BW216 219DH 4 Service Training

Service Training

Single Drum Rollers BW 216 DH / PDH - 4 BW 219 DH / PDH - 4 BW 226 DH / PDH - 4 Part-No. 008 097 20

08/2005

Service Training Table of contents Foreword

A1

Documentation

A2

General

A3

New features

A5

Technical data and adjustment values

B1

Maintenance

C1

Maintenance chart and table of fuels and lubricants

C2

DEUTZ diesel engine 2012C with EMR

D1

Service side

D2

Starter side

D3

Lubrication oil circuit

D4

Coolant circuit

D5

Fuel system

D6

EMR

D10

Trouble shooting

D22

Diagnostics SERDIA

D24

Checking and adjusting the valve clearance

D26

Assembly of plug-type injection pump

D28

Engine components

D44

Travel system

E1

Travel pump

E3

Control

E7

Charge pressure relief valve

E8

High pressure relief valve

E9

Pressure override valve

E11

Axle drive motor

E14

Drum drive motor

E17

Test and adjustment points, travel system

E19

Trouble shooting travel system

E27

BW 216 / 219 / 226 DH / PDH -4

Service Training Vibration

F1

Vibration pump

F3

High pressure relief valves

F6

Control

F7

Vibration motor

F8

Drum

F11

Test and adjustment points, vibration system

F13

Trouble shooting vibration

F15

Steering

G1

Charge pump

G2

Steering pump

G3

Steering valve

G5

Articulated joint

G7

Measuring and adjustment points

G9

Trouble shooting steering

G10

Electrics Wiring diagram Hydraulic diagram

BW 216 / 219 / 226 DH / PDH -4

H1

Service Training Foreword and new features Reliable construction equipment is of greatest advantage for all parties involved: • 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. 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 quality 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 alterations to the machine.

BW 216 / 219 / 226 DH / PDH -4

-A1-

Service Training Documentation This Service Training is valid for the following BOMAG single drum rollers of series 4:

BW 216 DH / PDH -4 BW 219 DH / PDH-4 BW 226 DH / PDH-4

with Deutz diesel engine BF6M 2012C EMR

For the BOMAG machines described in this training manual the following documentation is additionally available:

1. Operating and maintenance instructions 2. Spare parts catalogue 3. Wiring diagram * 4. Hydraulic diagram * 5. Repair instructions 6. Service Information * The document versions valid at the date of printing are part of this training manual.

Attention! The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial number of the machine.

BW 216 / 219 / 226 DH / PDH -4

-A2-

Service Training General The new BOMAG single drum rollers of series 4 are mainly further developments of their predecessors of series 3. These machines have been successfully and reliably used for years on construction sites all over the world, especially in earth construction and on sanitary landfill sites. High compaction power and excellent traction are characteristics, which are of utmost importance for this type of machine. All components installed in these machines are manufactured in series production and are subjected to stringent quality tests. This guarantees a high level of reliability and safety. As with many other BOMAG products, and here especially with the large single drum rollers of the new generation, we have decided to use the same successful drive concept with diesel engine (water cooled) and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the engine directly to drum, drive wheels and steering. The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by slow running radial piston motors. On construction machines the work place of the operator is of utmost importance. Under such working conditions the health and safety of the operator must be the greatest concern. The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be individually adjusted for every operator, even for his weight. All control elements and gauges are within the reach and in the sight of the operator. A monitoring display with light emitting diodes and clear pictograms informs the operator about any operating faults. The operator is therefore always informed about the present condition of the machine. The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens, as well as a heated rear windscreen, offers clear vision to all sides.

BW 216 / 219 / 226 DH / PDH -4

-A3-

Service Training Important characteristics of the new generation of single drum rollers are • strong ROPS/FOPS according to SAE-standard • wear free service brake by closed hydrostatic travel circuits • disc brakes in axle and drum drive motor serve as parking and emergency brakes • high stability due to low centre of gravity and the use of an articulated joint • operating safety due to the use of monitoring boards for all important system data • automatic engine shut down after 15 seconds, if the engine temperature is too high • automatic engine shut down after 10 seconds, if the coolant level is too low and the engine oil pressure is too low. The single drum rollers of series 4 are well designed down to the smallest detail, so that they can meet the toughest demands on large scale construction sites all over the world.

BW 216 / 219 / 226 DH / PDH -4

-A4-

Service Training New features The multi-function travel lever and the display

Back

Front

up

down

BW 216 / 219 / 226 DH / PDH -4

-A5-

Service Training Control, operation, data collector,

BW 216 / 219 226 DH / PDH -4

-A -

Service Training

Translation Rückseite Vorderseite Rechts Auf Vibr. Taste Links Ab INFO Teste 1 INFO Taste 2

Back Front Right Up Vibr. button Left Down INFO button 1 INFO button 2

Translation: Fahrhebel Datensammler Luftfilter Blink. L Blink. R Licht an D+ Signal Hyd. Ölfilt. Hyd. Temp. Klimaanl. Ampere Wasserab. Kühl. Füll.

Travel lever Data collector Air filter Indic. l Indic. r Lights on D+ signal Hyd. oil filter Hyd. temp. Aircon Ampere Water separ. Coolant level

Fahrhebel Stufenschalter Sitzkontaktschalter Drucksensor Verstellung Sensor Vorderrahmen Hinterrahmen Verstellung Fahrmotor vorne Neigungssensor Sensor Verstellung Fahrmotor hinten Fahrpumpe Travel pump

Travel lever Speed range switch Seat contact switch Pressure sensor Control Sensor Front frame Rear frame Control Front travel motor Inclination sensor Sensor Control Rear vtravel motor

BW 216 / 219 226 DH / PDH -4

-A -

Service Training Diesel engine with EMR

BW 216 / 219 / 226 DH / PDH -4

-A -

Service Training Travel System

BW 216 / 219 / 226 DH / PDH -4

-A -

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 216 / 219 / 226 DH / PDH -4

-B1-

BOMAG Central Service

Seite 1 von 2

BOMAG Central Service - Technical data and adjustment values Status: 2005-08-05

Product type:

BW 216 DH Serie 4

Type No.: Serial numbers from:

582 60 101 582 60 1001

Engine: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage: Starter power:

BF6M2012C 4-stroke-Diesel Water 6 147 kW 2300 1/min 850+/-150 1/min 2475+/-125 1/min 222 g/kWh 0,3 mm 0,5 mm 250 bar 12 V 3,1 kW

Travel pump: Type: System: Max. displacement: Max. flow ratio: High pressure limitation: Charge pressure, high idle:

90R 075 (EP) Axial piston-swash plate 75 cm3/U 75ccm x n l/min 400 bar 25+/-1 bar

Reduction gear, drum: Type: Transmission ratio:

CR 51 73,5

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

51D110 (EP) Axial piston-bent axle 110 cm3/U 55,3 cm3/U 2 + 10 l/min 10 l/min 16 bar

Drum drive: Type: System: Displacement stage 1:

51C 110 (EP) Axial piston-swash plate

http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?... 05.08.2005


Seite 2 von 2

110 cm3/U Displacement stage 2: Perm. leak oil quantity: Rinsing oil quantity: Rinsing oil pressure limitation:

31,4 cm3/U 2 + 10 l/min 10 l/min 16 bar

Vibration pump: Type: System: Max. displacement:

90R 075 (EP) Axial piston-swash plate

75 cm3/U Starting pressure: 365+/-65 bar Operating pressure, soil dependent: ca.100 bar

Vibration motor: Type: System: Displacement: Frequency: Amplitude: Rinsing oil quantity: Rinsing oil pressure limitation:

A2FM 56 HDD Axial piston-bent axle 56 cm3/U 31 / 36 Hz 2,0/0,9 mm 6 l/min 13 bar

Steering and charge pump: Type: System: Displacement: Max. steering pressure:

HY/ZFS11/16 Gear pump 16 cm3/U 175+26 bar

Rear axle: Type: Differential: Degree of locking: Reduction ratio:

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

Filling capacities: Engine coolant:

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) Engine oil: 12,5 l (SAE 15W-40, API CG-4 (for details see maintenance manual)) Hydraulic oil: 60 l (HVLP 46 VI 150) Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF) Rear axle: 11 l (SAE 90 EP, API GL 5) Rear axle wheel hubs: 2 l (SAE 90 EP, API GL 5) Rear axle, transmission: 1,9 l (SAE 90 EP, API GL 5) Reduction gear, drum: 3,2 l (SAE 90 EP, API GL 5) AC refrigerant: 1400 g (R 134a) Compressor oil (filling the system): 100 ml (PAG Öl)



Seite 1 von 2


Product type:

BW 219 DH Serie 4


582 70 101 582 70 1001




90R 100 EP Axial piston-swash plate 100 cm3/U 100ccm x n l/min 435 +/-15 bar 26+/-1 bar


CR 51 73,5







Seite 2 von 2


31,4 cm3/U 2 + 10 l/min 10 l/min 16 bar









CHC 193/55 No-Spin 100 % 93,74

Filling capacities: Engine coolant:

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) Engine oil: 12,5 l (SAE 15W-40, API CG-4 (for details see maintenance manual)) Hydraulic oil: 60 l (HVLP 46 VI 150) Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF) Rear axle: 11 l (SAE 90 EP, API GL 5) Rear axle wheel hubs: 2 l (SAE 90 EP, API GL 5) Rear axle, transmission: 1,9 l (SAE 90 EP, API GL 5) Reduction gear, drum: 3,2 l (SAE 90 EP, API GL 5) AC refrigerant: 1400 g (R 134a) Compressor oil (filling the system): 100 ml (PAG Öl)



Seite 1 von 3


Product type:

BW 226 DH Serie 4


582 80 101 582 80 1001




90R 100 EP Axial piston-swash plate 100 cm3/U 100ccm x n l/min 435 +/-15 bar 26+/-1 bar


715 C 3B 129,2







Seite 2 von 3


31,4 cm3/U 2 + 10 l/min 10 l/min 16 bar








Steering valve: Type: System:

OSPC 500 ON Rotary valve


CHC 193/55 No-Spin 100 % 93,74

Filling capacities: Engine coolant: Engine oil: Hydraulic oil: Vibration bearing housing: Rear axle: Rear axle wheel hubs: Rear axle, transmission:

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 12,5 l (SAE 15W-40, API CG-4 (for details see maintenance manual)) 60 l (HVLP 46 VI 150) 2x 0,8 l (SAE 15W-40, API SJ/CF) 11 l (SAE 90 EP, API GL 5) 2 l (SAE 90 EP, API GL 5) 1,9 l (SAE 90 EP, API GL 5)


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 the machines must always be ready to be loaded up to their limits. Furthermore, all safety installations, protections and guards must always be in place and fully functional. Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably higher functional safety, but also prolongs the lifetime of the machine and of important components. The time required for thorough maintenance is only minor when being compared with the malfunctions and faults that may occur if these instructions are not observed. The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance interval all the work for shorter preceding intervals must also be performed. During the 2000 hours interval you must also perform the work described for the service intervals after 50, 250 and 500 hours. During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and lubricants (oils, fuels, grease etc.).

The designation specified under No: in the first column of the maintenance chart refers to the corresponding number of the service work to be performed, as specified in the operating and maintenance instructions. This also helps to find detailed information on the individual maintenance tasks.

BW 216 / 219 / 226 DH / PDH - 4

-C1-

Maintenance

5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx. Attention Observe the level marks

Engine

Engine oil ACEA: E3-96/E5-02 or

approx. 12,5 litres without oil filter

API: CG-4/CH-4 SAE 10W/40 (-20 °C to +40 °C) SAE 15W/40 (-15 °C to +40 °C) Fuel Diesel Hydraulic system

Winter diesel fuel

Hydraulic oil (ISO), HV46, kinem. viscosity

approx. 300 litres approx. 60 litres

46 mm2/s at 40 °C Vibration bearings

Engine oil SAE 15W/40

approx. 2x0.8 litres

Drive axle

Gear oil SAE 90, API GL5

approx. 11 litres

Wheel hubs


approx. 2.9 per side

Axle reduction gear


approx. 1,9 litres

Drum drive gear


approx. 2,8 litres

Air conditioning system

Refrigerant R134A

Engine cooling system

Cooling system protection agent

approx. 16 litres

Water

approx. 195 litres

Tires

Calcium chloride (CaCl2) or magnesium chloride (MgCl2)

82

BOMAG

1400 g

approx. 100 kg

BW 216 DH-4

Maintenance

5.4

Running-in instructions

The following maintenance work must be performed when running in new machines or overhauled engines: Caution Up to approx. 250 operating hours check the engine oil level twice every day. !

Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours. After a running-in time of 30 minutes Retighten the V-belt l

After 250 operating hours l

Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts. l

Retighten the bolted connections on the machine. l

Retighten all wheel fastening screws with the specified tightening torque. l

1. Oil change vibration bearings l

Oil change in drive axle l

Oil change in wheel hubs l

Oil change, axle reduction gear l

1. Oil change, drum drive reduction gear After 500 operating hours

BW 216 DH-4

l

2. Oil change vibration bearings l

2. Oil change, drum drive reduction gear

BOMAG

83

Maintenance

Dipstick mark

5.7

Check the water separator

X

5.8

Check the fuel level

X

5.9

Check the hydraulic oil level

5.10 Check the coolant level

X

Inspection glass

X

Inspection glass

X

5.11 Check the dust separator

X

5.12 Check the tire pressure

X

5.13 Clean the cooling fins on engine and hydraulic oil cooler

X

5.14 Check the oil level in the drive axle

X

5.15 Check the oil level in the wheel hubs

X

5.16 Check the oil level in the axle reduction gear

X

5.17 Check the oil level in the drum reduction gear

X

5.18 Check the oil level in the vibration bearings

X

5.19 Change engine oil and oil filter cartridge*

min. 1x per year

X

5.20 Change the fuel filter cartridge

X

5.21 Drain the sludge from the fuel tank

X

5.22 Service the battery

Pole grease

5.23 Change the fuel pre-filter cartridge

84

as required

Check the engine oil level

every 3000 operating hours

5.6


Remark


Maintenance work


No.


every 10 operating hours, daily

Maintenance chart

Running-in instructions after 250 operating hours

5.5

X X

BOMAG

BW 216 DH-4

5.24 Check, replace the refrigerant compressor V-belt

X

5.25 Service the air conditioning

X

5.26 Check, adjust the valve clearance

Intake = 0,3 mm

as required





Remark


Maintenance work


No.


Maintenance

X

Exhaust = 0,5 mm 5.27 Check, replace the ribbed V-belt

X

5.28 Check the engine mounts

X

X

5.29 Oil change in drive axle

min. 1x per year

X

X

5.30 Oil change in wheel hubs

min. 1x per year

X

X

5.31 Oil change, axle reduction gear

min. 1x per year

X

X

5.32 Oil change in drum drive reduction gear**

min. 1x per year

X

X

5.33 Oil change vibration bearings**

see foot note, min. 1 X x per year

X

5.34 Retighten the fastening of the axle on the frame

X

5.35 Tighten the wheel nuts

X

5.36 Check the ROPS 5.37 Clean the oil bath air filter

X X

min. 1x per year

X

5.38 Change hydraulic oil and breather fil- at least every 2 years ter***

X

5.39 Change the hydraulic oil filter****

at least every 2 years

X

5.40 Change the coolant


X

5.41 Check the injection valves

BW 216 DH-4

X

BOMAG

85

5.42 Service the combustion air filter

min. 1x per year, safety cartridge at least every 2 years

as required





Remark


Maintenance work


No.


Maintenance

X

5.43 Adjusting the scrapers

X

5.44 Adjust the parking brake

X

5.45 Change the tires

X

5.46 Change the fresh air filter in the cabin

X

5.47 Tightening torques

X

5.48 Engine conservation

X

* Oil change intervals depend on quality of oil and fuel (sulphur content) ** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h. *** Also in case of repair in the hydraulic system. **** Also in case of repair in the hydraulic system.

86

BOMAG

BW 216 DH-4

Maintenance

5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx. Attention Observe the level marks

Engine

Engine oil ACEA: E3-96/E5-02 or

approx. 12,5 litres without oil filter

API: CG-4/CH-4 SAE 10W/40 (-20 °C to +40 °C) SAE 15W/40 (-15 °C to +40 °C) Fuel Diesel Hydraulic system

Winter diesel fuel

Hydraulic oil (ISO), HV46, kinem. viscosity

approx. 150 litres approx. 60 litres

46 mm2/s at 40 °C Vibration bearings

Engine oil SAE 15W/40

approx. 2 x 1,8 litres

Drive axle


approx. 12,5 litres

Wheel hubs


approx3.5 l per side

Axle reduction gear


approx. 1,9 litres

Drum drive gear


approx. 7,5 litres

Air conditioning system

Refrigerant R134A

Engine cooling system

Cooling system protection agent

approx. 16 litres

Water

approx. 390 litres

Tires

Calcium chloride (CaCl2) or magnesium chloride (MgCl2)

62

BOMAG

approx. 130 kg

BW 226 DH-4/PDH-4

Maintenance

5.4

Running-in instructions

The following maintenance work must be performed when running in new machines or overhauled engines: Caution Up to approx. 250 operating hours check the engine oil level twice every day. !

Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours. After a running-in time of 30 minutes Retighten the V-belt l

After 50 operating hours l

Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts. l

Retighten the bolted connections on the machine. l

Retighten all wheel fastening screws with the specified tightening torque. l

Oil change vibration bearings l

Oil change in drive axle l

Oil change in wheel hubs l

Oil change, axle reduction gear l

Oil change, drum drive reduction gear After 500 operating hours l

BW 226 DH-4/PDH-4

BOMAG

Oil change vibration bearings

63

Maintenance

Dipstick mark

5.7

Check the water separator

X

5.8

Check the fuel level

X

5.9

Check the hydraulic oil level

5.10 Check the coolant level

X

Inspection glass

X

Inspection glass

X

5.11 Check the dust separator

X

5.12 Check the tire pressure

X

5.13 Clean the cooling fins on engine and hydraulic oil cooler

X

5.14 Check the oil level in the drive axle

X

5.15 Check the oil level in the wheel hubs

X

5.16 Check the oil level in the axle reduction gear

X

5.17 Check the oil level in the drum reduction gear

X

5.18 Check the oil level in the vibration bearings

X

5.19 Change engine oil and oil filter cartridge*

min. 1x per year

X

5.20 Change the fuel filter cartridge

X

5.21 Drain the sludge from the fuel tank

X

5.22 Service the battery

Pole grease

5.23 Change the fuel pre-filter cartridge

64

as required

Check the engine oil level


5.6


Remark


Maintenance work


No.



Maintenance chart


5.5

X X

BOMAG

BW 226 DH-4/PDH-4

5.24 Check, replace the refrigerant compressor V-belt

X

5.25 Service the air conditioning

X

5.26 Check, adjust the valve clearance

Intake = 0,3 mm

as required





Remark


Maintenance work


No.


Maintenance

X

Exhaust = 0,5 mm 5.27 Check, replace the ribbed V-belt

X

5.28 Check the engine mounts

X

X

5.29 Oil change in drive axle

min. 1x per year

X

X

5.30 Oil change in wheel hubs

min. 1x per year

X

X

5.31 Oil change, axle reduction gear

min. 1x per year

X

X

5.32 Oil change in drum drive reduction gear

min. 1x per year

X

X

5.33 Oil change vibration bearings**

see foot note, min. 1 X x per year

X

5.34 Retighten the fastening of the axle on the frame

X

5.35 Tighten the wheel nuts

X

5.36 Check the ROPS 5.37 Clean the oil bath air filter

X X

min. 1x per year

X

5.38 Change hydraulic oil and breather fil- at least every 2 years ter***

X

5.39 Change the hydraulic oil filter****


X

5.40 Change the coolant


X

5.41 Check the injection valves

BW 226 DH-4/PDH-4

X

BOMAG

65

5.42 Service the combustion air filter

min. 1x per year, safety cartridge at least every 2 years

as required





Remark


Maintenance work


No.


Maintenance

X

5.43 Adjust the scrapers

X

5.44 Adjust the parking brake

X

5.45 Change the tires

X

5.46 Change the fresh air filter in the cabin

X

5.47 Tightening torques

X

5.48 Engine conservation

X

* Oil change intervals depend on quality of oil and fuel (sulphur content) ** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h. *** Also in case of repair in the hydraulic system. **** Also in case of repair in the hydraulic system.

66

BOMAG

BW 226 DH-4/PDH-4

Service Training Deutz diesel engine The single drum rollers of product range BW 216 / 219 / 226 DH/PDH-4 are powered by a Deutz diesel engine of series BF6M 2012 COM2 with electronic engine management (EMR). The engine cooling system uses an external radiator. The cooling fan is mounted to the engine fan block and is directly driven by the engine. These engines are characterized by the following positive 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 216 / 219 / 226 DH / PDH -4

-D1-

Service Training Service side 3

4

2

5

1

6

14

7

13

12

11

10

9

8

Fig. 1: Service side BFM 2012 1

Oil filler neck

8

Fuel pump

2

Valve, boost fuel supply

9

Engine mounting

3

Engine solenoid

10

Fuel filter

4

Oil pressure switch

11

Lubrication oil filter

5

Cooling air blower

12

Oil sump

6

Coolant pump

13

Dipstick

7

V-belt pulley

14

Steering/charge pump

BW 216 / 219 / 226 DH / PDH -4

-D2-

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 216 / 219 / 226 DH / PDH -4

-D3-

Service Training Lubrication oil circuit 3

4

2

5

6

9

7

8

22

21

1

10

11

20

12

13

19 18

14

17

15

16

Fig. 3: Lubrication oil circuit 1

Oil sump

12 Piston cooling nozzle

2

Return flow turbo charger to crankcase

13 Camshaft bearing

3

Turbo charger

14 Main oil channel

4

Oil line to turbo charger

15 Lubrication oil cooler

5

Line to mass balance wheel (2 x)

16 Lubrication oil pump

6

Oil pressure sensor

17 Pressure relief valve

7

Valve with pulse lubrication

18 Leak oil return line

8

Push rod, oil supply to rocker arms

19 Lubrication oil filter

9

Line to spray nozzles

20 Suction line

10 Rocker arm

21 Crankshaft bearing

11 Return flow to oil sump

22 Conrod bearing

BW 216 / 219 / 226 DH / PDH -4

-D4-

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 cooling

7

Cylinder head cooling

8

Ventilation connection between cylinder head and heat exchanger

BW 216 / 219 / 226 DH / PDH -4

-D5-

Service Training FuelFuel system 7

6

4

1a

1b

1c

Fuel tank

1d

Fig. 5: Fuel system BW 216 / 219 / 226 DH / PDH -4

-D6-

Service Training Legend Fig. 6: 1a

Fuel lift pump

1b

Fuel pre-filter

1c

Water separator

1d)

Water proportion sensor

2

Feed to fuel lift pump

3

Fuel lift pump

4

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

5

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 line

11

Pressure retaining valve - 5 bar

12

Return flow to tank

BW 216 / 219 / 226 DH / PDH -4

-D7-

Service Training Fuel pre-filter with water separator 1 2

3

4

5

6

Fig. 6: Fuel pre-filter with water separator 1)

Lift pump

2)

Vent valve

3

Filter element

4)

Water and dirt collecting bowl

5

Drain valve

6

Electric connection for water level sensor

The fuel pre-filter / water separator consists mainly of: • the dirt / water sediment bowl with water level warning sensor • and the filter element

BW 216 / 219 / 226 DH / PDH -4

-D8-

Service Training Function:

The fuel lift pump draws the fuel through both filters. 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 in the dashboard lights up.

Draining off water or fuel : 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.

Draining off larger dirt particles or sludge: • Unscrew the water separator housing

Bleed the system by operating the fuel lift 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 original 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 216 / 219 / 226 DH / PDH -4

-D9-

Service Training Electronic engine control EMR II The Deutz engines in single drum rollers DH-4 are equipped with an electronic engine speed control (Deutz EMR II). The most important benefits of this system are: • shorter response times compared with mechanically controlled engines, i.e. the response times are significantly better. This improvement is achieved without increasing the acceleration fumes or the fuel consumption. • electronic idle speed control enabling a higher starting torque • no mechanical throttle control (light moving, maintenance free, less susceptible for faults) • in comparison to the first version of the Deutz-EMR the essential advantage is that an EMR-fault is directly displayed in form of a fault code. The EMR-injection system is based on the approved Deutz-injection system of series 2012 with individual injection pumps for each cylinder. However, the fuel quantity per stroke is not regulated mechanically via a throttle cable, but is controlled by the EMR II-system by means of an electromagnetic actuator acting on the governor rod.

