erase Switch, erase Switch,frequencycontrol Switch,testmodestandard / mode Switch, PD−D Paper formfeed Switch,fuelpre−heating

TERRAMETER DIP−SCHALTER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER TERRAMETER

Diode Diode Diode

Diode Diode Diode

DIODENMODUL DIODENMODUL DIODENMODUL

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

4

1 0

1 0 4

5 8 2 7 0 0 8 9

Bl. 003 003 008 008 008 008 009 009 011 011 017 017 017 016 017 017 017 016 006 006 004

Pf. 18 14 8 12 16 19 4 5 9 12 13 17 19 1 15 18 12 3 2 2 6

Benennung

V05 V08 V09 V09 V09 V09 V09 V09 V09 V09 V09 V09 V09 V11 V12 V13 V14 V15 V21 V22 V42

Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode (A2)

Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode (A2)

title

X1:1 X1:2 X1:3 X1:4 X1:5 X1:6 X1:7 X1:8 X1:9 X1:S X1:10 X1:10 X1:11 X1:12 X1:13 X1:14 X1:15 X1:16 X1:17 X1:17 X1:18 X1:19 X1:20 X1:21 X1:22 X1:23 X1:24 X1:25

002 002 002 002 002 003 003 003 003 010 002 009 003 002 002 006 006 003 003 006 006 006 006 006 006 006 006 006

1 2 2 3 3 10 10 6 10 2 19 18 7 6 6 9 8 15 11 12 16 15 17 14 16 18 12 17

WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN

WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX

X1:26 X1:27 X1:27 X1:28 X1:28 X1:29 X1:30 X1:31 X1:31 X1:31 X1:31 X1:32 X1:32 X1:32 X1:32 X1:33 X1:34 X1:35 X1:36 X1:36 X1:37 X1:37 X1:37 X1:37 X1:38 X1:40 X1:41 X1:42 X1:43

006 006 016 002 006 002 006 003 006 006 008 002 006 006 008 008 006 015 006 008 002 002 006 008 009 003 003 008 008

19 14 3 8 12 10 16 3 13 18 2 8 4 14 9 9 4 11 5 9 8 10 5 6 2 15 15 7 7

WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN

WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX

X1:44 X1:44 X1:44 X1:45 X1:46 X1:48 X1:50 X1:50 X1:51 X1:52 X1:54 X1:54 X1:54 X1:54 X1:54 X1:55 X1:56 X1:56 X1:56 X1:57

008 008 010 010 003 010 004 005 008 010 008 008 008 010 012 010 008 008 010 008

11 16 5 6 18 6 14 7 16 7 4 11 18 14 17 6 11 18 6 15

WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO. E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN

WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO. E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX

TYP DIODENMODUL DIODENMODUL

VENTIL LÜTZE LÜTZE LÜTZE LÜTZE WAGO, FE5B WAGO, FE5B WAGO, FE5B WAGO, FE5B FE5B FE5B FE5B FE5B/KABEL

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

5

1 0

1 0 5

5 8 2 7 0 0 8 9

Bl. 010 003 003 008 014 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 003

Pf. 5 14 18 15 3 5 2 2 2 8 11 10 10 10 11 8 11 11 5 4 2

Benennung

X1:57 X1:58 X1:58 X1:58 X1:58 X1:59 X1:60 X1:61 X1:62 X1:63 X1:64 X1:65 X1:65 X1:66 X1:67 X1:68 X1:69 X1:70 X1:71 X1:72 X1:73

WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN

WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX

title

X1:73 X1:74 X1:75 X1:76 X1:77 X1:78 X1:78 X1:79 X1:7A X1:80 X1:81 X1:82 X1:83 X1:84 X1:84 X1:85 X1:85 X1:86 X1:86 X1:87 X1:87 X1:88 X1:89 X1:8A X1:90 X1:91 X1:92 X1:93 X1:94

016 016 016 015 015 002 016 016 003 002 012 012 012 010 012 010 012 010 012 010 012 012 012 003 012 008 008 009 009

11 11 9 7 5 12 7 5 8 12 4 2 2 12 2 11 2 11 3 12 3 7 4 7 7 7 7 5 5




011 009 009 014 014 006 006 006 006 006 009 009 006 008 008 008 008 010 010 010 010 017 017 007 007 007 007 016 017