The essential components of the EMR II-system for engine speed control are: • EMR II control unit [A48] at the left under the operator's stand. • The control unit processes the input signals from: •

displacement measuring system in the EMR actuator [Y 137] (current position of the injection pump control rod)

•

the coolant temperature sensor [B 113] on the cylinder head

• the rotary speed sensor [B 114] on the camshaft • the engine oil pressure sensor [B 88] on the oil filter housing • the charge air pressure and charge air temperature sensor [B 115] connected to the intake manifold • The cold start device (heating flange) is additionally triggered by the EMR II in dependence on the coolant temperature

BW 216 / 219 / 226 DH / PDH -4

- D 10 -

Service Training These input signals are processed, sent as output signals to the EMR actuator Y 137 and there they are converted to the required fuel quantity per stroke. In ECO-mode the travel lever determines the engine speed setpoint. The control unit compares this nominal value with the actual speed value detected by the engine speed sensor. If the nominal value corresponds with the actual value, the signal to the EMR actuator will remain unchanged. However, if the nominal speed deviates from the actual speed (e.g. when changing the travel lever position or under higher load), the control unit uses the current turbo charger pressure and the coolant temperature to determine the necessary change in fuel quantity to achieve the nominal speed value. The control unit then sends a signal to the EMR actuator to change the control rod position and thereby the engine speed. This automatic speed adaptation only takes place in ECO-mode the first DH-4 machines this was called "AUTO")

(in

Throttle control lever

BW 216 / 219 / 226 DH / PDH -4

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Service Training Individual EMR II components Control unit EMR II The EMR control unit is located above the central electrics under the operator's stand in the access area. This is the computer unit of the EMR and it processes the input signals from the sensors to output signals for the EMR actuator (governor rod).

1

2

3

Pos.

Designation

1 2 3

Control unit EMR II Plug, engine side Plug, vehicle side

BW 216 / 219 / 226 DH / PDH -4

Pos. in wiring diagram A 48 X 31 X 30

Deutz designation EMR II

Measuring values

- D 12 -

BW 216 / 219 / 226 DH / PDH -4

Y 137

EMR-actuator

Pressure

B 113

B 114

B 88

Coolant Flywheel Engine oil

Temperature Speed

B 115

Charge air

B 130

Crankshaft

Pressure and temp.

EMR central plug engine [X57]

EMR II

Speed

Plug on vehicle [X30]

EMR engine wiring harness

Pin assignment complies with X 31

Connecting cable Engine wiring harness Control unit EMR II

Control unit

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

15 Pin assignment X 31

Plug, engine side [X31]

Service Training

Connection overview EMR sensors/actuators on engine

- D 13 -

Service Training Plug assignment X 31 (engine plug on EMR control unit)

BW 216 / 219 / 226 DH / PDH -4

Pos.

Deutz designation

Description

1 2 3 4 5 6 7 8

Spare

9

Input: Analogue 7

10

GND

11

Input: Speed 2

12

GND

13

Input: Speed 1

14

STG -

15

STG +

16 17

Screen RF -

18

RF REF

19

RF MESS

20

GND

21

Input: Analogue 4

22

+5V REF

23

GND

24

Input: Analogue 2

25

+ 5V LDA

Spare not used Switching output heating flange (ground!) empty Charge air temperature empty empty Reference potential for signal pin 9 coolant temperature sensor B 113 Analogue input coolant temperature sensor B 113 Reference potential Pin 11 crankshaft speed sensor B 130 Digital input rotary speed sensor crankshaft B 130 Reference potential Pin 13 camshaft speed sensor B 114 Digital input rotary speed sensor camshaft B 114 PWM-output, signal for EMR-actuator coil Y 137 PWM-output, signal for EMR-actuator coil Y 137 not used common connection for reference and measuring coil EMR-actuator Y 137 analogue input, measuring signal of reference coil of EMR-actuator Y 137 analogue input, measuring signal of measuring coil of EMR-actuator Y 137 Reference potential for signal on pin 21, oil pressure sensor B 88 Analogue input, sensor signal oil pressure sensor B 88 + 5 V reference voltage for signal on Pin 21, oil pressure sensor S 88 Reference potential for signal on pin 24, boost pressure sensor B 115 Analogue input, sensor signal boost pressure B 115 + 5 V reference voltage for signal on pin 24 (max. 15mA), boost pressure sensor B 115

Output: Digital 4 Input temp. (option)

GND

- D 14 -

Service Training Plug assignment X 30 (vehicle plug on EMR control unit)

Pos.

Designation

Description

1 2 3 4 5

U Batt -

Vehicle ground through X1:182

Output: Digital/ PWM 1 Spare NC NC NC L-line K-line CAN high CAN low U Batt +

empty

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Output: Digital/ PWM/Frequency Ground Input: digital/PWM 1 Input: digital / analogue Input: digital / analogue Input: digital/PWM 2

Spare empty empty empty to diagnostics plug EMR, X32:L to diagnostics plug EMR, X32:K X1:180, CAN2X1:181, CAN2+ Power supply, vehicle voltage (ignition on) from relay K11, X1:179 empty empty empty empty empty empty

22 23 24 25

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Service Training EMR actuator Y 137 The EMR actuator is directly connected with the governor rod of the injection pump and moves this rod by being excited by the signal currents from the EMR control unit. At the same time the actual position of the actuator is fed back to the EMR control unit. This component is generally a proportional magnet with integrated path measuring system. In case of a fault in the path measuring system the engine is shut down and a fault code displayed.

Pin assignment EMR-actua view on actuator (plug pins mirror inverted)

8

2 Stg+

7

3 RF -

1 Stg+

9

6

4 RFMeß

5 RF Ref

Pin assignment of EMR-actuator looking towards actuator (plug pins mirror inverted) EMR-actuator Pos.

Designation

Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7

Signal input actuator coil Signal input actuator coil common connection for measuring and reference coil Measuring signals measuring coil Measuring signals reference coil not used not used

8 9

EMR-plug EMR-actuator

BW 216 / 219 / 226 DH / PDH -4

Pos. in wiring diagram

Deutz designation

Measuring values

STG STG + RF RF MESS RF REF

X 57 Y 137

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Service Training Temperature sensor B 113 The EMR coolant temperature sensor is mounted to the flywheel end of the engine. is the bottom sensor.

The EMR sensor

The coolant temperature influences the calculated injection quantity of the EMR. The EMR sensor value is not only used for the EMR itself, but also for the high coolant temperature control light in the display and for the heating flange control. In case of a too high temperature the EMR shuts down the engine and a fault code is displayed. In case of a sensor failure the display shows a fault code.

1

Pos.

Designation


1

EMR temperature sensor for coolant

B 113

BW 216 / 219 / 226 DH / PDH -4

Deutz designation

Measuring values Switching point 110°C

- D 17 -

Service Training Speed sensors: Camshaft B114 and crankshaft B 130 The sensors for camshaft and crankshaft speeds are installed in the side of the engine block. These sensors deliver the actual engine speed value for the EMR control unit. If the engine speed is too high (pushing operation) the governor rod is returned to zero position, until the speed has dropped to the permissible range. In case of a sensor failure the engine is shut down and the fault code appears in the display. With a missing rotary speed signal from standstill the engine will not start, however, no fault message will be displayed, because the EMR assumes that the engine is at standstill and does therefore not release any fuel. The EMR speed sensor has a fixed stop and does not need to be adjusted after installation.

1 1

22

Pos.

Designation


1

EMR speed sensor camshaft SAE housing EMR speed sensor crankshaft SAE housing

B 114

2

BW 216 / 219 / 226 DH / PDH -4

Deutz designation

Measuring values

B 130

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Service Training Engine oil pressure sensor B88 The engine oil pressure sensor is mounted on the engine oil filter housing. The oil pressure is permanently monitored by the EMR. With a too low engine oil pressure the display shows a fault code. • In case of a too low pressure the EMR shuts down the engine and a fault code is displayed. • In case of a sensor cable defect or a broken sensor cable the engine keeps on running and the display shows a fault code. .

Pin 3 (+ 5 V from EMR) Pin 2 (Signal) Pin 1 (AGND)

1 Ventilation

Ventilation

Fig. 7Oil pressure sensor Pos.

Designation


1

EMR oil pressure sensor

B 88

BW 216 / 219 / 226 DH / PDH -4

Deutz designation

Measuring values

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Service Training Charge air pressure and temperature sensor B 115

The Deutz engine BF4M 2012C (EMR) is fitted with a combination sensor for charge air pressure and charge air temperature. This sensor measures the pressure and temperature in the intake manifold. The sensor itself is located on the intake manifold. Charge air pressure and charge air temperature inform the EMR about the actual load state of the engine.

1 1

1

Pos.

Designation


1

EMR charge air pressure and temperature sensor

B 115

BW 216 / 219 / 226 DH / PDH -4

Deutz designation

Measuring values

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Service Training Heating flange R 19 Instead of glow plugs this engine is fitted with a heating flange before the intake air manifold, which heats up the passing air with resistance heated wires when the engine is cold. This system is electrically supplied via high current relay K14, located to the left next to the engine. This high current relay is triggered by the EMR-control unit (ground triggering) in dependence on the coolant temperature.

1 2

2 1

1

2

Pos.

Designation


1 2

Heating flange High current relay

R 19 K14

BW 216 / 219 / 226 DH / PDH -4

Deutz designation

Measuring values

- D 21 -

Service Training Trouble shooting The display shows the fault codes

For a detailed description of how to read out fault codes and the display please refer to the page on "Electrics" (Service Training Electrics)

All electric faults are mainly shown by the display

BW 216 / 219 / 226 DH / PDH -4

- D 22 -

Service Training WZ-4 DH Version and higher

2 Selected Fault Reactions of the ESX Control Reaktion

Symbol in fault message display

Signal

Warning

Warning

Engine stop

Code output without buzzer

Code output with buzzer


5100 5112

5101 5112

Engine oil pressure (from EMR)

1)

Coolant temperature (from EMR)

5100 5116 1)

Coolant level

Engine air filter

2)

after 10s

5101 5116 2)

after 15s

5024

5025

after 5s

after 10s

5026

5027

after 5s

after 2min. 3)

Charge control

Preheating of engine

Brake

ASC

Various error causes and reaction times. See error codes Hydraulic oil filter

Water separator in fuel filter

5502

5503

after 5s

after 2min.

5028

5029

after 5s

after 2min.

Ant-theft warning display (Option)

Seat contact (Option) Air conditioning fault (Option) 1)

After reaching the warning limit!

Version/Status: V2.07 / 24.06.05 Author: Seis / TE Dateiname:

p:\schulung\wz-4\elektrik\esx\englisch\schulung elektrik wz4 v2_07_gb.doc

3)

Shut-down currently deactivated via parameter

Page 6 of 67

Service Training Possible diagnostics with SERDIA with fault code 5140: a fault diagnose is only possible via SERDIA SERDIA is a software program from Deutz which can be used in connection with a laptop computer to perform more detailed fault analyses, especially reading out of the error log. This displays information on • Fault location (e.g. ’sensor’, ’coolant temperature sensor’) • Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’) • Environmental data / operating data (speed and operating hours at the time of the last fault occurrence) • Number of fault locations • Frequency of fault • Fault status (active – fault present / passive- fault no longer present) Fault messages for non-present / rectified faults can be deleted with SERDIA.

Further display possibilities: • Function test: With the engine shut down the control outputs and the travel of the governor rod can be activated. • Assignment of inputs/outputs Display of the current input/output assignment of the EMR-control • Representation of measuring values: There are a lot of measuring values available which can be used if no EMR II fault is present (starting performance, engine sawing, lack of power). •

Operation of SERDIA is described in a separate operation manual.

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Service Training Connection of SERDIA (in electric installation box) For this purpose the PC or Laptop is connected to the diagnostic interface with a special interface cable. The EMR diagnostics plug is located in the electric installation box of the machine.

EMR Replacement of system components • Replacement of the EMR II-control unit: Each control unit is clearly designated to the engine, in accordance with the respective application. In case of a replacement the control unit therefore needs to be completed with the engine specific data set. When ordering a new control unit you must not only specify the part-number, but also the engine serial number (see sticker on EMR-control unit). Note: The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue. • Replacement of the EMR actuator (Y137) On engines of types 1013 and 2012 the actuators can be replaced without any additional programming of the control unit. • Replacement of other EMR-components All other EMR-components (sensors etc.) must not be repaired, but should only be replaced if they are faulty. Programming of the control unit is not required

BW 216 / 219 / 226 DH / PDH -4

- D 25 -

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 valve: = 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. 9: 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. 10: Crankshaft position 2 • Turn the crankshaft one full turn (360°) further. Check and adjust the valve clearance by following the black marking in the adjustment schematics. BW 216 / 219 / 226 DH / PDH -4

- D 26 -

Service Training plug-in injection pump Deutz diesel engines of product range 2012 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

12 mm

•

Diameter

9 mm

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 The constant volume relief is 50 mm³.

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 the start of delivery is adjusted without tolerance. The start of delivery is entered 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 216 / 219 / 226 DH / PDH -4

- D 28 -

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 on engines of series 2012 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“ it 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.

BW 216 / 219 / 226 DH / PDH -4

- D 29 -

Service Training Fig. 11: 2. EMR engines are not fitted with a lift solenoid !

Fig. 12: 3. Insert the pressing device, WILBÄR No. 100 830 carefully into the groove in the governor rod and tighten.

Fig. 13: 4. Turn the knurled fastening screw to press the governor rod to stop position. Note: Tighten the knurled fastening screw by hand.

Fig. 14:

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- D 30 -

Service Training 5. Set the cylinder of the injection pump to be replaced to ignition top dead centre (valves overlapping). Then turn the crankshaft approx. 120° against the sense of rotation. Note: View on flywheel

Fig. 15: 6. Remove injection line and injection pump.

Fig. 16: 7. Take the compensation shim carefully out with the rod magnet.

Fig. 17: Determine the thickness of the new compensation shim:

BW 216 / 219 / 226 DH / PDH -4

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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. 18: Injection pump code BFM 2012

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

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- D 32 -

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. 19: Injection pump code table BFM 2012 Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from table 1.

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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 position - 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

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- D 34 -

Service Training

A=XXX

Fig. 21: Individual injection pump

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- D 35 -

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 Lo.

Lo A = XX

A/100

Fig. 22: Presentation of measurement „A“

• Lo = 117,5 mm - BFM 2012

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- D 36 -

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.

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Service Training Theoretical thickness „Ts“

Compensation shim thickness „Ss“ (mm)

(mm)

Theoretical thickness „Ts“

Compensation shim thickness „Ss“ (mm)

(mm)

0.95 - 1.049

1.0

2.45 - 2.549

2.5

1.05 - 1.149

1.1

2.55 - 2.649

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: Shims 2012 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 - (Lo + A/100) [mm] The real compensation shim thickness „Ss“ is determined with the help of table 2.

BW 216 / 219 / 226 DH / PDH -4

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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 = 2.955 mm see also table 1 Ts = 3,0 mm

8. P?lace the new calculated compensation shim on the roller plunger.

Fig. 24:

BW 216 / 219 / 226 DH / PDH -4

- D 39 -

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

Fig. 27:

BW 216 / 219 / 226 DH / PDH -4

- D 40 -

Service Training 12. Slightly oil the screws and tighten them evenly with 5Nm.

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

Fig. 29: 14. Carefully turn the injection pump with and open end spanner in anti-clockwise direction against the noticeable stop

Fig. 30:

BW 216 / 219 / 226 DH / PDH -4

- D 41 -

Service Training 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: If necessary replace the gasket.

Tools BW 216 / 219 / 226 DH / PDH -4

- D 42 -

Service Training 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 216 / 219 / 226 DH / PDH -4

100 830 (Wilbär)

- D 43 -

Service Training Electrical components and measuring points on the engine

2 1 1

2

Fig. 34: Auxiliary power take-off side

Pos.

Designation


1 2

EMR - central plug Hand pump - fuel pre-cleaner

X 57

BW 216 / 219 / 226 DH / PDH -4

Pos. in hydraulic diagram

Measuring values

- D 44 -

Service Training

1 1

Fig. 35: Diesel engine starter side

Pos.

Designation


1

Air filter vacuum switch

B 03

BW 216 / 219 / 226 DH / PDH -4


Measuring values

50 mbar

- D 45 -

Service Training

1

Pos.

Designation


1

Coolant level sensor

B 55

BW 216 / 219 / 226 DH / PDH -4


Measuring values

- D 46 -

Service Training

Charging from Charge pressure filter

25

Travel system

BW 216 / 219 / 226 DH / PDH-4 -E1-

Service Training Pos.

Designation

10 10

BW 216 travel pump 90R075 EP BW 219 and 226 travel pump 90R100 EP Drum drive motor electr.-prop. 51C110 Axle drive motor, electr.-prop. 51D110 Axle BW 216 and 219 reduction gear CR 51 BW 226 reduction gear 715 C 3B

12 13 14 25 25



Measuring values

10 10 12 13 14 25 25

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 reduction gear; • axle drive motor, • two charge pumps, • 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 ∆p = 400 bar between low and high pressure sides. The flushing valves in axle drive and drum drive motors flush 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 also flows through the hydraulic oil filter and is then available for the closed circuit charging system. The charge circuit also provides the oil for the control functions in the closed circuits for travel and vibration drive and to release the parking brakes. Both travel motors and the travel and vibration pumps are electrically proportionately controlled.

BW 216 / 219 / 226 DH / PDH-4 -E2-

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.

3

1

4

2

Charging

Pos.

Designation

1 1

BW 216 travel pump 90R075 EP BW 219 and 226 travel pump 90R100 EP Charge pressure relief valve Control, electr.-prop. Multi-function valve

2 3 4



Measuring values

10 10

75ccm 100cm

10 10 10

26 bar 400 bar

BW 216 / 219 / 226 DH / PDH-4 -E3-

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. 1: Travel pump 1

Electric prop. control

5

Cylinder block

2

Drive shaft

6

Valve plate

3

Swash plate bearing

7

Control piston

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.

BW 216 / 219 / 226 DH / PDH-4 -E4-

Service Training Cross-sectional view of travel pump

2 4 5

1

3 6 7

10

9 8

11 Fig. 2: Cross-sectional view of travel pump 1

Retainer for swash plate

7

Swash plate bearing

2

Sliding block

8

Swash plate guide

3

Control piston

9

Swash plate

4

Servo arm

10

Swashing lever

5

Servo valve

6

Feedback device

BW 216 / 219 / 226 DH / PDH-4 -E5-

Service Training View of the rotating group 1 2

5

4

3

Fig. 3: Travel pump, view of the rotating group 1

Working pistons

2

Slipper pad

3

Pre-tensioning spring

4

Cylinder block

5

Drive shaft

BW 216 / 219 / 226 DH / PDH-4 -E6-

Service Training Description of function

2

4

3

5

6

1

8

6

7

Fig. 4: Function of travel pump 1

Drive shaft

5

Cylinder block

2

Drive shaft bearing

6

Multi-function valves

3

Swash plate

7

Charge pump (only in vibration pump)

4

Pistons with slipper pads

8

Valve plate

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 rotation 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 216 / 219 / 226 DH / PDH-4 -E7-

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 216 / 219 / 226 DH / PDH-4 -E8-

Service Training Travel and vibration pump as tandem pump

BW 216 / 219 / 226 DH / PDH-4 -E9-

Service Training Sauer-Danfoss tandem pump general, connections and adjustment points

38

Thermostat housing

Fig. 5: Connections and adjustment points

BW 216 / 219 / 226 DH / PDH-4 - E 10 -

Service Training 1

Rear vibration pump connecting plate, turned by 90° !!!

2

Proportional solenoid (vibration pump)

3

Multi-function valve 400 bar (charging and pressure limitation), travel system

4

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

5

Multi-function valve 400 bar (charging and pressure limitation), travel system

6

Pump flange

7

Port L, leak oil to vibration pump

8

Electr.-prop. control (travel pump)

9

Pressure test port, pilot pressure

10

High pressure port B, high pressure reverse

11

Charge pressure relief valve, 26 bar

12

not on EP-pumps

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, (connection to vibration pump)

20

not on EP-pumps

21

Filter block for charge circuit

22

Multi-function valve 400 bar (charging and pressure limitation), vibration high frequency

23

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

24

Multi-function valve 400 bar (charging and pressure limitation), vibration low frequency

25

Charge pressure relief valve, vibration pump (fixed setting 40 bar)

26

Filter block for charge circuit

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

Thermostat housing: 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

BW 216 / 219 / 226 DH / PDH-4 - E 11 -

Service Training servo control The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal from the proportional valve 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 input signal from the proportional valve. A mechanical feedback device ensures the fixed correlation between the proportional valve input signal and the swashing angle of the swash plate (displacement of pump). Servo cylinder

Control piston

Sliding block

Servo arm

Control piston in pump

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 pressure in the charge circuit drops below a certain value.

BW 216 / 219 / 226 DH / PDH-4 - E 12 -

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. 6: Multi-function valves 1

to the control

6

Drive shaft

2

Multi-function valve

7

to the control piston

3

Charge pump

8

to the control piston

4

Charge pressure relief valve

A

Port A

5

Pilot pressure relief valve

B

Port B

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 216 / 219 / 226 DH / PDH-4 - E 13 -

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.

3

2

4

5

1

6 9

7 8

10 11

Fig. 7: Multi-function valve, details 1

Reducing fitting

7

Check valve

2

Hydraulic by-pass piston

8

Pressure limitation

3

Spring plate

9

Spring

4

Spring

10

By-pass housing

5

High pressure relief valve

10

By-pass sleeve

6

Valve seat

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 216 / 219 / 226 DH / PDH-4 - E 14 -

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 (26 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 216 / 219 / 226 DH / PDH-4 - E 15 -

Service Training Axle drive motor The axle drive motor is a swash plate controlled Sauer-Danfoss axial piston motor of series 51 D 110 with an electrical proportional control for variable displacement. HD-Pump

Charge pressure

Brake valve

6

5 4 2

Leak oil 3

HD-Pump

Fig. 1Hydraulic diagram, axle drive motor 1

Motor drive

2

Control piston

3

Proportional control with proportional solenoid

4

Flushing valve with flushing pressure limitation valve

5

Axle with brake

6)

Rotary speed sensor (flange sensor)

BW 216 / 219 / 226 DH / PDH-4 - E 16 -

Service Training .

5

8

7

6 9

1

11 4

2

10

3 Fig. 2: Axle drive motor, 1

Control piston

7 Cylinder block

2

Flushing valve with flushing limitation valve8 Universal joint

3

Proportional control

9 Output shaft

4

Spindle with ball

10 Output shaft bearing

5

Qmin-screw

11 Working piston

6

Valve plate

BW 216 / 219 / 226 DH / PDH-4 - E 17 -

Service Training 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 roller 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.

Control The motor is electric-proportionally controlled. 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 displacement, high speed and low torque. The displacement is changed by a control piston, which is tightly connected with the valve segment.

The front travel motor (drum drive) also is an axial travel motor from Sauer-Danfoss.

51C110

BW 216 / 219 / 226 DH / PDH-4 - E 18 -

Service Training Speed sensor in form of a flange sensor The Sauer-Danfoss travel motors of series 51 with electrical proportional control have a flange sensor for speed and travel direction. Due to the simple fastening of the flange sensor time-consuming adjustment work is no longer necessary. The sensor is plugged in against the stop and fastened with a socket head cap screw.

BW 216 / 219 / 226 DH / PDH-4 - E 19 -

Service Training Excerpt from the electric wiring diagram: Page 004, rear travel motor B60 and front travel motor B59

BW 216 / 219 / 226 DH / PDH-4 - E 20 -

Service Training Flushing valve 2

1 Fig. 8Cross-section of flushing valve 1 Flushing spool with flushing quantities from 10 to 16 l/min 2 Flushing quantity limitation valve (16 bar ) 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 216 / 219 / 226 DH / PDH-4 - E 21 -

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. 9: Manual releasing of rear axle brakes • Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm. • Turn the brake releasing screw (2) in against the stop. • To release the brake tighten the screw for max. 1 complete turn. Attention! Turn the screws on both sides in uniformly (alternately by 1/4 of a turn) • Repeat this procedure on the opposite side of the axle.