6 5 5 4 3 2 1 3 5 2 2 2 12 3 2 4 2 16 18 18 19 9 16 16 18 3 3 5 7




017 017 007 013 007 007 007 009 016 016 016 016 016 002 016 014 014 014 014 014

11 14 3 18 3 17 14 5 2 3 5 5 2 9 4 2 5 18 19 7

WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN

WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO. E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX

TYP

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

6

1 0

1 0 6

5 8 2 7 0 0 8 9

Benennung

title


Bl. 014 014 017 017 017 017 017 017 017 017 017 017 017 017 004 004 004 004 004 004 015

Pf. 9 14 4 16 16 12 14 16 18 9 9 3 5 11 2 3 3 7 7 7 3

X1:201 X1:202 X1:211 X1:212 X1:213 X1:214 X1:215 X1:216 X1:217 X1:221 X1:222.10 X1:222.20 X1:223.10 X1:223.20 X1:224.10 X1:224.20 X2:3 X2:4 X2:5 X2:5 X2:5 X2:6 X2:7 X2:8 X2:9 X2:9 X2:10 X2:11 X2:12

015 015 005 005 005 005 005 005 005 009 09 09 09 09 09 09 011 011 011 011 015 011 011 011 011 012 011 011 011

3 WAGO, E−KASTEN 3 WAGO, E−KASTEN 5 WAGO. E−BOX 4 WAGO. E−BOX 4 WAGO. E−BOX 5 WAGO. E−BOX 6 WAGO. E−BOX 19 WAGO. E−BOX 4 WAGO. E−BOX 13W AGO, E−KASTEN 15W AGO, E−KASTEN 15W AGO, E−KASTEN 15W AGO, E−KASTEN 15W AGO, E−KASTEN 15W AGO, E−KASTEN 14W AGO, E−KASTEN 7 VARIOCONTROL 7 VARIOCONTROL 7 VARIOCONTROL 13 VARIOCONTROL 16 VARIOCONTROL 2 VARIOCONTROL 2 VARIOCONTROL 11 VARIOCONTROL 3 VARIOCONTROL 16 VARIOCONTROL 11 VARIOCONTROL 3 VARIOCONTROL 18 VARIOCONTROL

X2:13 X2:14 X2:15 X2:16 X2:17 X2:1A X2:1E X2:20 X2:21 X2:22 X2:23 X2:24 X2:25 X2:2A X2:2E X2:31 X2:31 X2:31 X2:31 X2:32 X2:32 X2:32 X2:33 X2:34 X2:35 X2:36 X2:37 X2:38 X2:39

011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011

18 17 18 17 17 12 12 6 8 9 9 9 9 13 13 5 14 17 17 14 17 17 16 16 15 16 16 2 2

VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL

variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol


011 011 011 015 015 011 011 011 011 011 012 015 011 011 011 011 011 011 011 011

9 2 5 16 16 12 13 2 20 6 15 16 8 8 7 16 16 9 10 3

VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL

variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol

WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN WAGO, E−KASTEN

WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX Wago. E−BOX Wago. E−BOX Wago. E−BOX Wago. E−BOX Wago. E−BOX Wago. E−BOX Wago. E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX WAGO, E−BOX variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol

TYP

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

1 0

1 0 7

Bl. 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011 011

Pf. 4 5 5 13 7 9 10 7 4 4 7 6 10 14 14 15 16 16 17 19 19


011 011 011 011 011 011 011 011 011 015 015 0118 0118 0118 0118 0111 0116 0119 0111 0117 0117 0113 0114 0115 0115 0111 0113 0115 0111

19 VARIOCONTROL 20 VARIOCONTROL 19 VARIOCONTROL 17 VARIOCONTROL 18 VARIOCONTROL 13 VARIOCONTROL 10 VARIOCONTROL 11 VARIOCONTROL 10 VARIOCONTROL 16 VARIOCONTROL 16 VARIOCONTROL WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE 0 WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE 0 WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE 3 WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE WEIDMÜLLER, BANDAGE 3 WEIDMÜLLER, BANDAGE