BW 216 / 219 / 226 DH / PDH-4 - E 22 -

Service Training BW 216 and 219 DH-4

Drum drive motor 51C110 with reduction gear CR 51 The drums on the DH-4 and PDH-4 versions are driven by a Sauer axial piston motor 51C110. This motor is almost identical with the rear axle motor. Another detailed description at this point is therefore not necessary. The motor is a plug-type motor plugged into a reduction gear CR51. 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 216 / 219 / 226 DH / PDH-4 - E 23 -

Service Training Reduction gear CR 51 3

6

4 5

7

2

8

9

10 11

1

7

12 13

16

15

14

1

Travel motor

9

Planet gear 2nd stage

2

Brake releasing device

10

Planet gear 3rd stage

3

Fastening on frame

11

End cover

4

Mechanical seal

12

Planet shaft

5

Oil filler screw

13

Sun gear

6

Housing and fastening on drum

14

Brake discs

7

Tapered roller bearing

15

Brake piston

8

Planet gear 1st stage

16

Brake spring

BW 216 / 219 / 226 DH / PDH-4 - E 24 -

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.

BW 216 / 219 / 226 DH / PDH-4 - E 25 -

Service Training Manual drum drive brake release (in the reduction gear) Brake releasing device in operation position

Brake releasing device in position “brake manually released”

For manual brake release both screws on the drum drive reduction gear (marked with arrow) must be turned in uniformly, until the drum is able to rotate freely.

BW 216 / 219 / 226 DH / PDH-4 - E 26 -

Service Training BW 226 DH-4 Drum drive motor 51C110 with reduction gear 715 C 3B

2

5

4

7

6

8 9

1

3 10 13

11 12

1

Travel motor

8

Planet gear 2nd stage

2

Brake releasing device

9

Planet gear 3rd stage

3

Oil drain plug

10

Brake spring

4

Mechanical seal

11

Sun gear

5

Oil filler screw

12

Brake discs

6

Planet gear 1st stage

13

Brake piston

7

Roller bearing

This gear has no manual brake releasing device

BW 216 / 219 / 226 DH / PDH-4 - E 27 -

Service Training Travel circuit with drum drive motor 51C110 and gear

2

9 Travel lever forward

1

3 8

4 7

5

6 a Tr

High pressure Low pressure Charge pressure Leak oil

l ve

ec dir

n ti o

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

Travel circuit 51 C 110 and CR 51 or 715 C 3B

BW 216 / 219 / 226 DH / PDH-4 - E 28 -

Service Training Brake control BW 226 (with Sauer motor 51C110 and 715 C 3B)

Brake valve

Charge pressure Brake releasing pressure Leak oil

BW 216 / 219 / 226 DH / PDH-4 - E 29 -

Service Training Test and adjustment points, travel system Charge pressure filter and travel pump

2 2 3 3 1 5 4

4

5

Pos.

Designation

1 2

charge oil filter Charge oil filter pressure differential switch Pressure test port, charge pressure Travel pump - pressure test port Travel pressure forward Test port travel pump forward A

3 4 5



Measuring values

16 ∆p 3,5 bar

B21 Page 005 MA 10 / A / MD

26 bar max. 426 bar

10 / A

BW 216 / 219 / 226 DH / PDH-4 - E 30 -

Service Training Travel pump

2 2 3

3 1

Pos.

Designation

1 2

Travel pump - pressure test port Travel pressure reverse Prop. solenoid travel forward

3

Prop. solenoid travel reverse

1


Y17 / X16 Page 004 Y16 / X15 Page 004


Measuring values

10 / B / MC

max.426 bar 12V / 0,4-1,2 A 12V / 0,4-1,2 A

BW 216 / 219 / 226 DH / PDH-4 - E 31 -

Service Training Travel and vibration pump BW 219 and 226 DH-4

2 1

2

1

Pos.

Designation

1 2

Test port travel pump reverse B Pressure test port, charge pressure



10 / B MA

Measuring values

26+/-3 bar

BW 216 / 219 / 226 DH / PDH-4 - E 32 -

Service Training Travel and vibration pump BW 216 DH-4

1 2 2

1

Pos.

Designation

1 2

Test port travel pump reverse B Pressure test port, charge pressure



10 / B MA

Measuring values

26 bar

BW 216 / 219 / 226 DH / PDH-4 - E 33 -

Service Training Travel motor (drum drive)

4 3 1

5

2

6 Pos.

Designation

1 2 3 4 5 6

Pressure travel forward Pressure travel reverse Port X Prop. solenoid Speed flange sensor PPU Brake port in travel gear



12 - A 12 - B X1 Y30 Page 004 B59 Page 004

Measuring values

approx. 26bar 12V / 0,4-1,2 A Brake closed without pressure

BW 216 / 219 / 226 DH / PDH-4 - E 34 -

Service Training Travel motor (axle drive)

5

4

6 3 2 1 Pos.

Designation


1 2 3 4

Prop. solenoid Port X Travel pressure sensor High pressure travel pump forward and further to drum drive motor High pressure travel pump reverse and further to drum drive motor Speed sensor (flange sensor)

Y 31 Page 004

5 6


X1 B 112 Page 004

Measuring values

12V / 0,4-1,2 A approx. 26bar 0 - 426 bar

13 - B 13 - A B 60 Page 004

BW 216 / 219 / 226 DH / PDH-4 - E 35 -

Service Training Speed sensor and travel pressure sensor

1 2 1 3

2 1

NEW : Speed flange sensors in both travel motors and a pressure sensor at the front left hand side under the operator's platform!

Pos.

Designation


1

Speed flange sensor PPU axle motor Speed flange sensor PPU drum drive motor Travel pressure sensor in frame, front left under operator's platform

B60 Page 004

1 2


travel

Measuring values

B59 Page 004 B112 Page 004

0 - 426 bar

BW 216 / 219 / 226 DH / PDH-4 - E 36 -

Service Training Brake valve BW 216 DH-4

5

2 1 3

4

3

1 1

Pos.

Designation



Measuring values

1

Brake valve

Y 04 Page 006

08

0V closed open

12V

BW 216 / 219 / 226 DH / PDH-4 - E 37 -

Service Training Brake valve BW 219 DH-4

5

2 1 3

4

11 3 1

Pos.

Designation



Measuring values

1

Brake valve

Y 04 Page 006

08

0V closed open

12V

BW 216 / 219 / 226 DH / PDH-4 - E 38 -

Service Training Brake valve with manual pump for emergency brake release BW 226 DH-4

5 2 2 1 3

4

3

1

1

1 5 4

3

Pos.

Designation



Measuring values

1

Brake valve

Y 04 Page 006

08

0V closed open

2 3 4 5

Hand pump Emergency release button Pressure test port, brake pressure PRV

17 17 17 17

12V

26 bar 38 bar

BW 216 / 219 / 226 DH / PDH-4 - E 39 -

Service Training Travel lever

5

4

Multi-function travel lever

For a detailed description of the travel lever buttons please refer to the page on "Electrics" (Service Training Electrics)

BW 216 / 219 / 226 DH / PDH-4 - E 40 -




The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past.

BW 216 / 219 / 226 DH / PDH-4 - E 41 -

Service Training Procedure: The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.

SYMPTOME

FEHLERSUCHE FAHRANTRIEB BW 216/219/226 DH/PDH-4

Maschine fährt nicht (vor und zurück) Maschine fährt nur in eine Fahrtrichtung Maschine fährt mit Fahrhebel in Stellung 'Neutral' Max.Fahrgeschwindigkeit wird nicht erreicht Hydrauliköl wird zu heiss

The number specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

MÖGLICHE URSACHEN Bremsventil (elektrisch/mechanisch/hydraulisch) Bremse Achse/Bandagenmotor (mechanisch/hydraulisch) Fahrpropverstellung /defekt/Verkabelung Speisepumpe / Speisedruckbegrenzungsventil(e) verschmutzt/defekt Pumpenansteuerung (Servoverstellung) Druckabschneidung/ Hochdruckbegrenzung Fahrpumpe verschmutzt/verstellt/defekt Fahrhebel Nullage Fahrpumpe Fahrpumpe(n) defekt Stellventil Fahrmotoren (elektrisch / mechanisch / hydraulisch) Spülventil Fahrmotoren hängt Fahrmotor(en) defekt Hydraulikölkühler verschmutzt (intern/extern) Thermostat (Hydraulik) verschmutzt/verklemmt/defekt Kupplung Dieselmotor-Pumpe Dieselmotor Drehzahl-Flanschsensoren im Fahrmotor (Verkabelung)

1 2

2 3 1

2

3

2 1 2 3 3 2

3 3 1 2 3 3 3 2 1 2

3 3 3

3 1 2

2 1 1

1 2

BW 216 / 219 / 226 DH / PDH-4 - E 42 -

Hydraulic oil overheats

Max. travel speed is not reached

Machine travels with travel lever in 'Neutral'

Machine moves to one direction only

SYMPTOMS

Machine does not move (forward and reverse)

TROUBLE SHOOTING TRAVEL SYSTEM BW 216/219/226 DH/PDH-4

POSSIBLE CAUSES Brake valve (eletrical/mechanical/hydraulical) Brake axle/drum drive motor (mechanical/hydraulical) Proportional solenoid travel system /defective/wiring Charge pump / charge pressure relief valve(s) dirty/defective Pump control (servo control) Pressure override/high pressure limitation travel pump dirty/deadjusted/defective Travel lever Travel pump neutral position Travel pump(s) defective Travel motor control valve (electrical / mechanical / hydraulical) Flushing valve for travel motors stuck Travel motor(s) defective Hydraulic oil cooler soiled (internally/externally) Thermostat (hydraulics) soiled/jammed/defective Coupling engine - pump Engine Flange-type speed sensors in travel motor (wiring)

1 2

2 3 1

2

3

2 1 2 3 3 2

3 3 1 2 3 3 3 2 1 2

3 3 3

3 1 2

2 1 1

1 2

TROUBLE SHOOTING

Service Training

2

4

3

Vibration

Pos.

Designation

1 2 3

Vibration pump 75 cm³ Integrated charge pump 17 cm³ Multi-function valves with high pressure limitation and boost check valve function Proportional control

4

BW 216 / 219 / 226 DH / PDH -4



11 11 11

Measuring values

400 bar

11

-F1-

Service Training Pos.

Designation

5

Vibration motor with flushing valve



Measuring values

15

The vibration system on these single drum rollers works with different frequencies and tow amplitudes. This enables perfect adaptation of the machine to various types of soil and different applications.

The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit. The main components of this circuit are vibration pump, Vibration motor and the pressure resistant hydraulic hoses.

Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the diesel engine. By operation of a proportional valve the pilot oil is guided to one of the control piston sides. This actuates the pump from neutral position to one of the two possible maximum displacement positions. When changing the swashing angle through the neutral position to the opposite side, the flow direction of the oil and the sense of rotation of the vibration motors will change.

Since the engine speed is variable in "Position ECO", the pump displacement must always be proportionately adapted in order to maintain the vibration frequency at a constant level.

The vibration motor output shaft is joined with the exciter shaft in the drum via a Bowex coupling. The rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically suspended drums. The eccentric weights on the vibrator shaft are fitted with additional change-over weights.

BW 216 / 219 / 226 DH / PDH -4

-F2-

Service Training Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights. Basic weight + change-over weight = high amplitude Basic weight - change-over weight = low amplitude

The displacement of the pump may be different to both flow directions. This results in different exciter shaft speeds for the different senses of rotation of the motor. The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.

Sense of rotation of exciter shaft

BW 216 / 219 / 226 DH / PDH -4

-F3-

Service Training Vibration pump The vibration pump is a swash-plate controlled axial piston pump with variable displacement of type 90 R 075 EP from Sauer-Danfoss. The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit.

5

4

2

Pos.

Designation

1 2 3

Vibration pump 75 cm³ Integrated charge pump 17 cm³ Multi-function valves with high pressure limitation and boost check valve function Prop. solenoids servo control Safety valve in charge circuit

4 5 6

BW 216 / 219 / 226 DH / PDH -4

3

6



11 11 11

X 6 and X 7

Measuring values

400 bar

11 11 11

-F4-

Service Training Function

1

2

6

5

4

3

Cross-section of vibration pump 1 Servo piston 2 Working pistons 3 Charge pump 4 Valve plate 5 Roller bearing 6 Swash plate

BW 216 / 219 / 226 DH / PDH -4

-F5-

Service Training 1 2 5

4

3

Cross-section of vibration pump 1 Control 2 Servo piston 3 Friction free swash plate bearing 4 Attachment plate 5 Spool valve

BW 216 / 219 / 226 DH / PDH -4

-F6-

Service Training 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. 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 converts the electric proportional input signal into a load controlling output signal.

The vibration pump has an integrated charge pump, an internal gear pump with a displacement of 17 cm³ per revolution

The vibration pump is equipped with an integrated charge pressure relief valve, which is set to a pressure of 40 bar. This valve only has a safety function in the charge circuit.

Multi-function valve

BW 216 / 219 / 226 DH / PDH -4

-F7-

Service Training 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

1 From the charge pump 2 Closed circuit 3 High pressure relief valve with integrated boost check valve 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. 426 bar (pressure difference between high and low pressure side = 400 bar + charge pressure = 26 bar). The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the closed vibration circuit.

Vibration motor

BW 216 / 219 / 226 DH / PDH -4

-F8-

Service Training The vibration motor is a Bosch-Rexroth axial piston motor of series A2FM with fixed displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits. Vibration motors of the machines: BW 216- A2FM56,

BW 219- A2FM63,

BW 226- A2FM80

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 426 bar by the corresponding high pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a

BW 216 / 219 / 226 DH / PDH -4

-F9-

Service Training 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

1

B

MB

Circuit diagram of vibration motor 1 Vibration motor 2 Flushing valve 3 Flushing pressure relief valve

Flushing valve All vibration motors are fitted with a flanged on flushing valve

BW 216 / 219 / 226 DH / PDH -4

- F 10 -

Service Training The vibration motor is equipped with an integrated flushing valve. This flushing valve is located inside the bolted on connecting block. 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

Flushing valve 1 Flushing spool 2 Flushing pressure relief valve The flushing valve is fitted with a downstream 16 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 216 / 219 / 226 DH / PDH -4

- F 11 -

Service Training Speed sensor The vibration system fixed displacement motor A2FM is equipped with a Hall effect rotary speed sensor from Bosch Rexroth HDD1L or HDD2L

Fixed displacement motor A2FM

BW 216 / 219 / 226 DH / PDH -4

- F 12 -

Service Training Connection in wiring diagram, vibration speed sensor B16 on page 006

BW 216 / 219 / 226 DH / PDH -4

- F 13 -

Service Training Drum

4

14

5

9

2

6

13

7 10

3

8

11

12

1 Fig. 1Cross-section of drum 1

Drum shell

8

Change-over weight

2

Vibration bearing

9

Coupling vibr.-motor – vibrator shaft

3

Basic weight

10

Travel bearing

4

Vibrator housing

11

Travel bearing housing

5

Cooling fan

12

Rubber buffer

6

Vibrator shaft

13

Vibration motor

7

Elastic coupling between shafts

14

Flanged bearing housing

BW 216 / 219 / 226 DH / PDH -4

- F 14 -

Service Training Test and adjustment points, vibration system Vibration pump

7 6

6

1

8 72

6

8

5

7 5 5

4 Pos.

Designation

1

Pressure test port, vibration pressure low amplitude Pressure test port, vibration pressure high amplitude High pressure port low amplitude High pressure port high amplitude Multi-function valve with high pressure limitation low amplitude Multi-function valve with high pressure limitation high amplitude Solenoid valve, low amplitude Solenoid valve, high amplitude

2 3 4 5 6 7 8

4

3

2

BW 216 / 219 / 226 DH / PDH -4

1 4

1 3

2 Pos. in wiring diagram

3 Pos. in hydraulic diagram

Measuring values

11 - B - ME

Starting pressure 330 -400 bar Starting pressure 330 -400 bar max. 400+26 bar max. 400+26 bar

11 - A - MF 11 - B 11 - A 11 - B 11 - A Y07 / X 8 Y07 / X 7

11 - B 11 - A

12V / 0,4 - 1,2A 12V / 0,4 - 1,2A

- F 15 -

Service Training Vibration motor BW 216 and 219 DH-4

3

5 1

1

2 2

4 3 4

2 Pos.

Designation

1 2 3

High pressure port high amplitude High pressure port, low amplitude Flushing valve with pressure retaining valve Leakage and flushing

4

BW 216 / 219 / 226 DH / PDH -4

31



Measuring values

15 - A 15 - B 15 15

approx. 8-10 l incl. flushing quantity

- F 16 -

Service Training Vibration motor BW 216 and 219 DH-4

1

Pos.

Designation



1

RPM-sensor

B 16

15

BW 216 / 219 / 226 DH / PDH -4

Measuring values

- F 17 -

Service Training Vibration motor BW 226 DH-4

2

3

1

4

5

Pos.

Designation

1 2 3 4

High pressure port high amplitude High pressure port, low amplitude Flushing valve with pressure retaining valve Leakage and flushing

5

RPM-sensor

BW 216 / 219 / 226 DH / PDH -4



Measuring values

15 - A 15 - B 15 15

B 16

approx. 8-10 l/min incl. flushing quantity

15

- F 18 -





BW 216 / 219 / 226 DH / PDH -4

- F 19 -


SYMPTOME

FEHLERSUCHE VIBRATION BW 216/219/226 DH/PDH-4

Keine Vibration (Speisedruck OK) Vibration nur in einer Amplitude Erregerwellendrehzahl nicht korrekt


MÖGLICHE URSACHEN Vibrationschalter (Amplitudenvorwahl) Fahrhebel, Taster Vibration (an/aus), Verkabelung Elektrik defekt / Verkabelung Pumpenansteuerung (elektrisch / hydraulisch) Druckabschneidung/ Hochdruckbegrenzung Vibrationspumpe verschmutzt/verstellt/defekt Speisepumpe / Speisedruckbegrenzungsventil verschmutzt/defekt Frequenzeinstellung Vibrationspumpe Vibrationspumpe defekt Kupplung zwischen Dieselmotor und Fahrpumpe defekt Erregerwellenlager defekt Vibrationsmotorkupplung defekt Vibrationsmotor defekt Dieselmotor Drehzahlsensor (Verkabelung) Spülventil Vibmotor hängt

1 1 1 2 2 1 1 2 2 2

2 2

3 2 2 1 1 1 1 1 1 1 2

FEHLERSUCHE

BW 216 / 219 / 226 DH / PDH -4

- F 20 -

Exceiter shaft speed not correct

Vibration only with one amplitude

SYMPTOMS

No vibration (charge pressure OK)

TRROUBLE SHOOTING VIBRATION BW 216/219/226 DH/PDH-4

POSSIBLE CAUSES Vibration switch (amplitude pre-selection) Travel lever, vibration button (on/off), wiring Electrics defective / wiring Pump control (electric / hydraulic) Pressure override/ high pressure limitation vibration pump soiled/deadjusted/defective Charge pump / charge pressure relief valve soiled /defective Vibration pump frequency setting Vibration pump defective Coupling between engine and travel pump defective Exciter shaft bearing defective Vibration motor coupling defective Vibration motor defective Engine Rotary valve (wiring) Flushing valve in vibration motor stuck

1 1 1 2 2 1 1 2 2 2

2 2

3 2 2 1 1 1 1 1 1 1 2

TROUBLE SHOOTING

Service Training Steering Single drum rollers BW 216 / 219 / 226 of series 4 are equipped with a hydrostatically operated articulated steering system. The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure resistant connecting hoses.

to charge system 1 7

6 5

3 2 4 from steering pump

Fig. 1Steering hydraulics 1

Rating pump

2

Distributor valve

3

Steering pressure relief valve (∆p =175 bar)

4

Check valve (pre-loaded to 0.5 bar)

5

Anti-cavitation valve

6

Shock valves (240 bar)

7

Steering cylinders

The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve and the connected steering unit under the operator's platform of the machine. If the steering is not operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel circuits. When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side of the steering cylinder. 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 retract or extend and steer the machine. The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175 bar. The charge pressure must, however, be added to this value, because the oil leaving the steering system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.

BW 216 / 219 / DH / PDH -4

-G1-

Service Training Charge pump The charge pump for travel circuit and vibration works also as steering pump The pump is an external 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 216 / 219 / DH / PDH -4

-G2-

Service Training Steering pump The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to the steering cylinders or to the boost check valves for travel and vibration circuits.

9

9

6

1

7

9

3 8 2

4

5

Fig. 2Steering pump 1

Housing

2

Flange

3

Shaft

4

Bearing plate

5

Bearing plate

6

Cover

7

Gear (driving)

8

Gear (driven)

9

Seals

BW 216 / 219 / DH / PDH -4

-G3-

Service Training Working principle of the gear pumps 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 created between the tooth flanks, the inside wall of the housing and the faces of the bearing plates. When the pump is running the chambers transport hydraulic oil from the suction side to the pressure side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The tooth chambers transport the fluid to the outlet of the pump 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. For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial pressure field. This pressure field is always under the actual system pressure.

BW 216 / 219 / DH / PDH -4

-G4-

Service Training Steering valve The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and shock valves.

1 9

2

3 4

5 8

6 7

Fig. 3Cross-sectional view of steering valve 1

Neutral setting springs

2

Housing

3

Inner spool

4

Outer spool

5

Universal shaft

6

Ring gear

7

Gear

8

Check valve

9

Pressure relief valve

When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating pump. The rating pump guides the oil flow through the distributor valve to the corresponding sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the rotation angle of the steering wheel. This oil flow to the steering cylinders articulates the machine and causes a steering movement.

BW 216 / 219 / DH / PDH -4

-G5-

Service Training

240 bar

∆p = 175 bar 240 bar

0,5 bar

Fig. 4Steering valve, hydraulic diagram The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar. The charge pressure value must be added to this pressure, because the oil leaving the steering system is fed into the charge circuit for the closed travel circuits. The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks which may occur, e.g. when driving over obstructions, and protect the system against overloads. Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond these anti-cavitation valves protect the system against cavitation damage. A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would act as pumps and press the oil back to the pump.

BW 216 / 219 / DH / PDH -4

-G6-

Service Training Articulated joint Front and rear frames of series 4 single drum rollers are connected by an oscillating articulated joint. This ensures that drum and wheels are at all times in contact with the ground, even when driving extreme curves.

Fig. 5Articulated joint

BW 216 / 219 / DH / PDH -4

-G7-

Service Training 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. The use of rocker bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°. This gives drum and wheels excellent ground contact, even under extremely severe conditions. The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted in friction bearings. The steering cylinder anchor point is welded to the front console. When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the front console around the vertical bolts. This articulates the machine and results in a steering movement. All bearings on the articulated joint are maintenance free and do not require any lubrication. Notes on assembly: When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest importance. Please follow the instructions in the repair manual for the articulated joint.

BW 216 / 219 / DH / PDH -4

-G8-

Service Training Test and adjustment points steering points

5

3

1 2

4

1

2

2

Steering pump Pos.

Designation

1 2

Steering pump (and charge pump) Steering pressure test port

BW 216 / 219 / DH / PDH -4



09 MB

Measuring values

max.170+26 bar

-G9-

Service Training Vibration and noise damper

The damper is located in the steering/charge circuit directly after the steering and charge pump. It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises. The damper is mounted to the front plate of the rear frame, between both steering cylinders.