X4:1 0108 X4:2 0109 X4:3 0109 X5:1 006 14 X5:2 006 14 X6:1 008 1 X6:2 008 2 X6:3 008 2 X7:1 008 3 X7:2 008 4 X7:3 008 4 X8:1 009 2 X8:2 009 2 X9:1 008 9 X9:2 008 9 XS 002 19 XS 002 19 X10:1−190 131 6 X11:1 0111 9 X11:2 0111 8 X11:3 0111 8 X11:4 0111 9 X11:5 0111 9 X11:6 0112 0 X11:7 0112 0 X11:8 0117 X11:9 0119 X11:10 011 10 X11:11 011 17

7

5 8 2 7 0 0 8 9

Benennung



011 011 0117 0117 0117 0118 0118 0116 011 011 011 011 011 017 017 017 017 017 017 017

17 18

VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL VARIOCONTROL

AMP, POTI FAHRHEBEL AMP, POTI FAHRHEBEL AMP, POTI FAHRHEBEL AMP, WARNSUMMER AMP, WARNSUMMER AMP FAHRHEBEL AMP FAHRHEBEL AMP FAHRHEBEL AMP FAHRHEBEL AMP FAHRHEBEL AMP FAHRHEBEL AMP FAHRHEBEL AMP FAHRHEBEL AMP WARNSUMMER AMP WARNSUMMER Steckdose Steckdose ANSCHLUßSTECKER BCM SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAU DIAGNOSE SCHALTBAU DIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE

SCHALTBAU SCHALTBAUDIAGNOSE DIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE SCHALTBAUDIAGNOSE 14 AMP, SCHALTER 16 AMP, SCHALTER 14 AMP, SCHALTER 16 AMP, SCHALTER 16 AMP, SCHALTER 4 PLATTENKUPPLUNGANBA 5 PLATTENKUPPLUNGMASC 4 PLATTENKUPPLUNGANBA 5 PLATTENKUPPLUNGMASC 3A MP, SENSOR 3A MP, SENSOR 2A MP, SENSOR

title variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol variocontrol Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum Weidmueller drum AMP, poti travel lever AMP, poti travel lever AMP, poti travel lever AMP, buzzer AMP, buzzer AMP, travel lever AMP, travel lever AMP, travel lever AMP, travel lever AMP, travel lever AMP, travel lever AMP, travel lever AMP, travel lever AMP, buzzer AMP, buzzer Socket Socket connector BCM Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbaudiagnosis Schaltbaudiagnosis Schaltbau Schaltbaudiagnosis diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis Schaltbau diagnosis AMP, switch AMP, switch AMP, switch AMP, switch AMP, switch platesclutchassemblingunit platesclutch,machine platesclutchassemblingunit platesclutch,machine AMP, sensor AMP, sensor AMP, sensor

TYP

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

8

1 0

1 0 8

5 8 2 7 0 0 8 9

Benennung

X17−1:1 X17−1:2 X17−1:3 X17−1:4 X17−1:6 X17−1:7 X17−1:8 X17−2:2 X17−2:3 X17−2:4 X17−2:5 X17−2:6 X17−2:8 X18−1:1 X18−1:2 X18−1:3 X18−1:4 X18−1:5 X18−1:6 X18−1:7 X18−2:1

Bl. 006 006 002 002 003 006 006 006 003 003 003 003 003 002 002 006 006 006 006 003 003

Pf. 16 9 6 6 15 8 15 17 10 10 8 7 11 6 6 9 16 15 8 15 10

X18−2:2 X18−2:3 X18−2:5 X18−2:7 X18−2:8 X19:1 X19:2 X19:3 X20:1 X20:2 X20:3 X21:1 X21:2 X21:3 X22:1 X22:2 X23:1 X23:2 X24:1 X24:2 X24:3 X25:1 X25:2 X25:3 X26:1 X26:2 X26:3 X27:1 X27:2

003 006 003 003 003 0177 0177 0176 011 011 011 011 011 011 014 014 014 014 014 014 014 014 014 014 014 014 014 014 014

10 MOTORSTECKERMASCH. 17 MOTORSTECKERMASCH. 11 MOTORSTECKERMASCH. 7 MOTORSTECKERMASCH. 8 MOTORSTECKERMASCH. AMP POTI PLATTEN AMP POTI PLATTEN AMP POTI PLATTEN 16 AMP POTI S107 16 AMP POTI S107 16 AMP POTI S107 17 AMP POTI S106 17 AMP POTI S106 17 AMP POTI S106 2 STECKERSCHEINW.STVZ 2 STECKERSCHEINW.STVZ 2 STECKERSCHEINW.STVZ 2 STECKERSCHEINW.STVZ 5 STECKERSCHLUßLEUCHTE 18 STECKERSCHLUßLEUCHTE 5 STECKERSCHLUßLEUCHTE 6 STECKERPARKLEUCHTE 6 STECKERPARKLEUCHTE 17 STECKERPARKLEUCHTE 6 STECKERPARKLEUCHTE 6 STECKERPARKLEUCHTE 19 STECKERPARKLEUCHTE 19 STECKERSCHLUßLEUCHTE 7 STECKERSCHLUßLEUCHTE