BW 216 / 219 / DH / PDH -4

- G 10 -





BW 216 / 219 / DH / PDH -4

- G 11 -


SYMPTOME

FEHLERSUCHE LENKUNG BW 213/214 DH/PDH-4

Keine Lenkfunktion Endanschläge werden nicht erreicht Lenkung schwergängig


MÖGLICHE URSACHEN Lenkorbitrol Lenk- Speisepumpe Lenkzylinder Knickgelenk

BW 216 / 219 / DH / PDH -4

2 1 3 3

2 1 3 3

1 2 3 2

- G 12 -

End stops are not reached

Steering hard to move

SYMPTOMS

No steering function

TROUBLE SHOOTING STEERING BW 213/214 DH/PDH-4

2 1 3 3

2 1 3 3

1 2 3 2

POSSIBLE CAUSES Orbitrol steering valve Steering/charge pump Steering cylinder Articulated joint

TROUBLE SHOOTING

Service Training Electrics Single Drum Rollers – 4

Version 2.07 Version/Status: V2.07 / 24.06.05 Author: Seis / TE Dateiname:


Page 1 of 67


Table of contents 1

CONFIRMATION OF CHANGES ..................................................................................5

1.1

Document ..................................................................................................................................................................... 5

1.2

Software ....................................................................................................................................................................... 5

2

SELECTED FAULT REACTIONS OF THE ESX CONTROL ..................................6

3

DESCRIPTION OF ERRORS IN THE LC DISPLAY .................................................9

3.1

Calling up service mode............................................................................................................................................ 9

3.2

Entering input codes.................................................................................................................................................. 9

3.3

Adjusting the machine type....................................................................................................................................11

3.4

Changing the steering unit on BVC-4 machines (from version 1.09)...........................................................12

3.5

Teaching the travel direction sensor...................................................................................................................13

3.6

Automatic detection of surge currents in travel system................................................................................13

3.7

Teaching the electronic end stops of the steering angle sensor (BVC) .....................................................15

3.8

Automatic detection of surge currents on steering valves (BVC)................................................................17

3.9

Driving against the closed brake..........................................................................................................................18

3.10

Showing stored faults .............................................................................................................................................18

3.11

Delete all stored faults ............................................................................................................................................18

4

HOW TO PROCEED WHEN REPLACING COMPONENTS?...............................19

4.1

Replacement of an ESX-control............................................................................................................................19

4.2

Replacement of a travel pump / axle drive motor / drum drive motor .........................................................19

4.3

Replacement of a steering valve (BVC)...............................................................................................................19

4.4

Replacement of a steering angle sensor ...........................................................................................................19

4.5

How to proceed when replacing a front / rear axle sensors?.......................................................................19

4.6

Which components can be replaced without a subsequent adjustment procedure?............................20

5

DESCRIPTION OF THE SIGNALS ON THE ESX-CONTROL ..............................21

6

DESCRIPTION OF SIGNALS ON THE DATA COLLECTOR................................27

7

DESCRIPTION OF SIGNALS ON THE TRAVEL LEVER......................................29

8

DESCRIPTIONS OF SIGNALS ON THE LC - DISPLAY ........................................31

9

DESCRIPTION OF SIGNALS ON DIOS-MODULE..................................................32

10

FAULT CODES OF THE ESX CONTROL .............................................................34

10.1

Overview.....................................................................................................................................................................34

10.2

Description of fault reactions ................................................................................................................................35

10.3

Detailed description of fault codes and their possible causes....................................................................36



Page 2 of 67

Service Training WZ-4 DH Version and higher 10.3.1 10.3.2 10.3.3 10.3.4 10.3.5 10.3.6 10.3.7 10.3.8 10.3.9 10.3.10 10.3.11 10.3.12 10.3.13

General _________________________________________________________________ 36 Brake___________________________________________________________________ 37 Travel lever ______________________________________________________________ 37 Travel speed range selector switch ____________________________________________ 38 Travel system ____________________________________________________________ 39 Steering_________________________________________________________________ 42 Driver's seat arm rest sensor_________________________________________________ 43 Vibration ________________________________________________________________ 44 Attachment plates _________________________________________________________ 46 Diesel engine ____________________________________________________________ 47 Diesel engine EMR ________________________________________________________ 47 Miscellaneous ____________________________________________________________ 50 Machine type _____________________________________________________________ 50

11

INPUT CODES FOR ESX CONTROL ....................................................................51

11.1

Fault log.......................................................................................................................................................................51

11.2 Value displays ...........................................................................................................................................................51 11.2.1 General _________________________________________________________________ 51 11.2.2 Brake___________________________________________________________________ 51 11.2.3 Travel lever / driving ________________________________________________________ 52 11.2.4 Travel speed range selector switch ____________________________________________ 52 11.2.5 Travel pump: Travel direction forward___________________________________________ 53 11.2.6 Travel pump: Travel direction reverse___________________________________________ 53 11.2.7 Travel motor front (drum) ____________________________________________________ 54 11.2.8 Travel motor rear (wheel axle) ________________________________________________ 54 11.2.9 Adaption values for speed regulation ___________________________________________ 54 11.2.10 Travel pressure sensor _____________________________________________________ 55 11.2.11 55 11.2.12 Inclination sensor _________________________________________________________ 55 11.2.13 Travel condition values _____________________________________________________ 55 11.2.14 Speed limitation___________________________________________________________ 55 11.2.15 Arm rest contact___________________________________________________________ 55 11.2.16 Adaption values traction control _______________________________________________ 56 11.2.17 Steering: Steering valve _____________________________________________________ 56 11.2.18 Steering: Angle sensor in articulated joint _______________________________________ 56 11.2.19 Steering: Steering wheel ____________________________________________________ 57 11.2.20 Vibration ________________________________________________________________ 57 11.2.21 Attachment plates, option (only BW213 BVC) _____________________________________ 58 11.2.22 Engine __________________________________________________________________ 59 11.2.23 Hydraulics _______________________________________________________________ 59 11.3 Test settings ..............................................................................................................................................................60 11.3.1 Brake___________________________________________________________________ 60 11.3.2 Disable electric supply to wheel and drum drive motors (switch off)____________________ 60 11.4 Settings / Teach / Emergency functions .............................................................................................................60 11.4.1 Changing the machine code _________________________________________________ 60 11.4.2 Automatic detection of surge currents in travel system ______________________________ 60 11.4.3 Speed detection, trimming of measuring values __________________________________ 61 11.4.4 Speed detection, teaching of distance pulses ____________________________________ 61 11.4.5 Detection of wheel rotation___________________________________________________ 61 11.4.6 Steering: Automatic detection of surge currents on steering valve _____________________ 62 11.4.7 Steering: Determining the steering stops ________________________________________ 62 11.4.8 Steering: Emergency function ________________________________________________ 62 11.4.9 Steering: Other functions ____________________________________________________ 62 11.4.10 Vibration: Cancellation of the vibration permission in dependence on the travel speed _____ 62 11.4.11 Plates __________________________________________________________________ 63

12

TERMINOLOGY IN CONNECTION WITH ESX.....................................................64



Page 3 of 67




Page 4 of 67


1 Confirmation of changes 1.1 Document No. 2.01 2.02 2.03 2.04 2.05 2.06 2.07

Date 23.04.2004 06.05.2004 11.05.2004 24.06.2004 23.01.2005 29.04.2005 22.05.2005

Description of changes Creation of version 1.00 Revision, teach functions Revision, supplements version 1.01 Revision, supplements to version 1.02 Revision, supplement to software versions from 2.00 Revision, supplement to software versions from 2.06 Error code description 5121 changed

resp. Werner Fondel Seis MASH MASH Löw

1.2 Software Ver. Date Description of changes 1.03 02.09.2004 ⇒ Surge currents travel system teach function changed ⇒ Known faults ⇒ Revision of error codes ⇒ Deactivation of electric steering on BVC machines ⇒ How to proceed when replacing components? 2.00 16.12.2004 ⇒ List of error codes extended 2.02 08.03.2005 ⇒ Adaptive adaptation of gradability. Display codes for the factors "Front top" 1500 and "Tail top" 1501 ⇒ Input code to shut down the speed dependent Vib-limitation (3047..3049). ⇒ Error message (8440..8443) for invalid BabyBoard equipment of the ESX-travel control. ⇒ Overspeed protection for wheel drives (axle and drum drives)

resp. Schroeder, Fondel

Schroeder Fondel MASH MASH

2.06 29.04.2005 ⇒ Input codes (1158/1159) for manual adaptation of axle speed recording. ⇒ Input codes to record the pulse frequency of the drives: Recording of speeds (1160..1169) ⇒ Adapted tank characteristic. ⇒ Change of speed limitation for operation with plates.

MASH

2.07 22.05.2005 ⇒ Tank characteristic values changed.

MASH



Page 5 of 67


2 Selected Fault Reactions of the ESX Control Reaktion

Symbol in fault message display

Signal

Warning

Warning

Engine stop

Code output without buzzer



5100 5112

5101 5112

Engine oil pressure (from EMR)

1)

Coolant temperature (from EMR)

5100 5116 1)

Coolant level

Engine air filter

2)

after 10s

5101 5116 2)

after 15s

5024

5025

after 5s

after 10s

5026

5027

after 5s

after 2min. 3)

Charge control

Preheating of engine

Brake

ASC

Various error causes and reaction times. See error codes Hydraulic oil filter

Water separator in fuel filter

5502

5503

after 5s

after 2min.

5028

5029

after 5s

after 2min.

Ant-theft warning display (Option)

Seat contact (Option) Air conditioning fault (Option) 1)

After reaching the warning limit!



3)

Shut-down currently deactivated via parameter

Page 6 of 67

Service Training WZ-4 DH Version and higher 2)

After reaching the shut-down limit!



Page 7 of 67

Service Training WZ-4 DH Version and higher Known faults Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to detect all faults. The following list contains a selection of known fault reactions of the control, which mostly have a different cause to the one described in this documentation.

Effect: Display remains dark, no voltage Error code 5100, 5140 and engine does not respond to full speed switch or travel lever After switching on the display shows "Error code 8224“

Cause: PIN in display plug X 28 bent Switch the ignition off and on and restart the machine immediately. Code 8224 is no error code, but a software fault in the display software, which has been rectified in display firmware version 1.36 and higher



Page 8 of 67


3 Description of errors in the LC display Apart from its normal display function the LC display is also able to shpw error codes, which had previously been visualized by means of the 3-digit error code display. Currently existing faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes will change in a 3 second cycle. Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible. Negative values are identified by a "Minus sign". The following chapter describes the operation of the LC display via travel lever buttons.

3.1 Calling up service mode For this purpose the display must be switched via input mode to service mode. This is accomplished via the two yellow info buttons "INFO 1" and "INFO 2" on the back of the travel lever. Navigation in input and service mode takes place via the green and blue buttons on the front of the travel lever.

INFO 1 Taste (gelb)

Werte ändern (grün)

INFO 2 Taste (gelb)

Navigieren (blau)

Werte ändern (grün) Navigieren (blau)

The travel lever must be in locked braking position in order to activate input mode! Input mode is switched on by simultaneously pressing both INFO – buttons over a period of approx. 3 seconds.

3.2 Entering input codes Input mode starts with flashing of the left hand digit. Here service code 9 9 9 9 provides the possibility to change to the service mode. The green buttons can be used to increase or reduce the values of the corresponding digit. By operating one of the blue buttons one can jump to the next (left or right) digit. Once the last right hand digit has been entered the code will be transferred to the control by pressing the right hand blue button once again. If the access code has been entered correctly, the "Spanner" symbol is displayed and the first input digit flashes again. Individual operating states of the machine can now be interrogated by transferring the input code to the control (as described above). When operating both INFO buttons again for approx. 3 seconds, another input code can be entered. The input of code "0 0 0 0 " or switching of the ignition quits the service mode. If the travel lever is shifted out of the brake lock while in service mode, all machine functions will become active, with the exception of the LC-display, which remains in service mode and continues to display the operating values requested last.

Version/Status: V2.07 / 24.06.05 Author: Seis / TE

Functions of ESX control

Page 9 of 67


Normal mode (travel lever in brake gate!) Call up optional displays via Info button 1 and Info button 2

„Input“ - Modus: Press INFO 1 + INFO 2 approx. 3s

Press INFO 1 + INFO 2 approx. 3s or shift travel lever out of brake gate

Changeover display function Display setting Plate adjustment deactivated!

Input Access code 9999

„Service“- Modus: Input diagnostic codes Calling up / deleting the error log Change machine type Plate adjustment deactivated!

CODE – input „0000" or Ignition off

Travel lever out of brake gate: Diagnostics mode active in foreground



Page 10 of 67


3.3 Adjusting the machine type Since the same control is used for all DH-4 single drum rollers with electronically controlled engine (EMR II), it is necessary to adjust the machine type after installing a new control. This is necessary during first time commissioning as well as in case of a spare parts installation. This adjustment of machine type is necessary, because the machines may be equipped with different drum drive or axle drive motors or different tire sizes, thus resulting in different rolling circumferences, or they may be equipped with attachment plates or other options. For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the display module when switching the ignition on. It can also be checked by entering code 0720. The following machine types can be adjusted: 0

1

2

3

4

Default

BW 177 DH-4 (dozer blade) BW 219 DH-4

BW 177 PDH-4

BW 179 DH-4

BW 219 BW 226 PDH-4 DH-4 147kW

5

6

7

8

9

BW 179 BW 213/ PDH-4 BW 214 DH-4

BW 213 BW 214 PDH-4

BW 213 DH-4 USA

BW 213 PDH-4 USA

BW 216 DH-4

BW 226 BW 226 PDH-4 DH-4 147kW 174kW

BW 226 PDH-4 174kW

72XX 0

1 BW 216 PDH-4

DH

2

DH

3

DH

4

DH

5 BW 177 DH-4 BVC

BW 213 DH-4 BVC

BW 213 DH-4 BVC w. plates

BW 226 DH-4 BVC 147 kW

BW 226 DH-4 BVC 174 kW

BVC

6

BVC

7

BVC

8

BVC

9

BVC

EXAMPLE: Machine code for BW 219 PDH-4:

Note:

DH

7212

Parameter adjustments can only be performed when the engine is not running.



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Note:

This function can only be activated / deactivated when the travel lever is locked in the brake gate. (à Input mode) The following procedure must be used for initial start-up of a control: • • • • • • •

The control has been installed into the machine. Switch the ignition on. Approx. 4 seconds after switching on the letters C O D E are displayed for a period of approx. 3 seconds. After this the display changes and shows code 7200. Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes. Confirm the selection with the Arrow Right key. After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not switch the ignition off during this time! After this switch the ignition off and on again to accept the configuration. After this the normal display will appear again.

The following applies for a correction of the machine type code after it has been set. • •

Enter code number 9 9 9 9 (activation of service mode) Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.

The display module now permanently shows the code 7 2 0 0 . • • • •

Select the machine code from the table above and confirm it with the Arrow Right key. After operating the Arrow Right key the control switches automatically off and on again. After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not switch the ignition off during this time! After this switch the ignition off and on again to accept the configuration. After this the normal display will appear again.

Attention:

A machine must not be operated with a wrong type adjustment, because in such a case the correct function of the control cannot be assured! New controls are delivered with a default machine type setting 7 2 0 0 . This does not enable to drive or steer the machine. It only serves the purpose of commissioning.

3.4 Changing the steering unit on BVC-4 machines (from version 1.09) By standard all BVC-4 machines (code 72xx) are equipped with electric steering. If the hydraulic steering option is selected, the electric steering must be deactivated as follows. • • •

Enter code number 9999 (activation of service mode) Enter code number 2 0 6 0 . This code number activates the function "Adjusting the steering unit“. The following code numbers are available to activate the assembled steering unit. Hydraulic steering Electric steering

•

2062 2061

The display shows O K

Attention:

The steering unit can only be changed when the engine is not running!



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3.5 Teaching the travel direction sensor Teaching of the travel direction sensor is required for initial commissioning and after the replacement of a travel motor. Perform the following sequence • Turn the speed range selector switch to "MAX" • Shift the travel lever slowly out of neutral, until a travel speed of approx. 1 km/h is indicated. • If one or both travel direction sensors detected a counteracting direction the error codes 1106 and/or 1116 will appear after approx. one machine length. Otherwise no error code will be displayed. The travel direction detection is now automatically set. However, should one of the two error codes appear, this must be caused by a sebsor fault.

3.6 Automatic detection of surge currents in travel system This function is only valid from software version 1.09! For a sensitive and exact function of the travel system the surge currents in the travel system must be determined for both travel directions. The surge currents are automatically determined after entering a code number, so that no electric meter is required. The surge currents must only be determined during initial commissioning in the factory, after a service during which the control on a steering valve or the complete steering valve has been replaced and after the replacement of the ESX-control. The measurement is identical for both travel directions: After entering the respective code number the current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250 mA.. After each current increase the system waits for 3 seconds. If a considerable drum movement is measured during the waiting time, the surge current is reached. In order to enhance the measuring result this measurement is performed three times. The final surge current is the mean value of these three measurements. This surge current is automatically stored and is valid from the next start of the machine. Before the measurement you should strictly make sure that the machine is parked on level ground and has a sufficient distance for movement to front and back, because the machine will move to the respective direction when performing the measurement. Attention! First set the machine to input mode (code 9 9 9 9 ). It must be strictly assured that the speed sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code number 1 1 0 6 at the display module. This code can be used to display the number path pulses from the speed sensor. The displayed value must change when the machine is driven. If this value does not change even though the machine is moving, the measurement must not be performed! The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not be detected. (See also: „Resetting the surge currents in the travel system”) Attention! During the measurement the machine will move when the surge current is reached! Do not leave the machine while the measurement is progressing! During the measurement keep an eye on your environment! To stop the machine reset the travel lever to neutral position! The automatic measurement of the travel system surge currents is performed as follows: • The speed selection switch must be in position ECO. • If necessary enter code number 9 9 9 9 to access the service mode. • Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code number must be entered to be able to perform the following steps. From this point the machine can no longer be operated with the travel lever! The travel lever will only be in function again after the teach function has been completed or the machine has been restarted. Version/Status: V2.07 / 24.06.05 Author: Seis / TE


Page 13 of 67

Service Training WZ-4 DH Version and higher •

The measurements (forward/reverse) must be started by entering a code number. The code number required to teach the travel direction is as follows: Determination of control surge currents

• • • • • • • •

•

1 0 9 1

After the input of the above code number the display shows " F O R E ". Shifting the travel lever forward starts the first surge current measurement for forward travel. During the measurement the actual current is displayed (display value = current in mA). Once the surge current measurement is finished the display will show the reading O K for a period of 5 seconds. After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward to start the surge current measurement in reverse. During the measurement the actual current is displayed (display value = current in mA). After completion of the measuring process in reverse the display will show O K again. The travel lever must now be returned to braking position. Once both surge currents have been learned correctly and the travel lever is in "braking position", the display shows the reading "D O N E", the values are saved and the function is completed. Now the machine can be operated again with the travel lever. The new surge current values for the travel system are valid from the next start. The teach function can at any time be aborted by operation of the emergency stop or the ignition switch.

The following procedure applies for software versions 1.07 and 1.08: The automatic measurement of the travel system surge currents is performed as follows: • The seat must be adjusted for travel direction forward! • The speed selection switch must be in position ECO. • If necessary enter code number 9 9 9 9 to access the service mode. • Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code number must be entered to be able to perform the following steps. From this point the machine can no longer be operated with the travel lever! The travel lever will only be in function again after the teach function has been completed or the machine has been restarted. • Both measurements (forward/reverse) must be started by entering a code number. The code numbers for both travel directions are:

•

• • • • •

Determine surge current for control forward

1 0 9 1

Determine surge current for control reverse

1 0 9 2

After entering one of the above code numbers the measurement will only start after moving the travel lever to the respective travel direction. ATTENTION: The ASC fault indicator light will come on during the teach process. In this case this is of no relevance. The warning will disappear when restarting the machine. During the measurement the actual current is displayed (display value = current in mA). Teaching is required for both travel directions. When returning the travel lever to neutral position after the two measurements, the display will show O K for 3 seconds and the averaged values will be saved. Once both surge currents have been measured the machine can be operated again with the travel lever. The new surge current values for the travel system are valid from the next start. The teach function can at any time be aborted by operation of the emergency stop or the ignition switch.



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3.7 Teaching the electronic end stops of the steering angle sensor (BVC) Attention:

Note:

Does not apply for BVC machines with "hydraulic steering" option!

During the measurement the machine should be parked on level ground. The drum should be standing on old rubber tires or a metal plate. Specify the engine speed -> travel lever out of braking position = neutral position (Not while entering a code).

To prevent the steering from moving all the way to the mechanical stops of the steering cylinder it is necessary to determine a defined safety distance to these end stops. • • • •

• •

•

Enter code number 9 9 9 9 to access the service mode. Enter code number 2 0 1 0 to activate the mode "Teach steering stops". Return the travel lever to neutral position (no braking function, but to relieve the machine of strain). The display shows the standardized steering position (0..1000 → right ... left). Now turn the electric steering wheel clockwise, until the mechanical stop is reached The displayed value should be in the range of 100..300. Then shift the travel lever to braking position and enter code number 2 0 1 2 (press both Info-buttons first to access the input mode). In case of acceptance the value 2 2 2 2 will appear for a moment. In case of a fault the value 9 9 9 9 upon acceptance (see below). Return the travel lever to neutral position (no braking function, but to relieve the machine of strain). The display shows the standardized steering position (0..1000 → right ... left). Now turn the electric steering wheel anti-clockwise, until the mechanical stop is reached The displayed value should be in the range of 700..900. Then shift the travel lever to braking position and enter code number 2 0 1 3 (press both Info-buttons first to access the input mode). In case of acceptance the value 3 3 3 3 will appear for a moment. In case of a fault the value 9 9 9 9 upon acceptance (see below). To leave the mode the machine must be switched off or code 2 0 1 1 must be entered.

Possible error causes (code 9 9 9 9 ) : -

Incorrect connection of hoses -> have checked by engineer -> correct. Connecting fault on potentiometer -> have checked by an electrician -> correct. Potentiometer faulty -> replace the potentiometer.



Page 15 of 67

Service Training WZ-4 DH Version and higher Machine on level ground

START

Tires or metal plate under drum Machine on level ground

enter 9999

enter 2010 Travel lever in neutral position Turn steering wheel to the RIGHT to the STOP (PRV can be heard, cylinder full extended or retracted). Travel lever in brake position

enter 2012

Display shows

Display shows

2222 OK

9999 ERROR

Display shows

Display shows

3333 OK

9999 ERROR

Travel lever in neutral position Turn steering wheel to the LEFT to the STOP (PRV can be heard, cylinder full extended or retracted). Travel lever in brake position

enter 2013

Switch ignition off and on again

OR

enter 2011

FINISHED



Page 16 of 67


3.8 Automatic detection of surge currents on steering valves (BVC) Attention:

Note:

Does not apply for BVC machines with "hydraulic steering" option!

Execute this function only AFTER "Teaching electronic end stops of angle sensor". During the measurement the machine should be parked on level ground. Before the measurement both drums should be steered to straight ahead position. The travel motor must be moved out of braking position -> raised idle speed!

To enable a sensitive and exact function of the steering the surge currents of the two control solenoids and both steering valves must be measured. The surge currents are automatically adjusted after entering a code number, so that no electric meter is required. The surge currents must only be adjusted during initial commissioning in the factory, after a service during which the control on a steering valve or the complete steering valve has been replaced and after the replacement of the ESX-control. The measurement is identical for both solenoids: Example BW 177 BVC: After entering the respective code number the current is increased by the control solenoid in steps of 5 mA, starting from 650 mA.. After each increasing step the system waits for 2 seconds. If a change in drum angle is measured after the waiting time, the surge current is reached. In order to enhance the measuring result this measurement is performed three times. The final surge current is the mean value of these three measurements. This surge current is automatically stored and is valid from the next start of the machine. For all other machine types the same procedure is used, however, currents and times will vary. Before the measurement you must strictly make sure that the steering system is „bled“, because an air cushion in the steering cylinders would have a negative effect on the measurement and therefore on the steering performance of the machine. Sufficient bleeding is achieved by performing a few quick steering movements at full engine speed. The automatic measurement of the steering valve surge currents is performed as follows: • The engine must be operated in ECO-mode! • Enter code number 9 9 9 9 to access the service mode. • Travel lever in neutral position (Brake must be relieved!) • Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of steering valve surge currents"; the display now shows the reading 0 0 0 0 with the first digit flashing. • Now code number 2 0 0 1 must be entered. • After entering one of the above mentioned code numbers the measurement of the surge current will start immediately. • The drum is thereby first steered to the right and then to the left. • During the measurement the actual valve current is displayed (display value in mA). • Attention! During the measurement the drum cannot be steered ! The steering wheel has no effect. • During the measurement the machine should not be driven ! • Once the measurement is completed the display value OK will appear for 3 seconds, after this the code number 0000 is displayed with the first digit flashing, the next measurement can be started. • The new surge current values are valid from the next start.



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3.9 Driving against the closed brake After entering the code number 0 5 0 0 the brake will not be released. If the travel condition shifted out of the brake gate and moved to any travel direction, the travel triggered according to the chosen travel direction. At the same time a warning (fault appears on the display and the warning buzzer is triggered, in order to keep the operator the condition. The brake control light in the LC-display remains activated.

lever is in this pumps will be code 0 5 0 0 ) informed about

In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or switch the ignition off. After entering code number 0 5 0 1 the function is aborted and OK is displayed as confirmation for 5 seconds. After this the code needs to be entered again. Note:

This function can only be activated / deactivated when the travel lever is locked in the brake gate. (à Input mode)

3.10 Showing stored faults This function is only valid from software version 1.10! Switch on function „Show stored faults“: • Enter code number 0 7 0 0 . This code number enables the function „Show stored faults“. The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will appear again. If no faults are stored in the ESX, the display will show "- - - - - "

Switch off function „Show stored faults“: • Enter code number 0 7 0 1 . This code number disables the function „Show stored faults“.

Note:

Apart from the stored faults the current faults are also displayed.

Note:


3.11 Delete all stored faults This function is only valid from software version 1.10! Execute • • •

the function „Delete all stored faults“: The engine must not be running! Enter code number 0 7 1 0 . Switch the ignition off and on again.

All stored faults are now deleted.

Note:

The stored faults can only be deleted when the engine is not running.

Note:




Page 18 of 67


4 How to proceed when replacing components? Each machine is adjusted individually during initial commissioning. This adjustment or teaching process is necessary to make sure that the travel and steering functions are almost identical on all machines. Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic pump for travel system, proportional valves for steering, steering angle sensors and ESX control. These tolerances apply for both mechanical as well as electrical functions and are unavoidable for manufacturing reasons. To enable simple and quick adjustment procedures we have decided to do without expensive tools. All that is needed is this manual and a bit of time. By following the described procedure it is possible to take a machine back into operation after the replacement of one of the components specified above and to reestablish the usual functional quality, with almost any previous knowledge. Even an incorrectly or incompletely conducted teaching procedure can be repeated without problems as often as necessary. At the first glance it seems to be at bit awkward to perform this adjustment work on every machine, but this procedure enables the operation of all machines with the same operating software. At the end of the day this considerably increases the spare parts availability.

4.1 Replacement of an ESX-control Since the control stores all teach values of the machine, each teaching procedure must be performed with the new control after a replacement. Attention:

Before performing one of the following steps you must first set the corresponding machine type (see chapt. 3.3)! When changing the machine type all previously made adjustments will be lost!

Now the teach functions must be executed. •

From DH • Automatic detection of travel system surge currents (see chapt. 3.6)

•

On BVC • Automatic detection of steering valve surge currents (see chapt. 3.7) • Teaching the electronic end stops of the steering angle sensor (see chapt. 3.8)

4.2 Replacement of a travel pump / axle drive motor / drum drive motor • •

Automatic detection of travel system surge currents (see chapt. 3.6)

4.3 Replacement of a steering valve (BVC) • •

Automatic detection of steering valve surge currents (BVC) (see chapt. 3.7)

4.4 Replacement of a steering angle sensor •

Teaching the electric end stops of the steering angle sensor (see chapt. 3.8)

4.5 How to proceed when replacing a front / rear axle sensors? •

Teaching the travel direction sensor



Page 19 of 67


4.6 • • • • • • • •

Which components can be replaced without a subsequent adjustment procedure? Display Data collector Joystick Electric steering wheel Diesel engine All switches in the dashboard Vibration motor Vibration pump

Note:

A final function test of the complete machine is highly recommended.



Page 20 of 67

Service Training WZ – 4

Description of Signals on the ESX Control

5 Description of the Signals on the ESX-Control Notes: Wherever the value of 24 V is mentioned in the following text, it refers to the current battery voltage under due consideration of voltage drops in the lines.

ESX terminal Signal description X35:1 AGND = Analogue ground: Ground potential for sensors (steering angle sensor, steering unit etc.) X35:2 Output amplitude changeover Digital output (max. 2.5 A) X35:3 Output warning buzzer Digital output (max. 2.5 A) X35:4 RS 232 RxD interface, not used for normal operation. X35:5 RS 232 TxD interface, not used for normal operation. X35:6 Not used X35:7 Not used X35:8 Not used X35:9 Not used X35:10 Not used X35:11 Not used X35:12 Input axle speed Frequency input (0....7,5kHz)

X35:13

Not used


Nominal values (voltage / current) approx. 0 V measured against ground (terminal 31) active, i.e. high amplitude Fapprox. 12 V inactive, i.e. low amplitude F 0V Warning buzzer active Fapprox. 12 V Warning buzzer inactive F 0V Measurement not possible! Measurement not possible! ------------Signal changes between approx. 0V and 12V, when machine is driving. Frequency with travel speed m/min Machine type: XX m/min Fapprox.XX Hz XX m/min Fapprox.XX Hz Machine type: XX m/min Fapprox.XX Hz XX m/min Fapprox.XX Hz Machine type: XX m/min Fapprox.XX Hz XX m/min Fapprox.XX Hz ---


Page 21 of 67



ESX terminal Signal description X35:14 Not used X35:15 Input seat contact switch Digital input active high X35:16 Not used X35:17 Input BTS brake (from travel lever) Digital input active high X35:18 Input steering sensor (S1/A) Digital input active high X35:19

Input steering sensor (S1/B) Digital input active high

X35:20

Output steering left PWM digital output (max. 4 A) Output steering right PWM digital output (max. 4 A) Output vibration pump attachment plate PWM digital output (max. 4 A)

X35:21 X35:22

X35:23

X35:24 X35:25 X35:26 X35:27 X35:28

Nominal values (voltage / current) --Seat operated F 0V Seat not operated F ?V --Brake released Fapprox. 12 V Brake applied F 0V Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of turning Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of turning Steering left active F 0,4..1,6 A Steering left inactive F 0A Steering right active F 0,4..1,6 A Steering right inactive F 0A permissible current range: approx. 0..1,2 A Vibration pump active F 0,6..1,2 A Vibration pump not active F 0A Nominal voltage = 8,5 V Permissible range: approx. 7,65..9,35 V This voltage must be measured against AGND.

Voltage supply for sensors This output supplies steering angle sensor and steering unit. Without this voltage the control cannot work correctly and will switch to override mode (emergency function). Output backup alarm Backup alarm inactive Digital output (max. 2.5 A) Backup alarm active Not used --Interface CAN-Bus 1 Wire -, is used for communication with MESX, data collector, LCD-display and BOP. MEASUREMENT Interface CAN-Bus 1 Wire +, is used for communication with MESX, data collector, LCD-display and BOP. Input potential terminal 15 Digital input active high This signal must be present, so that the control can work.


F 0V Fapprox. 12 V

NOT POSSIBLE!

MEASUREMENT NOT POSSIBLE! Control switched on Control switched off


Fapprox. 12 V Fapprox.2 V

Page 22 of 67



ESX terminal Signal description X35:29 Input steering angle sensor Analogue input / voltage input 0..8.5 V

X35:30

X35:31

X35:32 X35:33

Nominal values (voltage / current) Position steering angle sensor (measured against AGND) right hand stop F 0,50..1,00 V straight ahead / neutral / middle F ..V left hand stop F 6,80..8,70 V Input longitudinal inclination of machine Inclination of machine (measured against AGND) Analogue input / voltage input 0..8.5 V -45° axle high F 0,50..2,49 V Neutral position F 2,50 V maximum down F 2,51..4,50 V Input hydraulic pressure travel pump circuit 0 bar F approx.4 mA Analogue input (current input 4mA..20mA) from pressure sensor on travel 600 bar F approx.20 mA pump Not used --Interface CAN-Bus 2 Wire -, is used for communication with travel lever and engine EMR. MEASUREMENT NOT POSSIBLE!

X35:34

Input drum speed Frequency input (0....7,5kHz)

X35:35

Input vibration motor Frequency input (0....2,0kHz)


Signal changes between approx. 0V and 12V, when machine is driving. Frequency with travel speed m/min Machine type: XX m/min Fapprox.XX Hz XX m/min Fapprox.XX Hz Machine type: XX m/min Fapprox.XX Hz XX m/min Fapprox.XX Hz Machine type: XX m/min Fapprox.XX Hz XX m/min Fapprox.XX Hz Frequency with vibration frequency in Hz Machine type: Vib. frequency XX Hz Fapprox.XX Hz Vib. frequency XX Hz Fapprox.XX Hz Machine type: Vib. frequency XX Hz Fapprox.XX Hz Vib. frequency XX Hz Fapprox.XX Hz Machine type: Vib. frequency XX Hz Fapprox.XX Hz


Page 23 of 67



ESX terminal Signal description X35:36

X35:37 X35:38 X35:39 X35:40

Input sense of rotation of vibration motor (currently not used) Digital input active high Input sense of rotation of drum Digital input active high Input sense of rotation of axle Digitaleingang aktiv high Not used Input steering sensor (S2/A) Digital input active high

X35:41

Input steering sensor (S2/B) Digital input active high

X35:42

Output emergency steering

X35:43 X35:44 X35:45 X35:46

Not used Not used Not used Output drum drive motor PWM power output (max. 4 A)

X35:47

Output axle motor PWM power output (max. 4 A)

X35:48

Output vibration pumpe PWM digital output (max. 4 A)

X35:49

Output travel pump forward PWM power output (max. 4 A)

Nominal values (voltage / current) Vib. frequency XX Hz Fapprox.XX Hz Sense of rotation forward Fapprox. 12 V Sense of rotation backward Fapprox.2 V Sense of rotation forward Fapprox. 12 V Sense of rotation backward Fapprox.2 V Sense of rotation forward Fapprox. 12 V Sense of rotation backward Fapprox.2 V --Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of turning Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of turning Emergency steering active Fapprox. 12 V Emergency steering inactive F 0V ------permissible current range: approx. 0..0,6 A Drum drive motor active F 0,0..2,0 A Drum drive motor not active F 0A permissible current range: approx. 0..0,6 A Axle motor active F 0,0..2,0 A Axle motor not active F 0A permissible current range: approx. 0..0,6 A Axle motor active F 0,0..2,0 A Axle motor not active F 0A Travel forward active F 0,0..2,0 A Travel forward inactive F 0A Sauer components with EDC Travel forward active



F 18..80 mA Page 24 of 67



ESX terminal Signal description

Nominal values (voltage / current) Travel forward inactive F -------

0 mA

X35:50 X35:51 X35:52 X35:53

Not used Not used Not used Interface CAN-Bus 2 Wire +, is used to communicate with the travel lever and engine EMR.

X35:54

Voltage supply for electronics (permanent voltage)

X35:55 X35:56 X35:57 X35:58 X35:59 X35:60 X35:61

Ground connection electronics Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Output brake Digital output (max. 4 A) Output blower coupling stage 2 (currently not used) Digital output (max. 4 A) Output blower coupling stage 3 (currently not used) Digital output (max. 4 A) Output travel pumps reverse PWM power output (max. 4 A)

Control running Fapprox. 12 V Control not running F 0V 0 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) Open brake Fapprox. 12 V Close brake F 0V Active Fapprox. 12 V Inactive F 0V Active Fapprox. 12 V Inactive F 0V Travel forward active F 0,0..2,0 A Travel forward inactive F 0A

X35:65

Test connection Baby Boards

Sauer components with EDC Travel forward active Travel forward inactive approx. 0 V

X35:66


approx. 0 V

X35:67


approx. 0 V

X35:68


approx. 0 V

X35:62 X35:63 X35:64


MEASUREMENT NOT POSSIBLE!


F 18..80 mA F 0 mA

Page 25 of 67

Service Training WZ – 4 ESX terminal Signal description


Description of Signals on the ESX Control Nominal values (voltage / current)


Page 26 of 67


Description of Signals on the Data Collector

6 Description of signals on the data collector Notes: Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage under due consideration of voltage drops in the lines.

PIN data collector X26:1 X26:2 X26:3 X26:4 X26:5 X26:6 X26:7 X26:8 X26:9 X26:10 X26:11 X26:12 X27:1 X27:2

X27:3

Signal description

Nominal values (voltage / current)

Input indicator right Digital input active high Input indicator left Digital input active high Input engine running (D+) Digital input active high Not used Input hydraulic oil filter differential pressure Digital input active low Not used Input air conditioning Digital input active high Input engine air filter Digital input active low Input background illumination Digital input active high Input coolant supply Digital input active low Not used Ground connection Not used Input fuel level Analog input

Indicator right active Indicator right inactive Indicator left active Indicator left inactive Engine running Engine not running --Filter clogged Filter OK --Air conditioning on Air conditioning off Filter clogged Filter OK Illumination on Illumination off Coolant supply too low Sufficient coolant supply --0V (measured against ground)

Not used


Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V F F

0V ?V

Fapprox. 12 V F 0V F 0V F ?V Fapprox. 12 V F 0V F 0V F ?V

The voltage signal changes with the filling level in the fuel tank Fuel tank empty F ?? V Fuel tank full F ?? V ---


Page 27 of 67



PIN data collector X27:4

Signal description


Voltage supply for monitoring of water separation (PIN X27:9)

X27:5 X27:6

Voltage supply O.K. No voltage supply 0V (measured against ground) Measurement not possible!

Ground connection Interface CAN-Bus 1 Wire +, is used for communication with MESX, ESX, LCD-display and BOP. Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, Measurement not possible! LCD-display and BOP. Voltage supply (permanent voltage) Control running Fapprox. 12 V Control not running F 0V Input water separation If a sufficient amount of water has been separated, a low current flows over Current input the over the contacts and the water in the separator bowl. This input analyses this current. No water separated F I= 0A Water separated F I∗ 0,03mA Not used --Not used --Not used ---

X27:7 X27:8 X27:9

X27:10 X27:11 X27:12



Fapprox.12 V F 0V

Page 28 of 67


Description of Signals on the Travel Lever

7 Description of signals on the travel lever Notes: Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage under due consideration of voltage drops in the lines.

PIN travel lever X23:1

Signal description


Voltage supply (permanent voltage)

X23:2 X23:3

Ground connection Output BTS brake Digital output (max. 4 A) Output BTS (not used) Digital output (max. 4 A) Output voltage supply for additional analog evaluations This output supplies the 24-stage travel range selector switch. This voltage is required to connect and evaluate further analog switches to the travel lever. Interface CAN-Bus 2 Wire +, is used to communicate with ESX and engine EMR. Interface CAN-Bus 2 Wire -, is used to communicate with ESX and engine EMR. AGND = Analogue ground: Ground potential for additional analog evaluations Reference to PIN X23:5 Node address addressing 1 Node address addressing 2

Electronics functioning Electronics not working 0V (measured against ground) Brake opens Brake closes

X23:4 X23:5

X23:6 X23:7 X23:8

X23:9 X23:10


Fapprox. 12 V F 0V Fapprox. 12 V F 0V

Nominal voltage = approx. 5,0 V Permissible range: approx. 4,8..5,2 V This voltage must be measured against AGND. Measurement not possible! Measurement not possible! approx. 0 V measured against ground (terminal 31)

Connection to machine ground (0V) Connection to machine ground (0V)


Page 29 of 67



PIN travel lever X23:11

Signal description


Input travel stage selector switch Analog input

X23:12 X24:1 X24:2

The voltage signal changes with the adjusted travel speed range Travel stage min. F ?? V Travel stage max. F ?? V ----High amplitude active Fapprox. 12 V High amplitude inactive F 0V Low amplitude active Fapprox. 12 V Low amplitude inactive F 0V -------

Not used Not used Input high amplitude Digital input active high Input low amplitude Digital input active high Not used Not used Input arm rest left (not yet realized) Digital input active high Output voltage supply for additional digital evaluations Voltage supply active This output supplies the amplitude selector switch. This voltage is Voltage supply inactive required to connect and evaluate further digital switches to the travel lever. Output voltage supply ground potential 0V (measured against ground) In connection with PIN X24:7 this output enables the control of additional components (relays, displays etc.)

X24:3 X24:4 X24:5 X24:6 X24:7

X24:8



Fapprox. 12 V F 0V

Page 30 of 67


Description of Signals on the LC-Display

8 Descriptions of signals on the LC - Display Notes: Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage under due consideration of voltage drops in the lines.

PIN Display X28:1

Signal description Voltage supply (permanent voltage "ignition on")

X28:2 X28:3

Ground connection Interface CAN-Bus 1 Wire +, is used for communication with MESX, ESX, data collector and BOP. Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, Measurement not possible! data collector and BOP. Voltage supply (permanent voltage "Battery +“ for RTC) Electronics functioning Electronics not working Not used --Input lower frequency Adjustment active Digital input active high Adjustment inactive Input higher frequency Adjustment active Digital input active high Adjustment inactive Input engine speed high idle High idle active Digital input active high High idle inactive Input engine speed low idle Low idle active Digital input active high Low idle inactive Not used --Not used --Output voltage supply for additional digital evaluations Voltage supply active This output supplies the engine speed switch and the switch for Voltage supply inactive frequency adjustment. This voltage is required to connect and evaluate further digital switches to the LCD. Not used ---

X28:4 X28:5 X28:6 X29:1 X29:2 X29:3 X29:4 X29:5 X29:6 X29:7

X29:8

Status: Author:

24.06.05 Seis / TE

Nominal values (voltage / current) Electronics functioning Fapprox. 12 V Electronics not working F 0V 0V (measured against ground) Measurement not possible!

Description of Signals on the LC-Display

Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V

Fapprox. 12 V F 0V

Page 31 of 67

Service Training WZ - 4

Description of Signals on the DIOS-Module

9 Description of Signals on DIOS-Module (only for option with attachment plates) DIOS terminal X62:1 X62:2 X62:3 X62:4

Signal description Interface CAN-Bus 1 Wire +, is used to communicate with the ESXcontrol. Interface CAN-Bus 1 Wire -, is used to communicate with the ESXcontrol. Voltage supply for electronics

X62:9

Input proximity switch, plates middle Digital input active high Output plates up Digital output (max. 4 A) Output plates down Digital output (max. 4 A) Output plates left Digital output (max. 4 A) Output plates right Digital output (max. 4 A) Voltage supply for outputs

X62:10

Voltage supply for outputs

X62:11 X62:12

Ground connection Input proximity switch, plates top Digital input active high Output plates float position 1 Digital output (max. 4 A) Output plates priority Digital output (max. 4 A) Output plates float position 2 Digital output (max. 4 A) Not used

X62:5 X62:6 X62:7 X62:8

X62:13 X62:14 X62:15 X62:16


Nominal values (voltage / current) Measurement not possible! Measurement not possible! Ignition ON: Ignition OFF: Plates in middle position Plates outside middle position Up active Up inactive Down active Down inactive Sliding to left active Sliding to left inactive Sliding to right active Sliding to right inactive Ignition ON: Ignition OFF: Ignition ON: Ignition OFF: 0 V measured against ground Plates lifted above sensor Plates lowered below sensor Float position active Float position inactive Priority active Priority inactive Float position active Float position inactive ---


Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V F 0V Fapprox. 12 V Fapprox. 12 V F 0V Fapprox. 12 V F 0V Fapprox. 12 V F 0V

Page 32 of 67

Service Training WZ - 4




Page 33 of 67

Service Training

Fault Codes on ESX Control

10 Fault codes of the ESX control 10.1 Overview Fault code 0000 0999 1000 1999 2000 2499 2500 2999 3000 4499 4500 4999 5000 5499 5500 5999 6000 6999 7000 7499 7500 7899 7900 7999 8000 8999 9000 9999 1

Fault description General faults / warnings / machine tests Fault in travel system Fault in steering system Fault in remote control Faults in work functions (vibration, attachment plates, rotor, chip spreader) Fault in measuring systems Fault diesel engine Fault hydraulic system Fault anti-theft warning system, localization system, access system, time account, etc. Input of machine codes Input of codes for measuring technology Operating hours, load spectrum, etc. Severe software error

1

Errors of external IO-nodes (joystick, data collector, Dios module, LC-display, etc.) 1

These faults are not broken down hereunder!


Fault Codes on ESX Control

Page 34 of 67


Description of Fault Codes on Control

10.2 Description of fault reactions Fault reaction Description of fault reaction

Note:

1

Warning. Fault code is displayed.

2

Warning. Fault code is displayed. Audible signal

3

Function affected, the faulty function is replaced by an emergency function. Fault code is displayed. Audible signal

4

Partial function faulty, the partial function cannot be overridden by an emergency function. The machine is stopped if this fault occurs. The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible. Fault code is displayed. Audible signal

5

Partial function faulty, the partial function cannot be overridden by an emergency function. F the diesel engine is shut down. The machine is no longer able to drive, e.g. because parts of the travel system are defective Fault code is displayed. Audible signal

6

Fatal fault. The function of the control can no longer be guaranteed. F Control is switched off. F the diesel engine is shut down, if possible. The fault code is displayed, the signal light in the monitoring board is permanently on. No audible signal! Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log.



Page 35 of 67



10.3 Detailed description of fault codes and their possible causes 10.3.1 General Fault Code

Fault description

Possible causes

Equip. conn.Terminal

DH-4

Assignment BVC-4

500

Driving against brake – warning The function "Driving against brake" is activated

A corresponding input code has been entered

X

X

502

Simulated engine run - warning The function "Simulated engine run" is activated


X

X

504

Ant- Slip Control (ASC) deactivated - warning The function "Anti Slip Control (ASC)" is deactivated


X

X

507

Drum drive deactivated - warning Test mode "Drum drive deactivated" was activated.


X

X

508

Axle drive deactivated - warning Test mode "Axle drive deactivated" was activated.


X

X

560

Overvoltage 8,5V The voltage level of the 8,5V range is impermissibly exceeded (see signal description) Undervoltage 8,5V The voltage level of the 8,5V range is impermissibly fallen short of (see signal description) Error "Voltage Override Relay" The voltage level of the 8,5V range is...

Connection of voltage level to operating voltage, another voltage potential or control defective

X35:23

X

X

Connection of voltage level to ground, another voltage potential or control defective

X35:23

X

X

X

X

561

562



Input code for diagnose

Fault reaction

Page 36 of 67



10.3.2 Brake Fault Code 1001

1002

1003 1004

1005

Fault description

Brake valve line breakage The required control power cannot be transmitted to the control solenoid. Brake valve Signal outside the valid range (see signal description) Brake valve Signal outside the valid range (see signal description) BTS brake / travel lever (BTS=output driver) Overheating of the BTS has the effect, that the braking position of the travel lever is not correctly recognized BTS brake / plausibility (BTS=output driver) Plausibility conflict in evaluation of travel lever X- and yaxes to the brake contact signal

Possible causes

The connecting line between control output and control solenoid is interrupted, or The proportional solenoid is defective Cable breakage in ground line, or Connecting cable between valve and ground connection has come loose Cable breakage in connecting line, or Connecting cable between valve and supply has come loose Hardware defect on travel lever

Equip. conn.Terminal X35:61

DH-4

Assignment BVC-4

X

X

X35:61

X

X

X35:61

X

X

X35:17

X

X

Hardware defect on travel lever, input X35:17 has not the same voltage as the BTS

X35:17

X

X

Possible causes



Fault reaction


Fault reaction

10.3.3 Travel lever Fault Code 1025 1026 1027 1028

1029 1030

Fault description

DH-4

Assignment BVC-4

Travel lever sum error X-axis Error in redundant evaluation of axis Travel lever cable breakage X-axis Signal outside the valid range (see signal description) Travel lever parameterization X-axis

Internal fault in travel lever -> Replace travel lever.

X

X

Cable breakage in travel lever -> Replace travel lever.

X

X


X

X

Travel lever direction evaluation X-axis The direction of travel lever movement could not be determined Travel lever difference error X-axis Error in redundant evaluation of travel lever signal Travel lever software error X-axis Software does not work fault free


X

X


X

X


X

X



Page 37 of 67


Fault Code 1031 1032 1033 1034

1035 1036

Fault description


Possible causes


DH-4

Assignment BVC-4

Travel lever sum error Y-axis Error in redundant evaluation of axis Travel lever cable breakage Y-axis Signal outside the valid range (see signal description) Travel lever parameterization Y-axis


X

X

Cable breakage in travel lever -> Replace travel lever.

X

X


X

X

Travel lever direction evaluation Y-axis The direction of travel lever movement could not be determined Travel lever difference error Y-axis Error in redundant evaluation of travel lever signal Travel lever software error Y-axis Software does not work fault free


X

X


X

X


X

X


Fault reaction


Fault reaction

10.3.4 Travel speed range selector switch Fault Code

Fault description

1040

Travel range selector switch "Ground connection" Signal outside the valid range (see signal description)

1041

Travel range selector switch "Supply connection" Signal outside the valid range (see signal description)

1042

Travel speed range selector switch Signal outside the valid range (see signal description)


Possible causes

Cable breakage in ground line, or Connecting cable between switch and ground connection has come loose Cable breakage in connecting line, or Connecting cable between switch and supply line has come loose Higher contact resistances have possibly caused a faulty signal. The switch must be replaced.