X27:3 X30:1 X30:2 X30:3 X30:3 X31:1 X31:2 X31:3 X31:4 X32:1 X32:2 X33:1 X33:2 X33:3 X34:1 X34:2 X34:3 X35:1 X35:2 X35:A X35:B X35:C X36:2−8 X37:1 X37:2 X38:1 X38:2 X38:3 X38:4

014 0169 0168 016 0168 0161 0161 0161 0161 016 016 016 016 016 016 016 016 0047 0047 003 003 003 002 002 002 011 011 011 011

7

STECKERSCHLUßLEUCHTE WISCHER HINTEN WISCHER HINTEN STECKERWISCHERHINTE WISCHER HINTEN 2W ISCHER VORN 1W ISCHER VORN 1W ISCHER VORN 0W ISCHER VORN 7 STECKERINNENLEUCHTE 7 STECKERINNENLEUCHTE 14S TECKER LÜFTER 14S TECKER LÜFTER 14S TECKER LÜFTER 3 STECKERKLIMAANL.KAB 3 STECKERKLIMAANL.KAB 5 STECKERKLIMAANL.KAB DEUTSCH 2−POL DEUTSCH 2−POL 15 MOTORSTECKERMOTOR 15 HUBMAGNETSTECKER 15 MOTORSTECKERMOTOR 16 DIAGNOSESTECKERHEIZU 14 STECKERKRAFTSTOFFPUM 14 STECKERKRAFTSTOFFPUM 19 VARIOCONTROL 19 VARIOCONTROL 19 VARIOCONTROL 19 VARIOCONTROL


011 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005

19 15S 13S 14S 13S 14S 15S 15S 12S 12S 7 8 6 7 8 9 10S 9 9 10S

MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMOTOR MOTORSTECKERMASCH. MOTORSTECKERMASCH. MOTORSTECKERMASCH. MOTORSTECKERMASCH. MOTORSTECKERMASCH. MOTORSTECKERMASCH. MOTORSTECKERMASCH. MOTORSTECKERMASCH.

8

VARIOCONTROL tecker Motor tecker Motor tecker Motor tecker Motor tecker Motor tecker Motor tecker Motor tecker Motor tecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor tecker Motor Stecker Motor Stecker Motor tecker Motor

title engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,engineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside engineplug,machineside APM poti vibration plates APM poti vibration plates APM poti vibration plates AMP poti S107 AMP poti S107 AMP poti S107 AMP poti S106 AMP poti S106 AMP poti S106 connectorheadlightsStvZO connectorheadlightsStvZO connectorheadlightsStvZO connectorheadlightsStvZO connectortaillights connectortaillights connectortaillights connectorparkinglights connectorparkinglights connectorparkinglights connectorparkinglights connectorparkinglights connectorparkinglights connectortaillights connectortaillights connectortaillights connector wiper rear connector wiper rear connectorwiperrear connector wiper rear connector wiper front connector wiper front connector wiper front connector wiper front connectorinsidelight,cabin connectorinsidelight,cabin connector blower connector blower connector blower connectoraircond.cabin connectoraircond.cabin connectoraircond.cabin connector DEUTSCH 2−pol connector DEUTSCH 2−pol engineplug,engineside connectorshut−off−solenoid engineplug,engineside connectorheater−diagnosis connectorfuel−pump connectorfuel−pump variocontrol variocontrol variocontrol variocontrol variocontrol connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine

TYP

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

9

1 0

1 0 9

5 8 2 7 0 0 8 9

Pf. Benennung 5 Stecker Motor 6 Stecker Motor 6 Stecker Motor 10S tecker Motor 11S tecker Motor 11S tecker Motor 6 EMR−Stecker Motor 7 EMR−Stecker Motor 7 EMR−Stecker Motor 3 EMR−Stecker Motor 4 EMR−Stecker Motor 5 EMR−Stecker Motor 7 EMR−Stecker Motor 2 EMR−Stecker Motor 2 EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor

title


Bl. 005 005 005 005 005 005 0051 0051 0051 0051 0051 0051 0051 0051 0051 0057 0058 0056 0057 0058 0059

X40:16 X40:17 X40:18 X40:19 X40:20 X40:21 X40:22 X40:23 X40:24 X40:25 X41:1 X41:2 X41:3 X41:4 X41:5 X41:10 X41:11 X41:12 X41:13 X41:14 X41:15 X41:17 X41:22 X41:23 X41:24 X41:25 X42:A X42:B X42:G

0051 0 0059 0059 0051 0 0055 0056 0056 0051 0 0051 1 0051 1 005 4 005 5 005 11 005 6 005 7 005 2 005 3 005 3 005 3 005 2 005 10 005 5 005 4 005 5 005 4 005 4 005 2 005 4 005 3

EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR−SteckerFahrzeug EMR Diagnose − EMR Diagnose − EMR Diagnose −

EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−connectorcompactor EMR−diagnosis EMR−diagnosis EMR−diagnosis

X42:H X42:K X42:L X43:1 X43:2 X43:3 X43:4 X43:5 X43:6 X43:7 X43:8 X28/1:3 X28/1:5 X28/1:6 X28/1:7 X28/1:8 X28/2:2 X28/2:5 X28/2:6 X28/2:7 X28/2:8 X29/1:3 X29/1:4 X29/1:5 X29/1:6 X29/1:7 X29/1:8 X29/2:1 X29/2:2

005 005 005 005 005 005 005 005 005 005 005 016 016 016 016 016 016 016 016 016 016 016 016 016 016 016 016 016 016

3 3 2 19T 18T 18T 19T 18T 19T 17T 20T 11 8 9 8 9 11 9 8 9 8 14 14 5 11 12 10 14 14

EMR Diagnose − EMR Diagnose − EMR Diagnose − rennstelle EMR II rennstelle EMR II rennstelle EMR II rennstelle EMR II rennstelle EMR II rennstelle EMR II rennstelle EMR II rennstelle EMR II KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER KABINEHAUPTSTECKER

EMR−diagnosis EMR−diagnosis EMR−diagnosis conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin mainconnectorcabin

X29/2:5 X29/2:6 X29/2:7 X29/2:8 XS13:1 XS13:2 XS13:3 XS13:4 XS13:5 XS13:6 XS13:7 XS14:1 XS14:2 XS14:3 XS14:4 XS15:1 XS15:2 XS15:3 XS15:4 XS16:1

016 016 016 016 0132 0132 0132 0133 0133 0133 0134 0135 0135 0135 0136 0132 0134 0133 0133 0136

10 12 KABINE KABINEHAUPTSTECKER HAUPTSTECKER 11 KABINEHAUPTSTECKER 6 KABINEHAUPTSTECKER Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckerschnittstelle Druckercontroller Druckercontroller Druckercontroller Druckercontroller Druckercontroller

connector engine connector engine connector engine connector engine connector engine connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine

main mainconnector connectorcabin cabin mainconnectorcabin mainconnectorcabin intreface printer intreface printer intreface printer intreface printer intreface printer intreface printer intreface printer intreface printer intreface printer intreface printer intreface printer Printer−controller Printer−controller Printer−controller Printer−controller Printer−controller

TYP

Name

W1 S 1 7 e 7 e 0 . rn .6 is 0 6 e . . 2 r 2 0 0 0 0 2 2


B a u te ill is te

1 0

1 0

1 1 0

5 8 2 7 0 0 8 9

XS16:2 XS16:3 XS16:4 XS16:5 XS16:6

Bl. Pf. Benennung 0136 Druckercontroller 0136 Druckercontroller 0135 Druckercontroller 0135 Druckercontroller 0135 Druckercontroller