DH-4

Assignment BVC-4

X

X

X23:5

X

X

X23:11

X

X

Page 38 of 67



10.3.5 Travel system Fault Code

Fault description

1070

Output travel pump forward The required control power cannot be transmitted to the proportional solenoid. Fault of current regulator forward Fault of current regulator forward Output travel pump forward Supply voltage UB applied to the output to the proportional valve. Error in teaching the surge current forward

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective Faults in valve control Check wiring. Faults in valve control Check wiring. Short circuit of connecting line (control to proportional valve) to voltage supply Machine mechanically blocked Travel system bypass valves out of adjustment

X35:49

Output travel pumps reverse The required control power cannot be transmitted to the proportional solenoid. Fault of current regulator reverse Fault of current regulator reverse Output travel pumps reverse Supply voltage UB applied to the output to the proportional valve. Error in teaching the surge current reverse

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective Faults in valve control Check wiring. Faults in valve control Check wiring. Short circuit of connecting line (control to proportional valve) to voltage supply Machine mechanically blocked Travel system bypass valves out of adjustment The function "Teaching pump surge currents" for the travel pump has not yet been executed. -> New machine/replacement of control

X35:64

1071 1072 1073

1074

1080

1081 1082 1083

1084

Possible causes


DH-4

Assignment BVC-4

X

X

X X X

X X X

X35:64

X

X

X35:64

X X X

X X X

X

X

X35:49

1088

Note! Surge currents for travel pump have NOT been learned. See 3.6

1100

Output front travel motor The required control power cannot be transmitted to the proportional solenoid. Speed sensor pulses front travel motor Incorrect or non-existent signal "Frequency"

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective Check connecting lines and plugs on wheel speed sensor, if necessary replace the wheel speed sensor

X35:46

X

X

X35:34

X

X

Direction signal pulses front travel motor Incorrect or non-existent signal "Direction"

Check connecting lines and plugs on wheel speed sensor, if necessary replace the wheel speed sensor

X35:37

X

X

1105

1106




Fault reaction

Note

Page 39 of 67

Service Training WZ – 4 Fault Code 1107

Fault description

Description of Fault Codes on Control Possible causes

Output front travel motor Short circuit of connecting line (control to proportional valve) to Supply voltage UB applied to the output to the proportional voltage supply valve.




DH-4

Assignment BVC-4

X


Fault reaction

X

Page 40 of 67



1110

Output rear travel motor The required control power cannot be transmitted to the proportional solenoid.

The connecting line from the output of the control to the proportional solenoid is interrupted or the proportional solenoid is defective

X35:47

X

X

1115

Speed sensor pulses rear travel motor Incorrect or non-existent signal "Frequency"


X35:12

X

X

1116

Speed sensor direction signal rear travel motor Incorrect or non-existent signal "Direction"


X35:38

X

X

1117

Output rear travel motor Short circuit of connecting line (control to proportional valve) to Supply voltage UB applied to the output to the proportional voltage supply valve.

X35:47

X

X

1140

Travel system pressure sensor "Signal" The current signal is not transmitted (see signal specification Travel system pressure sensor "Signal range" The current signal is outside the valid range (see signal specification) Travel system pressure sensor "no pressure" The electric signal indicates that the travel pressure is permanently missing.

The connecting line between control output and pressure sensor is interrupted, or The pressure sensor is defective The pressure sensor is defective

X35:31

X

X

X35:31

X

X

No pressure connection on sensor or supply line clogged, or No travel pressure built up

X35:31

X

X

1145

Inclination sensor "Supply connection" Signal outside the valid range (see signal description)

Cable breakage in supply line, or connecting cable sensor / voltage supply has come loose

X

X

1146

Inclination sensor "Ground connection" Signal outside the valid range (see signal description)

Cable breakage in ground line, or connecting cable sensor / ground supply has come loose

X35:?? .. X35:30 X35:1

X

X

1300

Seat connect not occupied

Cable breakage in signal line or driver's seat not loaded (driver not seated!)

X35:15

X

X

1500

Warning "Dangerous condition ASC"

Due to counter-rotating drive units the machine was stopped and the brake applied. After setting the travel lever to brake position the brake can be released.

X

X

1141

1142



Page 41 of 67



10.3.6 Steering (Only machine with electric steering) Fault Fault description Code 2060

Possible causes


DH-4

Assignment BVC-4

Output steering valve right The required control power cannot be transmitted to the proportional solenoid. Output steering valve left The required control power cannot be transmitted to the proportional solenoid.

The connecting line between control output and proportional solenoid is interrupted, or The proportional solenoid is defective The connecting line between control output and proportional solenoid is interrupted, or The proportional solenoid is defective

Error when teaching the surge current for the right hand valve Error when teaching the surge current for the left hand valve Note! Surge currents for steering pump have NOT been learned. See 3.7 (Only machine with electric steering)

Drum was not moved, maximum current was reached, steering is blocked (e.g. articulation lock applied) Drum was not moved, maximum current was reached, steering is blocked (e.g. articulation lock applied) The function "Teaching pump surge currents" for the steering pump has not yet been executed. -> New machine/replacement of control

X35:20

2170

Steering valve (arm rest) "direction change"

Wiring fault or steering sensor in left hand arm rest defective

X

2171

Steering valve (arm rest) "Pulse coverage" High difference in measuring values between sensor 1 and 2

Steering sensor in left hand arm rest defective.

2172

Steering wheel (arm rest) "Sensor 1 pulse range" The detected steering pulses on steering sensor 1 are outside the valid range (see signal description) Steering wheel (arm rest) "Sensor 2 pulse range" The detected steering pulses on steering sensor 2 are outside the valid range (see signal description) Steering wheel A45 (arm rest) "Sensor 1"

Check connecting line to steering sensor 1 or replace the steering sensor in the left hand arm rest, if necessary

X35:18 X35:19 X35:40 X35:41 X35:18 X35:19 X35:40 X35:41 X35:18 X35:19

Check the connecting lines to steering sensor 2, or replace the steering sensor in the left hand arm rest, if required.

X35:40 X35:41

X


X35:18 X35:19

X

2061

2065 2066 2068

2173

2174



X35:21


Fault reaction

X

X

X35:21 (X)

Note

X

X

Page 42 of 67

Service Training WZ – 4 Fault Code


Fault description

Possible causes

2175

Steering wheel A45 (arm rest) "Sensor 2"


2176

Steering wheel A45 (arm rest) "Sensor 1 cable breakage" Steering wheel A45 (arm rest) "Sensor 2 cable breakage"

Check the connecting lines to steering sensor 1, or replace the steering sensor in the left hand arm rest, if required. Check the connecting lines to steering sensor 2, or replace the steering sensor in the left hand arm rest, if required.

Steering "steering angle sensor... initialization" Internal control fault. Steering angle sensorB65 "Measuring value" Steering angle sensor B65 "Supply cable breakage" Steering angle sensor B65 "Ground cable breakage" Note! Teaching of steering stops for electric steering NOT yet executed. See 3.7

Replace the control

2177

2190 2191 2192 2193 2198

Equip. conn.Terminal X35:40 X35:41 X35:18 X35:19 X35:40 X35:41

DH-4

Assignment BVC-4


Fault reaction

X X X

X

Steering angle sensor on the articulated joint Power supply line to the steering angle sensor interrupted, or Steering angle sensor on the articulated joint Ground cable to the steering angle sensor interrupted, or Steering angle sensor on the articulated joint The function "Teaching steering stops" for the electric steering has not yet been executed. -> New machine/replacement of control

X35:29 X35:23

X X

X35:1

X

Possible causes

Terminal on ESX

(X)

Note

10.3.7 Driver's seat arm rest sensor (Only machine with electric steering) Fault Fault description Code 2300

Note! "Arm rest raised"

2301 2302

Signal fault Signal outside the valid range (see signal description) Supply cable breakage

2303

Ground cable breakage


The arm rest has been raised or the magnetic switch under the left hand arm rest is defective Cable breakage in magnetic switch signal line, or Magnetic switch under left hand arm rest defective Power supply line to the magnetic switch interrupted, or Magnetic switch under left hand arm rest defective Ground cable to the magnetic switch interrupted, or Magnetic switch under left hand arm rest defective


DH-4

Assignment BVC-4

X35:16

X

X35:16

X

X35:16

X

X35:16

X


Fault reaction

Page 43 of 67



10.3.8 Vibration Fault Code 3000

3001 3002 3003

3004

3005 3006

3007

3008 3009

Fault description

Vibration sensor "No signal" The sensor in the vibration motor does not pick up any pulses. Valve vibration pump (low amplitude on DH) General fault. Valve vibration pump (low amplitude on DH) Internal system fault. Valve vibration pump (low amplitude on DH) "Current range" The control current is outside the valid range (see signal specification) Valve vibration pump (low amplitude on DH) Line interruption

Valve vibration pump (low amplitude on DH) Internal system fault. Valve vibration pump (low amplitude on DH) "Control fault regulating up" The control current is outside the valid range (see signal specification) Valve vibration pump (low amplitude on DH) "Control fault regulating down" The control current is outside the valid range (see signal specification) Valve vibration pump (low amplitude on DH) Internal system fault. Vibration adaptation control (low amplitude on DH) "Frequency adaptation" Limits of adaptation range exceeded (see signal specification)


Possible causes

Check connecting lines and plugs to the vibration sensor, or replace the sensor in the vibration motor, if necessary.


DH-4

Assignment BVC-4

X

X

Details in 3004 – 3008

X35:48

X

X

System fault! Replace the control

X35:48

X

X

Faults in control line, or Connection to another potential (e.g. operating voltage)

X35:48

X

X

The connecting line between control output and proportional solenoid is interrupted, or The proportional solenoid is defective changeover relay / bridge missing System fault! Replace the control

X35:48

X

X

X35:48

X

X

Faults in connecting line, incorrect valve coil, or Connection to another potential (e.g. operating voltage)

X35:48

X

X


X35:48

X

X


X35:48

X

X

Wear or damage in vibration system hydraulic circuit.

X35:48

X

X



Fault reaction

Page 44 of 67

Service Training WZ – 4 3011 3012 3013

3014

Valve vibration pump (high amplitude on DH) General fault. Valve vibration pump (high amplitude on DH) Internal system fault. Valve vibration pump (high amplitude on DH) "Current range" The control current is outside the valid range (see signal specification) Valve vibration pump "Cable breakage" (high amplitude only DH)

Line interruption 3015 3016

3017

3018 3019

Valve vibration pump (high amplitude on DH) Internal system fault. Valve vibration pump (high amplitude on DH) "Control fault regulating up" The control current is outside the valid range (see signal specification) Valve vibration pump (high amplitude on DH) "Control fault regulating down" The control current is outside the valid range (see signal specification) Valve vibration pump (high amplitude on DH) Internal system fault. Vibration adaptation control (high amplitude on DH) "Frequency adaptation" Limits of adaptation range exceeded (see signal specification)


Description of Fault Codes on Control Details in 3014 – 3018

X35:48

X


X35:48

X

Faults in control line, or Connection to another potential (e.g. operating voltage)

X35:48

X


X35:48

X

X35:48

X


X35:48

X


X35:48

X


X35:48

X

Wear or damage in vibration system hydraulic circuit.

X35:48

X


Page 45 of 67



10.3.9 Attachment plates Fault Code 3051 3052 3053

3054

Fault description

Vibration pump, plates, valve General fault. Vibration pump, plates, valve "hysteresis" Vibration pump, plates, valve "current range" The control current is outside the valid range (see signal specification) Vibration pump, plates, valve "Cable breakage" Line interruption

3055

Vibration pump, plates, valve Internal system fault.

3056

Vibration pump, plates, valve "Control fault positive limit" The control current is outside the valid range (see signal specification) Vibration pump, plates, valve "Control fault negative limit" The control current is outside the valid range (see signal specification) Vibration pump, plates, valve Internal system fault.

3057

3058

3060

Warning ! Attachment plate lowered and backward travel


Possible causes

Details in 3052 – 3058, this fault always is connected with one of the faults listed below



The attachment plates are lowered and an attempt is made to drive backwards


Terminal on ESX

DH-4

Assignment BVC-4

X35:22

X

X35:22 X35:22

X X

X35:22

X

X35:22

X

X35:22

X

X35:22

X

X35:22

X


Fault reaction

X

Page 46 of 67



10.3.10 Diesel engine Fault Code

Fault description

Possible causes

5024 5025 5026 5027 5028

Diesel engine "Coolant level" warning Diesel engine "Coolant level" fault shut-down Diesel engine "Air filter" warning Diesel engine "Air filter" fault shut-down Water separator warning

Coolant level too low or sensor defective Coolant level too low or sensor defective Air filter soiled or sensor defective Air filter soiled or sensor defective Water or other dirt in fuel filter

5029

Water separator fault shut-down

Water or other dirt in fuel filter

Equip. conn.Terminal X26:10 X26:10 X26:8 X26:8 X27:4 X27:9 X27:4 X27:9

DH-4

Assignment BVC-4

X X X X X

X X X X X

X

X


Fault reaction


Fault reaction

10.3.11 Diesel engine EMR Fault Code

Fault description

5100

Diesel engine EMR "Warning light"

5101

Diesel engine EMR "red stop light"

5110

Diesel engine EMR "Nominal speed value"

5111 5112 5113 5114 5116 5117 5118

Diesel engine EMR "Engine oil filling level" Diesel engine EMR "Oil pressure" Diesel engine EMR "Charge air pressure" Diesel motor EMR "Temperaturein intake line" Diesel engine EMR "Coolant temperature" Diesel engine EMR "Fuel temperature" Diesel engine EMR "Engine speed"


Possible causes


DH-4

Assignment BVC-4

Collective warning F see further fault code for more accurate fault diagnose Collective message for engine shut down F see further fault code for more accurate fault diagnose

X

X

X

X

F CAN connection between ESX and EMR interrupted F CAN connection has short circuit against ground, against +12 V or connection between CAN+ and CAN-. F ESX without voltage supply F Battery charge level too low F Engine oil filling level too low F Engine oil pressure too low F Charge air pressure too low F Charge air temperature too high F Coolant temperature too high F Fuel temperature too high F Speed sensor 1 or 2 defective F Connection between EMR and speed sensor 1 or 2 interrupted

X

X

X X X X X X X

X X X X X X X


X31:21 X31:24 X31:4 X31:9 X31:13 X31:11

Page 47 of 67


Fault description


5120

Diesel engine EMR "CAN communication"

5121

Diesel engine EMR "CAN communication"

5122

Diesel engine EMR "Nominal speed value"

5123

Diesel engine EMR CAN communication

F CAN connection between ESX and EMR interrupted F CAN connection has short circuit against ground, against +12 V or connection between CAN+ and CAN-. F ESX without voltage supply F Battery charge level too low F CAN connection between ESX and EMR interrupted F CAN connection has short circuit against ground, against +12 V or connection between CAN+ and CAN-. F EMR without voltage supply. F CAN connection between ESX and EMR interrupted F CAN connection has short circuit against ground, against +12 V or connection between CAN+ and CAN-. F ESX without voltage supply F Battery charge level too low F CAN communication between EMR and ESX

5124


F CAN communication between EMR and ESX

5125



5126



5130

Diesel engine EMR "Oil pressure sensor"

5131

Diesel engine EMR "Charge air pressure sensor"

5132

Diesel engine EMR "Charge air temperature"

5133

Diesel engine EMR "Coolant temperature sensor"

5134

Diesel engine EMR "Speed sensor"

F Sensor defective F Wire breakage in current path F Current path has short circuit to ground F Sensor defective F Wire breakage in current path F Current path has short circuit to ground F Sensor defective F Wire breakage in current path F Current path has short circuit to ground F Sensor defective F Wire breakage in current path F Current path has short circuit to ground F Speed sensor 1 or 2 defective




DH-4

Assignment BVC-4

X31:12 X31:13 X31:12 X31:13 X31:12 X31:13 X31:12 X31:13 X31:22 X31:20

X

X

X

X

X

X

X

X

X

X

X31:25 X31:23

X

X

X31:25 X31:23

X

X

X31:8

X

X

X31:10

X

X


Fault reaction

Page 48 of 67


5140

Fault description

Diesel engine EMR "unknown fault"



Fault diagnostics only possible with DEUTZ diagnostics tool (SERDIA)



DH-4

Assignment BVC-4

X


Fault reaction

X

Page 49 of 67



10.3.12 Miscellaneous Fault Code 5502 5503 5504 5005

Fault description

"Hydraulic oil filter" warning "Hydraulic oil filter" fault shut-down "Oil temperature" warning "Oil temperature" fault shut-down

Possible causes


Hydraulic oil filter soiled or sensor defective Hydraulic oil filter soiled or sensor defective Hydraulic oil temperature too high or sensor defective Hydraulic oil temperature too high or sensor defective

DH-4

Assignment BVC-4

X X X X


Fault reaction


Fault reaction

X X X X

10.3.13 Machine type Fault Code 7011

7012

Fault description

Warning "Change of machine type" This warning is displayed when the machine type is changed. "Conflict machine type" This error message is displayed if the set machine does not comply with the basic parameters of the machine.


Possible causes

Only change the machine type after applying appropriate measures; e.g. conversion from D to PD (different rolling circumference of roller drum) The machine type has been changed to such an extent, that the type parameters no longer match the basic parameters → enter the correct machine code or one of the basic machine parameters was changed (e.g. different axle)



DH-4

Assignment BVC-4

X

X

X

X

Page 50 of 67


Description of Input Codes on Control

11 Input Codes for ESX Control Display and adjustment functions can generally only be accessed by entering "service code" 9999 beforehand!

11.1 Fault log without service code! Input code 0700 0701 0710

Description of display function Function "Show stored faults“ activated Function "Show stored faults“ deactivated Delete stored faults

Display values Fault codes are displayed one after the other 0000 once the fault log is deleted it is returned to 0000

11.2 Value displays 11.2.1 General Input code 0555 0556 0557 0720

Description of display function Display of "machine control software version ( ESX)" Display of Firmware version "LCD Display" Display of Firmware version "Data Collector" Display of "Machine Code"

Display values e.g.: "1.13" for software version V 1.13 e.g. "1.36" for version 1.36 e.g. "1.11" for version 1.11 The machine code is displayed (72xx) (see chapt. 3.6)

Description of display function Display of voltage at control output "Valve Brake"

Display values Display in V (e.g. 12.6 corresponds with 12,6V)

11.2.2 Brake Input code 1001



Page 51 of 67



11.2.3 Travel lever / driving Input code 1020

Description of display function Display "Travel lever end positions"

1021

Display "Values for axle forward reverse"

1022 1025

Display "Values for axle right left" Display "Travel lever actuating direction"

1026

Display "Travel direction"

1027

Display "Travel lever release"

Display values 100 = Forward 0 = Neutral 10 = Reverse 1000 = Left 10000 = Right Combinations are possible, e.g. 1100 for forward 0..1000 = Forward 0..-1000 = Reverse left -> - 1000..0..1000 -> right, i.e. brake gate 100 = Forward 0 = Neutral 1 = Reverse 0 = Neutral 1 = Forward 2 = Reverse 0 = locked 1 = released

11.2.4 Travel speed range selector switch Input code 1040 1041

Description of display function Display "Speed range / gear" Display "Voltage value for speed range / gear"


Display values Position of travel range selector switch from 1...24 Stages 0...4 = 4 Stages 5...9 = 3 Stages 10...14 = 2 Stages 15...19 = 1 Stages 20...24 = 0


Page 52 of 67



Input code 1042

Description of display function Display "Voltage value for speed range / gear standardized"

1044

Display "Speed range / gear" end value

Display values Stage 1 ≈ 956 Stage 4 ≈ 835 Stage 7 ≈ 716 Stage 10 ≈ 597 Stage 13 ≈ 478 Stage 16 ≈ 357 Stage 19 ≈ 238 Stage 22 ≈ 120 Stage 1 = 417 Stage 4 = 1‘667 Stage 7 = 2‘917 Stage 10 = 4‘167 Stage 13 = 5‘417 Stage 16 = 6‘667 Stage 19 = 9‘167 Stage 22 = 16‘667

Stage 2 ≈ 916 Stage 5 ≈ 795 Stage 8 ≈ 675 Stage 11 ≈ 557 Stage 14 ≈ 436 Stage 17 ≈ 318 Stage 20 ≈ 200 Stage 23 ≈ 80 Stage 2 = 833 Stage 5 = 2‘089 Stage 8 = 3‘333 Stage 11 = 4‘583 Stage 14 = 5‘833 Stage 17 = 7‘500 Stage 20 = 10‘000 Stage 23 = 20‘000

Stage 3 ≈ 875 Stage 6 ≈ 756 Stage 9 ≈ 637 Stage 12 ≈ 517 Stage 15 ≈ 396 Stage 18 ≈ 279 Stage 21 ≈ 160 Stage 24 ≈ 40 Stage 3 = 1‘250 Stage 6 = 2‘500 Stage 9 = 3‘750 Stage 12 = 5‘000 Stage 15 = 6‘250 Stage 18 = 8‘333 Stage 21 = 13‘334 Stage 24 = 23‘333

11.2.5 Travel pump: Travel direction forward Input code 1070 1071

Description of display function Display "Actual current value travel pump forward" Display "Nominal current value travel pump forward"

Display values Display in mA (0..350..1300) Display in mA (0..350..1300)

1078 1079

Initial current value (learned surge current) of the valve Maximum current value (derived end current) of the valve

Display in mA (permitted range 350mA..600mA) Display in mA (permitted range 1150mA..1400mA)

11.2.6 Travel pump: Travel direction reverse Input code 1080 1081

Description of display function Display "Actual current value travel pump reverse" Display "Nominal current value travel pump reverse"

Display values Display in mA (0..400..1300) Display in mA (0..400..1300)

1088 1089

Initial current value (learned surge current) of the valve Maximum current value (derived end current) of the valve

Display in mA (permitted range 350mA..600mA) Display in mA (permitted range 1150mA..1400mA)



Page 53 of 67



11.2.7 Travel motor front (drum) Input code 1100 1101 1105 1106 1107

Description of display function Actual pump current Nominal pump current Travel speed Pulses of speed sensor Direction signal of speed sensor

1108

Travel direction logics

Display values Display in mA (0..600..1000) Display in mA (0..600..1000) Display in m/min Counts the pulses up to 99'999 and starts again at 0 2 = Forward 1 = Standstill and reverse 1 = Forward 0 = Standstill 2 = Reverse

11.2.8 Travel motor rear (wheel axle) Input code 1110 1111 1115 1116 1117

Description of display function Actual pump current Nominal pump current Travel speed Pulses of speed sensor Direction signal of speed sensor

1118

Travel direction logics

Display values Display in mA (600..1000) Display in mA (600..1000) Display in m/min Counts the pulses up to 99'999 and starts again at 0 2 = Forward 1 = Standstill and reverse 1 = Forward 0 = Standstill 2 = Reverse

11.2.9 Adaption values for speed regulation Input code 1128 1129

Description of display function Pre-control factor forward travel Pre-control factor reverse travel


Display values 7000..10000 7000..10000


Page 54 of 67



11.2.10 Travel pressure sensor 11.2.11 Input code 1140 1141 1142 1143

Description of display function Pressure in bar Raw measuring value (voltage in V) Standardized measuring value Function status (internal logic -> diagnose)

Display values 0..600 0..5V 0..1000 0, 1, 2

11.2.12 Inclination sensor Input code 1145 1146 1147 1148

Description of display function Value in % Raw measuring value (voltage in V) Standardized measuring value Function status (internal logic -> diagnose)

Display values 0..80% 0..5V. 2.55V = 0% –1000..0..1000. (0 = 0%) 0, 1, 2

11.2.13 Travel condition values Input code 1150

Description of display function Current travel speed (in km/h)

Display values 0,00..20,00

11.2.14 Speed limitation Input code 1200

Description of display function Current setting (in km/h)

Display values 0 = No limitation 6, 7, 8, 9, 10, 11,12

11.2.15 Arm rest contact Input code 1300 1301 1302

Description of display function Function status Raw measuring value (voltage in V) Travel operation status by arm rest contact


Display values 1= arm rest up; 2= arm rest down Display in mV 1= Driving permitted; 2= Driving disabled


Page 55 of 67



11.2.16 Adaption values traction control Input code 1500 1501

Description of display function Pre-control factor front Pre-control factor rear

Display values 400..24000 400..24000

11.2.17 Steering: Steering valve Input code 2100 2101 2102 2103

Description of display function Display "Nominal current value steering valve right" Display "Actual current value steering valve right" Display "Nominal current value steering valve left" Display "Actual current value steering valve left"

Display values 0– 1200mA Display in mA 0– 1200mA Display in mA

2106 2107 2108 2109

Display Display Display Display

Display Display Display Display

"Minimum current value steering valve left" "Maximum current value steering valve left" "Minimum current value steering valve right" "Maximum current value steering valve right"

in in in in

mA mA mA mA

11.2.18 Steering: Angle sensor in articulated joint Input code 2110 2111 2112

Description of display function Raw measuring value (voltage in V) Standardized measuring value Standardized actual steering angle position


Display values 0...8,5VDC -1000...0...1000 -1000...0...1000


Page 56 of 67



11.2.19 Steering: Steering wheel Input code 2120

Description of display function Standardized nominal steering angle position

Display values -1000...0...1000

2130 2131 2132 2133

Steering wheel sensor 1 track 1 absolute pulses Steering wheel sensor 1 track 2 absolute pulses Steering wheel sensor 1 total pulses of sensor Steering wheel sensor 1 sense of rotation

Number of total pulses Number of total pulses

2140 2141 2142 2143

Steering wheel sensor 2 track 1 absolute pulses Steering wheel sensor 2 track 1 absolute pulses Steering wheel sensor 2 total pulses of sensor Steering wheel sensor 2 sense of rotation

1=steering wheel steers to the right (clockwise); 2=steering wheel steers to the left Number of total pulses Number of total pulses 1=steering wheel steers to the right (clockwise); 2=steering wheel steers to the left

11.2.20 Vibration Input code 3000

Description of display function Display "Switch for vibration mode"

3001

Display "Status of vibration relay“

3002

Display "Vibration pump valve current" The display shows the actual pump current. Display "Vibration pump valve current" (high amplitude on DH) The display shows the actual pump current.