Y01 Y04 Y07 Y08 Y13 Y13 Y14 Y15 Y22 Y30 Y30 Y31 Y31 Y31 Y58

003 008 009 009 003 0031 002 016 011 008 010 008 008 010 003

11 7 5 6 15 6 15 2 9 15 5 11 18 6 17

Y59 Y64 Y98 Y117 Y119 Y122 Y123 Y124 Y125 Y126 Y127 Y128 Y137

004 010 017 0037 011 017 017 017 011 011 011 011 005

7 MagnetventilAetherstartanlage 18 MagnetventilLenkung 9 MagnetventilVibrationsfrequenz,hinten Kaltstartbeschleuniger 13 MagnetventilArretierung 12 MagnetventilPlattenheben 18 MagnetventilPlattensenken 16 MagnetventilHydraulikumschaltung 3 Einlassventil 1 5 Einlassventil 3 5 Auslassventil 2 4 Auslassventil 4 9 EMR Verstellung

MagnetventilStartmehrmenge MagnetventilBremse MagnetventilVibrationvornegross MagnetventilVibrationvorneklein HubmagnetMotor Hubmagnet Motor KraftstoffpumpeHeizgeraet MagnetkupplungKlimakompressor MagnetventilVibration MagnetventilStufenumschaltungvorn MagnetventilStufenumschaltungvorn MagnetventilStufenumschaltunghinten MagnetventilStufenumschaltunghinten MagnetventilStufenumschaltunghinten MagnetventilKraftstoffabschaltung

title

TYP

Printer−controller Printer−controller Printer−controller Printer−controller Printer−controller Solenoidvalve,startboostfuel Solenoidvalve,brake Solenoidvalve,vibration,front,high Solenoidvalve,vibration,front,low Shutoffsolenoid,engine Shut off solenoid, engine Fuelpump,heatingunit Magneticclutch,airconditioningcompr. Solenoidvalve,vibration Solenoidvalve,speedrangesel.,front Solenoidvalve,speedrangesel.,front Solenoidvalve,speedrangesel.,rear Solenoidvalve,speedrangesel.,rear Solenoidvalve,speedrangesel.,rear Solenoidvalve,fuelswitchoff Solenoidvalve,etherstartingunit Solenoidvalve,steering Solenoidvalve,vibrat.freq.,rear cold starting unit Solenoidvalve,adjustment Solenoidvalve,liftplates Solenoidvalve,letdownplates Solenoidvalve,hydaulicswitchover Intake valve 1 Intake valve 3 Exhaust valve 2 Exhaust valve 4 EMR adjustment

MAX.1,8A MAX.2,5A MAX.2,5A 1,1A/55A 4A 3,5A 1,23A/1,67A 1,23A/1,67A MAX.1,23A MAX.1,23A MAX.1,23A 0,8A 0,33A 3A 2,5A 2,5A 2,5A

1 8 3 0 6 8 5 1 6 6 0 0 F F F F F F

D x o B

4 6 4 5 3 3 1 2 2 2 0 2 F F F F F F

C x o B

0 7 7 9 0 se 4 3 0 0 1 F F F F F R

B x o

3 − 2 1 2 W B

1 0 2

9 8 0 0 7 2 8 5 1

1

g n u t h c u le e B d n u e in b a K g n tsu ü rs u a zt a s u Z r ü F

B A x o B

5 1 3 9 2 1 0 1 1 1 2 2 F F F F F F

st h lig d a e h g n kri o w d n a n i b a c n ti p o r fo

3 5 1 5 5 7 5 0 5 0 3 4 5 7 5 0

1 1 K

021 801 701 601 501 401 301 101 001 99 89 79 69 59 49 39 29 19 09

2 3 K

) 3 − 2 1 2 W (B

st hgil daeh ot . cc a yl no gnut hc uel ebsti ebr Ai eb r un

08

3 3 4 6 6 7 5 0

97

2 4 8 6 2 7 5 0

5 0 K 6 3 K

87

4 3 7 6 6 7 5 0

4 0 K 0 6 4 6 6 7 5 0

8 4 K

3 2 A

9 2 4 6 5

77 67 57 47 37

5 7 0

785 5 65 55 45 15 05 94 44 34 24 14 04 93 83 73 63 53 43 33 23 13 03 92 82 72 62 52 42 32 22 12 02 91 81 71 61 51 41 31 21 11 01

2 2 K 6 2 K 6 0 K

4 2 4 6 5 7 5 0 0 2 4 6 5 7 5 0

7 4 7 6 4 6 5 4 3 1 5 0 B A K A A A

9 4 ,K 3 3 ,K 9 0 K

: n e : n s io t n p io t p Oo re re t h ie e tr wu r fr fü fo si s la ya e l R re