3003


Display values Off = 0 On = 1 0 = Relay K43 not switched 1 = Relay K43 switched Display value = mA Display value = mA


Page 57 of 67



11.2.21 Attachment plates, option (only BW213 BVC) Input code 3050

Description of display function Display "Attachment plates activated"

3051

Display "Sensor for height shut-down"

3052

Display "Sensor for middle position"

3053

Display "Logic vibration On-Off“

3054

Display "Switch for float position"

3055

Display "Contact plates coupled"

3056

Display "Potentiometer value frequency setting of plates"

OFF = Vibration switched off ON = Vibration switched on OFF = Switch switched off ON = Switch switched on Attention! Float position is not always activated when switch is in ON-position! OFF = Plates are not hydraulically connected with the machine ON = Plates are connected with the machine 0..1000 standard, 0 = min. frequency, 1000 = max. frequency

3057

Control status valve "move up" (Pin 5 DIOS module) Control status valve "move down" (Pin 6 DIOS module) Control status valve "retract sideways" (Pin 8 DIOS module) Control status valve "extend sideways" (Pin 7 DIOS module) Control status valve "floating position" (Pin 13 + 15 DIOS module) Control status valve "Priority change-over" (Pin 14 DIOS module)

OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered OFF = Output not triggered ON = Output triggered

3058 3059 3060 3061 3062


Display values OFF, i.e. software for plates switched off ON, i.e. software for plates switched on OFF = Sensor has switched, senses metal, plates raised ON = Sensor has not switched, senses no metal, plates lowered OFF = Sensor has not switched, senses no metal ON = Sensor has switched, senses metal, plates in middle


Page 58 of 67



11.2.22 Engine Input code 5000 5001 5010 5011

Description of display function

5024

Display "Status engine coolant level"

5026

Display "Status engine air filter"

5028

Display "Status of water separator"

5050

Charge air pressure (in bar * 100)

Actual speed (rpm) Nominal speed (rpm) Idle speed (EMR parameter) (rpm) Maximum speed (EMR parameter) (rpm)

Display values 0..3000 0..3000 600..1000 1600..3000 0= Coolant level OK 1= Coolant level too low 0= Air filter OK 1= Air filter soiled 0= Water separator OK 1= Water or dirt in fuel filter 0..300 -> 0..3bar

11.2.23 Hydraulics Input code 5502

Description of display function Display "Status hydraulic oil filter"


Display values 0= Hydraulic oil filter OK 1= Hydraulic oil filter contaminated


Page 59 of 67



11.3 Test settings 11.3.1 Brake Input code 0500

Description of display function Activates the function "Driving against the closed brake"

0501

Deactivates the function "Driving against the closed brake"

Display values 500 and brake control light stays on when shifting the travel lever out of the brake gate O K for 3seconds, then 0000

11.3.2 Disable electric supply to wheel and drum drive motors (switch off) Input code 1120 1121 1122

Description of display function Enable function Switch off function "Disable electric supply for drum drive motor" Motor remains in position: max. displacement. Function "Disable electric supply for drum drive motor" Motor remains in position: max. displacement.

Display values

11.4 Settings / Teach / Emergency functions 11.4.1 Changing the machine code Input code 7010

Description of display function Change "Machine code"

Display values see chapter "Change machine code"

11.4.2 Automatic detection of surge currents in travel system Input code 1090 1091 1092

Description of display function Activate the function Function "Determine surge currents forward" (only Vers.1.07 and 1.08) Function "Determine surge currents reverse" (only Vers.1.07 and 1.08)


Display values see chapt. "Teach travel system surge currents" see chapt. "Teach travel system surge currents" see chapt. "Teach travel system surge currents"


Page 60 of 67



11.4.3 Speed detection, trimming of measuring values Input code 1158 1159

Description of display function Enable function Activate the function

Display values Pulses per 10m. 4000 - 15000

11.4.4 Speed detection, teaching of distance pulses Input code 1160 1161 1162 1163 1164 1165

Description of display function Permit teach function Activate the function: Measurement over a travel distance of 5m Activate the function: Measurement over a travel distance of 10m Activate the function: Measurement over a travel distance of 20m Activate the function: Measurement over a travel distance of 50m Activate the function: Measurement over a travel distance of 100m

Display values

1168 1169

Reset to basic values Storing the learned values

"saved" "saved"

Pulses Pulses Pulses Pulses Pulses

read read read read read

11.4.5 Detection of wheel rotation Input code 1200 1201

1

Description of display function Permit teach function Teach sense of rotation1

Display values Raise travel speed over 10m/min

Only optional function! The logical sense of rotation is automatically adjusted



Page 61 of 67



11.4.6 Steering: Automatic detection of surge currents on steering valve Input code 2000 2001

Description of display function Activate function "Teach steering start current" Function "Teach steering start current"

Display values see chapter 3.5 see chapter 3.5

11.4.7 Steering: Determining the steering stops 2010 2011 2012 2013

Activate function "Teach steering stops" Deactivate function "Teach steering stops" Function "Accept right hand steering stop" Function "Accept left hand steering stop"

see chapter 3.7 0000 see chapter 3.7 see chapter 3.7

11.4.8 Steering: Emergency function 2050 2051

Steering with joystick buttons Steering wioth steering wheel (uncontrolled)

"OK". In case of steering wheel failure "OK". In case of steering angle potentiometer failure

11.4.9 Steering: Other functions 2060 2061 2062

Activates function „Change steering unit“ Activate: Electric steering unit Activate: Hydraulic steering unit

see chapter 0 see chapter 0 see chapter 0

11.4.10 Vibration: Cancellation of the vibration permission in dependence on the travel speed 3047 3048 3049

Activate function "Limitation of vibration permission" Limitation of vibration permission to travel stage 12 Cancelling the limitation of vibration permission



Page 62 of 67



11.4.11 Plates 3070 3071 3072 3075 3076

Enabling code "Change plate parameters" Code "Switch on plate operation" Code "Switch off plate operation" Code "Plate adjustment without sensors" Code "Plate pump energized without plates attached"


Only required if plates have been retrofitted Only required if plates have been removed Attention – danger of collision! Use only in case of a sensor fault! Only for initial commissioning!


Page 63 of 67


12 Terminology in connection with ESX Short circuit A direct, unwanted connection between two different cables or between machine and cables. Examples: Two lines rub against each other until the insulation has worn off. A conductive line rubs off the insulation at the vehicle ground.

Wire breakage This generally means that a connection is interrupted. Possible reasons may be: Line: • torn (not necessarily visible from outside) • rubbed through • chafed mostly in connection with a short circuit to ground

Terminal, cable lug • loosened, slipped off • broken off, • corroded, • socket / plug faulty


General Terminology

Page 64 of 67

Service Training WZ – 4 Short circuit to ground Line, terminal has direct connection to vehicle ground, often in connection with wire breakage

Digital There are only two permissible states, e.g. switched on or off; lamp on / off; current flows / does not flow; valve open / closed (black-white valve)

Analogue In contrast to Digital many conditions are permitted within a certain range. For instance room temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω; valve 0% to 100% opened (proportional valve)


General Terminology

Page 65 of 67

Service Training WZ – 4 Control Controlling describes the process during which an input value influences a distance (the value to be controlled), following a fixed command. For this purpose all possible interfering factors (e.g. temperature, humidity ...) must be known.

Closed loop control Closed loop control is a process during which a value, the closed loop control value (e.g. pressure), is continually measured and compared with a nominal value (guide value). The result of this comparison will affect the closed loop control value, thereby adapting the closed loop control value to the guide value. This sequence occurs in a closed circuit, the co-called closed loop control circuit.

Marking Operating path: Measurement and comparison of value to be adjusted: Reaction to faults (generally): Technical expense:

Performance in unstable systems

Closed loop control closed (closed loop control circuit) Value to be adjusted is measured and compared. Counteracts to all faults targeting the system to be controlled. Low expense: Measurement of the value to be controlled, comparison of nominal and actual value, power amplification For unstable systems closed loop controls must be used.


Control open (control chain) Values to be controlled are not measured and compared. Does not respond to unknown faults High expense if many faults have to be considered, low expense if not faults occur. In unstable systems controls cannot be used.

General Terminology

Page 66 of 67

Service Training WZ – 4 Current and voltage measurement

Ohm’s law: U = Voltage R = Resistance I = Current

U = R∗I U I= R U R= I

Plausibility check The control (ESX) runs a plausibility check on all inputs. This means the control checks permanently whether certain state combinations are permitted; e.g. travel lever position forward and reverse will cause an fault message, because this condition is normally not possible.

GND - AGND Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional analogue ground, which is only to be used for sensors. (see description of the signals on the ESXcontrol) PWM – digital output Certain outputs on the ESX are designed as so-called PWM – digital outputs. This means that these outputs are special current outputs. Here it is possible to measure a current, but no voltage. These outputs are used to trigger proportional valves.


General Terminology

Page 67 of 67

Inhaltsverzeichnis: table of contents: Blatt Nr.: sheet no.: 001 002 003 004 005 006 007 008 009 010 011 012 101

BW177..226DH−4

Zeichnungsnummer drawing − no. 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95

Funktionsgruppe

function unit

Stromlaufplan Versorgung, Starten, Hupe Motor Deutz EMR II Fahrantrieb, Neigungssensor, Sitzkontakt Datensammler, LC−Display Lenkung, Vibration Fahrhebel, Vibrationsplatten Variocontrol, Messtechnik Bomag Compaction Management BCM Beleuchtung und StvZO Kabinenausrüstung, Beleuchtung, Radio, Tachograph Kabinenheizung, Klimaanlage, Zusatzheizung Bauteilliste

Circuit Diagram supply, starting unit, signal horn engine Deutz EMR II driving system, slope sensor, seat contakt switch data−collector, LC−display steering, vibration joystick, vibration−plates Variocontrol, measurement equipm. Bomag Compaction Management BCM illumination and StvZO cabin−equipment, headlights, radio, tachograph cabin−heater, air conditioning, add. heater component listing

28.06.2004 Seis 28.06.2004 Werner

Stromlaufplan circuit diagram

001

001

582 700 95 001

30 K11 2:10

15A

X36:B

X1:15A X36:A

1

F05

2

125A

Startschalter starting swwitch

2

G03

+

X1:3

19 17

NOT−Aus Emerg.−Stop

50a

K61

K61

K32:86

S01:22 3:1 F05:2 5:8

−

D+

5:2

B+

2:11

87a

8:2

X1:1

167A

B+

D+ K09

X1:7

30

86

K11

85

85 31 EMR 3:5

X1:8

86

Taster Hupe push button, horn

X38:A

23

14

24

X1:97

X1:98

X1:101

X1:102

50 B11

M01

2 B−

13

2:6 B+

G02 2

87a

S03

+

S30

K05 30

30

87

85

11:1

X1:155

2:6

2

1

X1:4

7:3 87

X1:109

R19

54 58

1

86

1

−

1

15

X34:P

125mA

V01

D+ MESX G01

X3:3

X1:152

125A

1

1

2

2

V02

1

B11 XS 12V

M −

2

V03

1

1

2

+ −

W X1:110

X1:168

X1:103

X1:123

X1:104

31

31 2:8

Trennschalter Batter break switch battery Heizflansch heating−flange

2

X1:30A

22 12 32 42 52 62

Anzugsw.:50A / Haltew.:10A

F00

15A

21 11 31 41 51 61

X37:B

2

1

F39

2

S01

nur bei Klimaanlage only acc.to air conditioning

F48

15A

X1:28A

X1:151

30

2 x 10qmm

3

1

F23

2

X1:27A

X37:A

Hauptsicherung main fuse

3:19

1

X1:79

Sicherung Heizflansh heating−flange

K14

15A

X1:16A

S00

5

F95

2

X1:30E

X1:28E

4:9

30A

K11:87 5:1 X1:27E

X1:16E 1

F13

87

6:17

X1:15E

X1:10

X1:9

K30 11:1 30 4:1

Batterie battery

Batterie battery

28.06.2004 Seis 28.06.2004 Werner

12:7

2:16

Starter starter

Signalhörer warning horns

3:1 Steckdose socket

Nur bei Geländer/ROPS/SD only at hand−rail/ROPS/sun−roof

Generator generator

Versorgung, Starten, Hupe supply, starting unit, signal horn

1

1

582 700 95 002

2:17 S01:22

S01:22 6:1 X1:95 1 K14 Relais Heizflansch relay heating−flange

2

X1:179

X1:96

B114

B130

Y137

5

2

1

2

B115

X33:8

X33:4

X33:1

X33:6

X33:5

X31:7

X31:2

X31:3

X31:1

X31:6

X57:6

3

X57:1

4

X31:5

X31:8

X31:9 AGND

X31:4 Signal

X57:16

X31:25

1

B113

X34:N

X1:182 X1:186

2:4

B88

RF MESS

X57:19

ESX Fahrst.

X57:18

RF REF

RF−

1

X31:24

X31:23

X31:19

X31:18

X31:16

X57:8

6

X57:9

2

Signal Temperatur

7

X57:4

2

+5V

1

X57:25

X57:17

2

Signal Druck

X57:15

1

X57:24

X57:14

AGND

STG+

X57:11

3

X57:23

STG−

X57:10

X31:17

X31:15

AGND

Signal

X57:13

X31:14

X31:11

AGND

Signal

X57:12

X31:10

X31:13

+5V

X57:22

X31:12

X31:22

X31:21

X31:20 Signal

X57:21

X30:2 AGND

X57:20

X30:1

X30:13

Ubat −

2

EMR Stellglied EMR commander

X32:B

X32:G

X32:K

X1:184

CAN2− 4:11 CAN2+ 4:11

X32:H

1

X1:181

X1:180

CAN high

CAN low

X30:12

X30:14

A48 Motorsteuerung EMR2 engine−controller EMR2

X30:11

X30:10 L

K

X1:183 X32:L

X32:A 31

X33:3

8−polig PNEUTRON

Diagnosestecker EMR diagnosis interface EMR

2:20

X33:2

max 7A

X33:7

X1:185 Steckerschnittstelle Deutz connector interface Deutz

31 EMR 31 4:1 2:2 Motordrehzahlsensor sender engine rpm 2 Motordrehzahlsensor sender engine rpm 1 EMR Motoröldruck EMR engine oil pressure

28.06.2004 Seis 28.06.2004 Werner

EMR Kühlmitteltemperatur EMR coolant temperature Ladeluftdruck + Temp charging air pressure + temperature

Motor Deutz EMR II engine Deutz EMR II

1

1

582 700 95 003

2:14

30

30 5:1 F24:2 5:3

X1:2 EMR Deutz

X1:145

3:4 3:4

CAN2+

CAN2+ 7:6 CAN2− 7:6 CAN1+ 5:8

CAN2−

X1:42 31 X1:119

Fahrhebel

LC−Display, OPUS 21

CAN1− 5:8

X1:120

X1:146 32

1

F84 10A

X34:G

X34:H

X34:C

X1:174 3:20 31

Sensor Achse sender axle

X35:68

X35:67

X35:66

X35:65

X35:55 Gehäuse housing

X35:47

X35:26

CAN1−

X1:50

X1:49

X1:48 X35:27 X35:46

Achsmotor

8:2

6:4

X9:2

X16:2

X1:149

X1:117

X1:123

2

X15:2

1

Y30 2

Y31 2

X1:123

X1:144

2

X1:144

PITCH MESX

Neigungssensor slope sensor

X1:143

X14:A

1

Y16

X1:143

X1:55

−

X1:46

X15:1 1

Y17

X1:142

sw

S

X16:1 1

+ H14 −

X1:142

S06

X1:124

+

400 ... 1.200mA

X9:1

X14:B

400 ... 1.200mA

2,5V

−

31 5:1

Sitzkontaktschalter switch, seat contact

Prop.−Pumpe Vorw. prop.−pump forwards

Rückfahrwarnsummer back up alarm buzzer 28.06.2004 Seis 28.06.2004 Werner

X1:47

Bandagenmotor

X1:141

4V

Sensor Bandage sender drum

CAN1+

Fahrpumpe rückw.

X1:143

1V

−

X1:178

X1:54

X35:53 X35:49 Fahrpumpe vorw.

X1:122

X1:82

8:2 SPEED MESX

X35:33

CAN2+

RxD

X35:4 Rückfahrwarnsum.

X35:24

X35:15 Sitzkontakt

X1:121

400 ... 1.200mA

B57

dir.

11:6 SPEED TAC

R21

X1:114

speed 8:2 DIR MESX

R23

X1:158

0,46A

br

+

B59

120 OHM 1 2

−45_G=0,5V

bl

X1:172

sw

−

dir.

speed

ws

br

+ B60

Diagnosestecker Fahrzeug diagnosis interface equipment

X34:B

120 OHM 1 2

400 ... 1.200mA

X1:175

X35:5

TxD

Elektronik Neigung

X35:30

X35:54

X35:60

X35:59

X35:57

X35:58

X35:34 speed

X1:176 bl

X35:37 Richtung

X1:177 ws

X35:12

X35:56

X35:31

X35:28 speed

X1:44

X35:38 Richtung

X1:45

+45_G=4,5V

X1:173

X1:171

Leistung

Drucksensor

8:2

+

X34:A

2

X1:34A X1:34A

A34

X34:D

X35:64

2

X1:17A

Fahr−Steuerung driving controller

R20

X1:53

1

15A

Drucksensor Fahrpumpe pressure sensor drive pump

R22 X1:34E

F67

B112

120 OHM 1 2

CAN2−

X1:17E

120 OHM 1 2

X1:52

sw

X1:51

rt

X52:2

X52:1

S01 2:16

Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch

Prop.−Ventil Bandagenmotor prop.−Valve drum motor

Prop.−Pumpe Rückw. prop−pump backwards

Prop.−Ventil Achsmotor prop.−Valve axle motor

1

1 1

582 700 95 004

4:20 2:20

30

30 8:1 K11:87 7:14 F24:2 6:15

K11:87 F24:2

4:3

2:17 F05:2 4:17 CAN1+ 4:17 CAN1−

X1:29E 1

F24 15A

ESX Fahrsteuerung

2

F05:2 2:17 CAN1+ 7:14 CAN1− 7:14

DIOS Platten

X1:29A

X1:80

X1:86

X1:41

X1:40

X1:39

X1:87 X1:88

Ub out

not connected

not connected

Ub "15"

Ub "30"

CAN1 low

CAN1 high

CAN1 low

VCC

CAN1 high

X34:R

D+

P

X1:117

X1:94

X1:94

28.06.2004 Seis 28.06.2004 Werner

DIN6

X29:6

X29:7

X29:8

X28:6 DIN5

X29:5

X28:1

X29:4 DIN4

X29:3 DIN3

X29:1 DIN1

X28:4 X29:2 DIN2

GND

X28:2

X26:12 GND

X27:5 GND

X27:3 GND/UIN3

AIN1

AIN2

X27:1

X28:3

X27:7 X27:12

X27:11 UIN2

X27:10 UIN3

X26:11 DIN11

X26:4 DIN4

X26:6 DIN6

X26:2 DIN2

X26:9

X26:1 DIN1

DIN7

DIN9

X26:7

X27:2 UIN1

X27:9 Sepa2

Füllstand Diesel fuel−level

Wasserabscheider water−seperator

Q X8:2

ECO Low High

BL 10:17 BR 10:17 BEL 10:4 KLIMA 12:6

23

down

13

up

23

13

S120 24

14

S139

24

14

X10:2

2 X21:2

31

X8:1 B124

1 B55

A81 LC−Display LC−display

X1:105

R03 P 2

4:20

X1:108

X10:3 X1:117

0 .. 67 OHM

2:6

1 B03

X1:107

Kühlmittelvorrat coolant stock level X21:1

B21

Sepa1

DIN10

DIN8

X1:112

Luftfilter air cleaner

Hydraulikölfilter hydraulic oil filter

X1:111

X27:4

X26:10

connector−colour: X26−grey; X27−black

X26:8

X26:5 DIN5

X26:3 DIN3

X1:106

X27:6

Steckerfarbe: X26−grau; X27−schwarz

A80 Datensammler data−collector

X28:5

X27:8

Schalter Motordrehzahl switch engine−rpm mode X1:154

X1:149

Datensammler, LC−Display data−collector, LC−display

switch frequency−control Schalter Frequenzverstellung

X1:82

31 6:1

1

1

582 700 95 005

S01:22

S01:22

X1:148

Lenkwinkelsensor steering angle sensor

7:1

F24:2 X1:41 X1:187

Lenkeinheit steering unit

S1 A

X39:3

X35:18

A34 Fahr−Steuerung driving controller

X35:23

X35:29

X35:1

X1:42

8,5V

X1:207

X1:55

4:6

VIB

11:6

BTS BREMSE 7:2

X35:35

1

X22:3

X22:4 X1:189

0V

sw ws

BTS Bremse

A

X41:6

0V

X35:19

X39:4

bl

B16

X41:8

X41:2

X40:3

S2

− X22:2

X1:206

X1:162

2

B

X40:2

X35:41

X41:4 X40:4

X39:2

X41:7

X1:159

S1 B

X1:208

X41:3 X40:1 VCC

X35:40

X41:1 X39:1 VCC

X41:5

1

X1:161 X1:160

+

br

X1:205

1

2

X1:56 FM1 X1:57

2

X1:58 FM2 X1:59

X1:60 FM5 X1:61

X1:203

AGND

X34:J nur BVC only BVC

Sig.

−

87a

X1:196

X1:195

Y112 1

1 Y93

2 X1:149

2

X1:200

X1:197

KA MESX

X1:38 7:14

GA MESX

K56

1

86

K57

86

K43

2

85

86

85

85

X6:1 Y08

1

X1:197

31 6:4

6:3

6:14

12

X7:1 Y07 1

X1:150 X1:113

+

H07

8:2 BRAKE MESX

Y04 1

2

−

2

X7:2 X1:82

Anbau 177DH: h.r.

Anbau 177DH: h.l.

Anbau 213DH: oben

Anbau 213DH: unten

X1:117

X1:190 31

7:1

Magnetventil Bremse solenoid valve brake

Prop−Ventil Vibration groß prop. valve vibration big

Prop. Ventil lenken links prop. valve steering left

28.06.2004 Seis 28.06.2004 TS022 Werner

S01 2:16

Prop.−Ventil Vibration klein prop. valve vibration small

Notlenkung rechts emrg. valve steering right

11

8:2

X1:115

2 X6:2 X1:118

5:20

Notlenkung links emerg. valve steering left

X35:61

8:2

X1:37 X1:116

Bremse

Warnsummer

X35:3

X35:48 Prop. out

X35:2 X35:22

7:2 87a

Y92 2

X1:200

6:2

X35:16

X1:89

6:12 87a

max.1.8A

Y113 1

X1:198

K43 87

30 K48 87 X1:147

150mA

6:9

X1:199

400 ... 1.200mA

X35:16

400 ... 1.200mA

X1:154

30

400 ... 1.200mA

87a

Umsch. Amplitude

6:8 87

X35:22

X35:16

K56 30

Pumpe Vib.−Platten

6:9 87

Armlehne

X51:2

X51:3

K57 30

X35:25

X35:21

X43:1 X35:20

Schalter Armlehne armrest−switch

B132

−

Aufnehmer Vibrationsmotor sensor vibration motor

X22:1

Lenkwink.