2 0 ,A 6 1 K n i to a n i m u ill O vZ t S

g in n tiio d n o c ir / a g n / u e zn g e la r n g a e a kb m li n li K B

6 4 ,K 3 2 K

3 / 7 7 ,K 2 / 7 7 ,K /1 7 7 ,K 3 4 K

m e h syt s r e kl n ri p s

l o tr n o c d e e p s

/ g n lu e s ie r e B

l/ o rt n co d e e p S

l ro t n o c io r va , M T B ,r e t e m rra e t

5 1 1 ,K 7 6 ,K 0 3 K

ts a l p n i to a r b iv / n e tt la sp n o ti a r ib V

n e n sn io i t to p p O ro e re h e t it r e u w rf r fo ü f s le le u u d d o o Mm

C S A / C S A

l/ o tr n co o ir a V , M T B ,r e t e m rra e T

5 2 4 6 5 7 5 0

m e h syt s r e kl n ri p s / g n lu e s ie r e B

ts a l p n i to h a r p b ra iv g o h c a t / n e / tta h l p sp a n r o g ti o a h c r a ib T V

1 2 4 6 5 7 5 0

z n e u q e fsr n io t ra b vi / z n e u q e fsr n o ti a r ib V

7 1 4 6 5 7 5 0

2 2 4 6 5 7 5 0

3 2 4 6 5 7 5 0

9 1 4 6 5 7 5 0

9 8 a7 7 6 5 4 3 2 1

ni bac . ot. cc a yl no 08−37: 1x eni ba Ki eb r un 08 −37: 1 X st hgil daeh ot . cc a yl no gnut hc uel ebsti ebr Ai eb r un

e in t g g n le se e b n r rik o t o e P Mo s .t cc in rk a e d iP se e b u r ly u n No

C 5 5 8 .. 0 5 8 /C 3 − 5 2 2 ... 2 1 2 W B t h c sir e b ü n e st a ktl a h c S

2 0 0 2 . 6 s 0 . i 7 e 1 S

2 0 0 2 . 6 0 . 7 1

) 3 − 2 1 2 W (B

C 5 5 8 .. 0 5 8 C / 3 − 5 2 2 . .. 2 1 2 W B x o b − e w e vir e v o

r e n r e W

7 4 7 6 4 6 4 8 5 4 3 1 5 0 6 6 B A K A A A A A

D x o B

1 8 3 0 6 8 5 1 6 6 0 0 F F F F F F

9 4 K , 3 3 ,K 9 0 K

C x o B

4 6 4 5 3 3 1 2 2 2 0 2 F F F F F F 4 0 7 7 9 0 2 4 3 0 0 1 1 F F F F F F

B x o B

5 1 3 9 2 1 0 1 1 1 2 2 F F F F F F

A x o B135

: n e : n s n tio io p t Op o r re e e ti h e rt w fu r r ü f fo si s y la a e le Rr

5 5 7 5 0

5 0 3 4 5 7 5 0

1 1 K

3 3 4 6 6 5 7 0

4 3 7 6 6 7 5 0

4 3 1 K

2 8 4 6 2 7 5 0

5 0 K 6 3 K

6 4 ,K 3 2 K

n tio a n i m u lli O vZ t S

ts la p m e l n h o ts o it r a t ys n r o i r c b e d v kl e n ri e p p s / s n /l te t / o a l g tr p n n s u l o c n se d io t e ra ire e e p ib B S V

C S A / C S A

/l ro t n o c io r a V , M T B ,r e t e m a rr e T

m e h syt s r e kl in r p s / g n u l se ire e B

z n e u q re fs n ito a r le b u vi d o m / IB z V n − e E u / q lu e r d sf o n M ito B ra IV ib − V E

1

30 V

1

20 V

1

2

2

1

1

2

10 V

1 1 1 1

2

8 7

2 2 2 2

6 5 4

2

3

2 0 7 0 31 H 5 7 5 0

n o sir e v n d io n ru sre Gv n ic e ts sa a b ltk x, a o h c b − Se

1

1

30 466 750

ch it w s − t a e s/ r lte a h c zsit S

09 98 88 78 68 58 48 39 38 28 18

97 87

9 2 4 6 5 7 5 0

6 0

2 3 A 6 2 1 − 1 2 :1 1 X

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BW213DH-3 _SERVICE TRAINING.pdf

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