X1:55 X1:202

S

X35:17

A45

X1:188

X1:201 B65 +

X51:1

X43:2

F24:2

Vib.− Frequenz

X23:1

5:20

Vib.− Richtung

3:20

Warnsummer Störung warning buzzer, failure

Prop. Ventil lenken rechts prop. valve steering right

Lenkung, Vibration steering, vibration

1

1

582 700 95 006

CAN2+

5:14 5:14

LC−Display

CAN2−

5:20

CAN1+

CAN1+ 8:16 CAN1− 8:16 K11:87 8:1

CAN1− K11:87

Taster 1 = Platten rechts push button 1 = plates right

X1:31E

Taster 2 = Platten heben push button 2 = lift plates

Taster 4 = Platten links push button 4 = plates left

Taster 7 = Infotaste 1 push button 7 = info button 1 Taster 8 = Infotaste 2 push button 8 = Info button 2

BTS BREMSE 3

2

Näherungssch. Platten Mitte sensor plates centered

X1:156

X1:157

Taster 5 = platten senken push button 5 = lower plates

6:18

1 F145

Näherungssch. Platten oben sensor plates up

Taster 3 = Vibration EIN/AUS push button 3 = vibration ON/OFF

15A

X1:31A X1:209

B135 + −

B134 + −

X1:214

4:17 4:17

ESX Fahrst.

X1:213

6:2 X23:1

2

Fahrstufenschalter speed range selector

7

1

4

8

5

S

S

Add1 Add2

8

0V (Ref PIN5)

9 10

11 12

AK Ext1

X35:22

X62:1

X62:9 X62:10

X62:3

X62:2

X62:14

2

6:11

+5V out

X62:13

0V in

CAN+

X62:8

BTS zus.

CAN−

S55 Fahrhebel travel lever

X62:7

X1:153

7 6 5

1 3 4

X62:12 A54 Platten Steuerung plate−controller

X62:6

BTS Bremse

X62:11

Bremse auf = Ub

X25:3

Ub in

Bremse zu = 0V

X25:4 X25:2

+ − S

X62:5

X62:4

S42

AK Ext2

Stecker X23

400 .. 1.200 mA

X50:1

X50:2

X50:3

Ub out

8 OV out

7 DK Ext6

DK Ext5

DK Ext3

DK Ext1

DK Ext4

Stecker X24 3 4 5 6

2 DK Ext2

1

X1:210 S − + S35 K0G K48

86

K05

13

23

S09

13

S64

13 S36

13

S139

86

Y123 1 2 Y98

14

14

14

6:20 6:17

85

2

2

1

Y122 1

Y142 1

Y144 1

2

2

2

2

X72:2

X1:149

31

Y145 1

14

24 85

Y143 1

X72:1

X1:211

X1:212 8:1 31

2:12 nicht bei BVC not at BVC Schalter Amplitude switch amplitudes

28.06.2004 Seis 28.06.2004 TS022 Werner

Nur bei BVC Only at BVC

Schalter Schwimmstellung Platten sw. swimming pos. plates Frequenzverstellung Platten freq. adjust plates

Schalter Vibration Ein/Aus switch vibration on/off

Schalter Betriebsart Platten modesw. plates

Fahrhebel, Vibrationsplatten joystick, vibration−plates

Prop−Pumpe Platten prop.−valve plates

MV Platten heben MV Platten rechts plates up plates right MV Platten senken MV Platten Schwimmst plates down plates float−pos. MV Platten links MV Platten Priorität plates left plates priority

1

1

582 700 95 007

BTM

Beschleunigungssensoren acc. sensor front

Drucker printer

Aufnehmer Verstellmotor sens. adjust. motor

Display Messtechnik BOP display measurem. BOP

Bedieneinheit BEM control−unit BEM

GND

30 10:1 X2:48 + X2:66

X48:2

X48:1

X49:2

X49:1

X2:78

B62

X2:67

X2:68

X47:A

X47:B

AGND MESX

CAN−

X42:4

X74:4

CAN+

X4:E

X74:5

DIOS Platten

X4:C

X4:D

X74:3 X74:1

X74:2

X4:A

X4:B

X2:64

X2:65

120 OHM R21 1 2 120 OHM

10:4

2 X2:76

0..6VDC

CAN3−

X1:85

1

9:15 +

CAN3−

P07 E VIB

CAN3+

X2:60

9:15

−

2 X2:74

X2:63

8:19

CAN1−

X2:66

31.1

v.l.

BEL MESX

X2:51

X44:27 X44:3

X44:53

X44:5

X44:4 X44:68

X44:67

X44:66

CAN1+

v.r.

Y141

X42:3

1 R20 2

TxD

EVIB

400 .. 1.200mA

1

X2:73

X42:5

CAN1+

X2:50

GND

Y140

BRAKE MESX D+ MESX

Prop.

PITCH MESX

400 .. 1.200mA

X2:75

7:20

CAN1−

7:20

RxD

X44:46

X44:23 X44:47

6:15

Prop.

KA MESX GA MESX SPEED MESX DIR MESX

2:6

X2:69

P33

CAN3+

6:15

6:17

nur bei BTM prof only at BTM prof

−/sw

+/sw 20g/br

X44:41

X44:37

X44:31

X44:29

Elektronik

X44:60

X47:C

7:20

P11

X44:1

X2:59

X44:65

X2:58

X44:55

X2:55

S/ws

X44:9

X2:54

+/rt

8.5V

X49:4

B61

X44:7

X49:3 Aufn. vorne 20g

X48:4 Aufn. vorne 15g

X48:3

X44:54 X44:36

X44:59 X44:32

X44:14

X44:57 X44:35

X44:58

Leistung

X44:15

X44:38

X44:56

Pot. 15

X44:28

15g/bl

20g/br

15g/bl

−/gg

Aufn. hinten 20g

B62

9:15

X2:57

4:3 4:3 4:8

F2

X2:71

2

−/gg

A83 Messtechnik−Rechner measurement calc. unit

F1

nur bei BTM+/BTM prof only at BTM+/BTM prof

FM4

X42:8

X2:57

8:20

X2:60

X44:26

X2:53

X44:33

X2:56 2

X1:35A F148:2

P16 1

Erregerpos.

15A

2

X1:32A

X2:70

X2:77 1

Aufn. hinten 15g

10A

F146

X44:30

F148

+/sw

1

X2:49

− nur bei BEM only at BEM

X1:35E

X1:32E

31.1

Pot 15

X2:47

Pot 30

K11:87 10:1

X42:7

7:20

K11:87

X42:1

30

X42:2

5:20

X42:6

4:9

Beschleunigungssensoren acc. sensor rear

X1:34A

X1:82

31

31 9:1 Prop−Ventil Erreger auf solenoid−valve exciter up

EVIB−Meter EVIB−meter

Prop−Ventil Erreger ab solenoid valve exciter down

28.06.2004 Seis 28.06.2004 TS022 Werner

Variocontrol, Messtechnik Variocontrol, measurement equipm.

1

1

582 700 95 008

8:4

8:18

F148:2

CAN3−

8:18 CAN3+

1 R242

CAN3+

CAN3−

120 OHM X2:61

X2:62 R25 1 2 120 OHM

X4:N

X4:M

X75:7

X75:2

A87 USB−CAN Schnittst. USB−CAN Interface BCM X2:70 X76:1 P15

X4:G

X76:2 X4:F X2:63

BCM 05 BCM 05 nur bei BCM only at BCM 8:20

31

31 10:1

28.06.2004 Seis 28.06.2004 TS022 Werner

Bomag Compaction Management BCM Bomag Compaction Management BCM

1

1

582 700 95 009

K11:87 30

K06

X1:26A X1:83

12

87a

Anschluß Arbeitsschein− werfer ohne StvZO X1:21E

15A

X1:302

X1:21A E

30

24

10:10

85

− X3:1

X61:1

E09 1

E10 1

E11 1

2

2

2

2

Anschluß Arbeitsscheinwerfer bei ROPS/SD Aufbau Connection head lights acc.to ROPS/SD

11:1 31

Bel. Warnbinkschalter illumination, switch hazard light Blinkleuchte VL indicator front, LH Blinkleuchte HL indicator rear, LH

Blinkleuchte HR indicator rear, RH

Blinkleuchte VR indicator front, RH

Schlußleuchte rechts tail light, RH 28.06.2004 Seis 28.06.2004 Werner

X1:314 X59:2

E08 1 + H06

X1:321

24

1,75A

Warnblinkschalter switch, hazard light

X60:1

14

X1:313

23

X1:323 X60:2

2

13 01

X58:2

2

01 S14

1,75A

2

BR

X1:315 X58:6

2

4,6A

E25 1

BL

X1:304

Arbeitsscheinwerfer vorne rechts working head lights, front rh.

Arbeitsscheinwerfer vorne links working head lights, front lh.

Arbeitsscheinwerfer hinten rechts working head lights, rear rh.

E23 1

4,6A

86

E28 1

4,6A

K16

10:2 Schlußleuchte links tail light, LH Parkleuchte links parking light, LH Parkleuchte rechts parking light, RH

Scheinwerfer rechts head light RH

Arbeitsscheinwerfer hinten links working head lights, rear lh.

X1:320 X61:3 X1:324 X61:4

2

0,42A

X1:316 X59:6

2

0,42A

2

E27 1

4,6A

X1:312 X59:3

X1:303

X1:311 X58:3 2

0,42A

85

0,125A

X1:319 X60:3

Anschluß Arbeitsschein− werfer ohne StvZO connection working head lights without StvZO

86

X1:315 X58:6

4,6A

X1:316 X59:6

K06

E13 1 E12 1 E14 1 E15 1

X1:323 X60:4

X1:43

31 Scheinwerfer links head light LH

5:9 5:9

0,42A

8:7 0,125A

X1:310 X59:5

X1:84

R

X1:24A

13

BEL MESX

L

15A

X1:23A

S16 14

49R

49L

A02

BEL 5:9

2

4,6A

14

Anschluß Arbeitsscheinwerfer D bei Kabine Connection head lights with cabin STV1 11:17 STV2 11:17

F10

15A

Schalter Arbeitsbele switch, working head lights

X1:309 X58:5

87a

2 X1:315 X58:6

Schalter Blinker switch indicator

31 82

E16 1 E17 1

9:20

X3:5

X1:24E

F09

10:9 87

X1:22A

X3:4

X1:23E

4

F19

15A

23

L0R

S37

X1:22E 5

F22

24

K16 30

13

L0R

connection working head lights without StvZO

S15

X1:25A X1:305

X1:322

23

15A

X1:19A

10:4 87

11

32

30

1,75A

31

F08

15A

Schalter StvZO switch, StvZO 012

X1:25E

F07

X1:324 X61:2

X1:18A

X1:19E

1,75A

10A

X1:2

X1:316 X59:6

15A

X1:301

F18

X1:307

X1:26E

F11

X1:306

8:3 K11:87 8:19 30 X1:18E

Beleuchtung und StvZO illumination and StvZO

1

1

582 700 95 010

X3:6

K30

2:14

K32:87

12:2

X3:7 K32

X3:8

30

STV2 10:13 10:13 STV1

11:1 87 G

F143 15A

10A

7

87a

H

F42

A

F43 15A

8

B

F44 15A

1

C

F130 10A

2

F42 12:8 F130 11:14

E

F41

F

10A

3

6

5

11:9 F130

F144 15A

F130 12:7

1

VIB X3:18 5

B4

3

C3

E27

4,6A

2

P09

0,83A

X56:1

B3

X56:3

1

X56:4

A1

1

2

1 E28

1 E23

1 E25

1

2

2

2

2

XS 12V

+ −

Steckdose socket

7,8,9

A2+A3 6

5

4

4,6A

5

4,6A

S20

4,6A

4

6:18

+

K32 M

M05

M 2,9A

− 85

+ M04

M − M06

X56:2

I

15

E32

K141

M

− M07

X55:2

3 S158

4

31

+

5A

3,8A

A5+A6

−

3 min

+

5

S38

1 E72

4,7A

S86

S163 5

Abfallverzögert

Innenleuchte inside light, cabin

X3:17 4 4:3 SPEED TAC A16

−

1

E70

Tachographenmodul module, tachograph

A01

TK

2

2 S21

Radio radio

+

S45

01W 7 01

− − 31

Schalter Innenleuche switches interior lights

max. 13A

2

Kontrolleuchte indicator

E71 1

2

Nachtleuchte night illumination

− −

2

2 Heizung Heckscheibe heating rear screen

01W 7 01

3,8A

87a

R80

86

15 + + B51

E29

2:19 1

30

X55:1

11:16 87

K32:86

B51 + +

1

X55:3

30

X55:4

K141

1,75A

A12

ZA option 12:18 KABINE 31

Schalter Nachtleuchte switch, night illumination

Tachograph tachograph X3:2

Türkontaktschalter door switch

X3:1

Relais Kabine relais cabin

Schalterbel. switch illum.

10:20 31

31 12:1 Wascher hinten washer rear

11:6

Wischer hinten windscreen wiper, rear

28.06.2004 Seis 28.06.2004 Werner

Wascher vorn washer front Wischer vorne windscreen wiper, rear

Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph

Arbeitsscheinwerfer vorn working head lights, front

11:2

Arbeitsscheinwerfer hinten working head lights, rear

1

Rundumkennleuchte rotary beacon

1

582 700 95 011

11:17 F130 F42 Potential 15 aus Kabine 11:9

D

F31 20A

Potential 30 aus Kabine

F40 20A

4

Bedienteil Kabinenheizung/Klimaanlage X53:B

X54:4

0123

X54:3

3 A72 Steuergerät control unit 6 11 12

Schalter Kabinenlüfter switch blower cabin

X54:11

X54:6

K09

X54:12

5 1 X54:1

E30 Zusatzheizung add. heater

S28

Kleine Stufe = 0,67A mittleter Stufe = 1,0A große Stufe = 1.9A

6 2 1 3

X3:14

X18:1

X1:169 X19:1

B131

B103

1 2

X19:2 X20:1

rt

or

M

5:9

br

br

Stufe 1: 3.0A pro Lüfter Stufe 2: 4.5A pro Lüfter

X20:2 Y15

Stufe 3: 11.5A pro Lüfter

8

7

4

15

1

11:19

Y14 2

KABINE 31 2

2

2

X1:168 1 31

Klimakompressor air conditioning compr.

Kabinenlüfter cab ventilator

Y138 1 V06

V04 3,5A

X1:164

6

2

X18:2

1

X17:4

5

1

_t

HP

10 9

1A

_t

X20:4

ge

X1:167

Thermofühler Heizung temperature sensor heating unit

87a

KLIMA

11:20 31

0123

Regel aus = 0,4A

30

87

X1:170 Stromaufnahme Lüfter / current blower

12 11 13 14 16

2:8

X20:3 Überwachung Kühlmitt monitoring coolant pressure

Thermofühler Klimaan temperature sensor air conditioning

X17:2 X1:165

X3:12

X3:11

X53:H

X53:M X3:10

X53:L X3:9 X17:1 X1:163

X17:3 X1:166 or

M09

M

1

Anlaufstrom beim Start = 8,3A

B104 P LP 3

M09

3

Power Stufe = 2,8A

4

rt

2

A

2

X3:13

ge

5A

X54:2

4

S44

F15

8

1

control−unit cab−heater /air conditioning

X53:C

H

Schalter Kabinenzusatzheizung switch, cab add.−heater

11:19 K32:87 Potential 15 aus Kabine

Magnetventil Heizung solenoid valve, heating unit

Kraftstoffpumpe fuel pump heating unit

Kabinenlüfter cab ventilator

28.06.2004 Seis 28.06.2004 Werner

Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater

1

1

582 700 95 012

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 1 9 101

582 700 95

Bl. 010 011 011 004 006 006 003 007 012 005 005 008 009

Pf. 17 5 6 6 5 9 3 17 11 3 18 6 15

Benennung

A02 A12 A16 A34 A34 A45 A48 A54 A72 A80 A81 A83 A87

Blinkrelais Radio Elektronik Tachograph Prozessorplatine Prozessorplatine Lenkrad Elektronische Motorsteuerung Modul Pumpenansteuerung Steuergeraet Klimaanlage, Heizung Modul Datensammler Anzeigeeinheit Elektronik Messtechnik USB−CAN Schnittstelle BCM

indicator relay Radio Electronic system, tachograph Prozessing circuit board Prozessing circuit board Steering wheel Electronic engine management Modul pump control Control unit,air conditioning,heating modul data−collector Display−Unit electronic measurement−equipment USB−CAN Interface BCM

title

TYP

B03 B11 B11 B16 B21 B51 B51 B55 B57 B59 B60 B61 B62 B62 B65 B88 B103 B104 B112 B113 B114 B115 B124 B126 B130 B131 B132 B134 B135

005 002 002 006 005 011 011 005 004 004 004 008 008 008 006 003 012 012 004 003 003 003 005 003 003 012 006 007 007

3 16 18 16 2 4 6 4 6 4 2 12 8 10 4 6 7 7 3 13 7 11 5 14 8 10 2 17 16

Unterdruckschalter Luftfilter Signalhorn Signalhorn Aufnehmer Vibrationsfrequenz vorne Differenzdruckschalter Hydr.−Oelfilter Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Neigungssensor Stufenumschaltung Aufnehmer Bandagengeschwindigkeit Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Sensor, Lenkwinkel vorn Druckgeber Motoroel Temperaturschalter Klimaanlage Druckschalter Klimaanlage Druckgeber Fahrpumpe EMR Temperaturgeber Kuehlmittel EMR Aufnehmer, Motordrehzahl 1 Geber Ladeluftdruck Geber Wasserstandsabscheider Diesel EMR Temperaturgeber Kraftstoff EMR Aufnehmer, Motordrehzahl 2 Temperaturschalter Heizung Inititator Armlehne links Näherungsschalter Platten oben Näherungsschalter Platten mitte

Vacuum switch, air cleaner Warning horn Warning horn Transducer, vibration frequency, front Pressure diff. switch, hydr. oil filter Speaker radio Speaker radio Coolant charge expansion tank Slope sensor, speed range selection Sensor, drum speed Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Sensor, angularity steering, front Sender, engine oil pressure Temperature switch, air conditioning Pressure switch, air conditioning pressure sender, driving pump EMR Temperature switch, collant EMR Trancducer, engine speed 1 Sender, charging air pressure Sender, water separator fuel EMR fuel temperature sender EMR Trancducer, engine speed 2 Temperature switch, heating proximity switch left arm rest proximity switch, plate up proximity switch, plate middle

E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E23 E23 E25 E25 E27 E27 E28 E28 E29 E30 E32 E70 E71 E72

010 010 010 010 010 010 010 010 010 010 010 011 010 011 010 011 010 011 011 012 011 011 011 011

17 18 19 19 7 6 7 8 2 2 11 18 12 19 10 17 11 17 3 13 19 15 3 16

Blinkleuchte vorne links Blinkleuchte hinten links Blinkleuchte vorne rechts Blinkleuchte hinten rechts Parkleuchte links Schlussleuchte links Parkleuchte rechts Schlussleuchte rechts Scheinwerfer links Scheinwerfer rechts Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten rechts Arbeitsscheinwerfer hinten rechts Innenleuchte Kabine Heizgeraet Kennleuchte Nachtleuchte Kontrolleuchte Schalter Heckscheibenheizung Beleuchtung Bedienschalter

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. Working head light, front, lh. Working head light, front, lh. Working head light, front, rh. Working head light, front, rh. Working head light, rear, lh. Working head light, rear, lh. Working head light, rear, rh. Working head light, rear, rh. Inside light, cabin Heating unit Warning light Night lamp indicator light switch rear screen illum. Switches

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 1,75A

F00 F05 F07 F08 F09 F10 F11 F13 F15 F18 F19 F22 F23 F24 F31 F39 F40 F41 F42 F43 F44 F48 F67 F84 F95 FM1 FM2 FM4 FM5 F130

002 002 010 010 010 010 010 002 012 010 010 010 002 005 012 002 012 011 011 011 011 002 004 004 002 006 006 008 006 011

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

Hauptsicherung Batterie Sicherung Steckdose Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li. Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Steuerung (Potential 30) Sicherung Steuerung (Klemme 54) Sicherung Motormanagement intern Platinensicherung Platinensicherung Platinensicherung Platinensicherung Sicherung Nachtleuchte

Fuse, main, battery Fuse, socket Fuse, hazard light Fuse, indicators a. work. head light Fuse, parking and tail light, lh. Fuse, parking and tail light, rh. Fuse, head light, lh. Fuse, starter switch Fuse, heating unit Primary fuse, work. head light, fr. Fuse, working head light, front, lh. Fuse, working head lights, rear Fuse, warning horn Fuse, monitoring module Fuse, cabin ventilator Main fuse, cab Fuse, heating unit cab Fuse, rotary beacon Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, controller (pot.30) Fuse, controller (Pin 54) Fuse, engine controller (internal) Multifuse Multifuse Multifuse Multifuse Fuse, night lamp

125A 15A 15A 15A 10A 10A 15A 30A 5A 30A 30A 30A 15A 15A 20A 15A 20A 10A 10A 15A 15A 125A 15A 10A 15A MULTIFUSE MULTIFUSE MULTIFUSE MULTIFUSE 10A

5A 0,83A 1,75A

Name F143 F144 F145 F146 F148

Bl. 011 011 007 008 008

G01 G02 G03

Pf. 2 20 18 5 2

Benennung

title

TYP

28.06.2004 Seis 28.06.2004 Werner


582 700 95

Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Anhängeplatten Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15)

fuse rear screen heating unit Fuse cabin−socket fuse vibration plates Fuse Controller (Pot. 30) Fuse Controller (Pot. 15)

15A 15A 15A 15A 10A

002 3 002 5 002 4

Batterie Generator Batterie

Battery Generator Battery

103A

H06 H07 H14

010 15 006 16 004 11

Meldeleuchte Warnblinker Warnsummer Betriebsstoerung Warnsummer Rueckwaertsfahrt

Indicator light, hazard light Warning buzzer, breakdown Back−up alarm buzzer

LED ROT 0.15A MAX O,46A

K05 K06 K09 K11 K14 K16 K32 K43 K48 K56 K57 K61 K141

007 010 002 002 003 010 011 006 007 006 006 002 011

3 4 8 10 19 9 1 12 2 8 9 6 16

Relais Startstrom Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Vorgluehen Relais Scheinwerfer vorne Relais Kabine Relais Vibration Relais Fahrhebel 0−Stellung Relais Lenkung Relais Lenkung Relais Ladekontrolle Relais Heckscheibenheizung

Relay, starting current Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, glow plug system Relay, head lights, front Relay, cabin Relay, vibration Relay, travel lever 0−position Relay, steering system Relay, steering system Relay, charge control relay, heating rear screen

BOSCHW BOSCHW BOSCHW BOSCHL TYCOX BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW

M01 M04 M05 M06 M07 M09 M09

002 011 011 011 011 012 012

11 12 10 13 11 3 4

Starter Scheibenwischermotor vorne Scheibenwischermotor hinten Scheibenwaschermotor vorne Scheibenwaschermotor hinten Kabinenluefter Kabinenluefter

Starter Windscreen wiper motor, front Windscreen wiper motor, rear Windscreen washer motor, front Windscreen washer motor, rear Cabin ventilator Cabin ventilator

2.3 KW 4,7A 2,9A MAX. 3,8A MAX. 3,8A

P07 P09 P11 P15 P16 P33

008 011 008 009 008 008

15 8 14 16 16 18

Omegameter Frequenz− und Geschwindigkeitsanzeige Drucker BCM 03 Bildschirm Diagnose, Variomatic Opus 21

Omegameter Frequency− and Speedometer Printer BCM 03 terminal Diagnostics, varimatic Opus 21

R03 R19 R20 R20 R21 R21 R22 R23 R24 R25 R80

005 002 004 008 004 008 004 004 009 009 011

6 2 15 17 15 17 12 12 15 15 2

Geber Tankanzeige Heizflansch Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Heizung Heckscheibe

Sender, level gauge heater flange Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor heating rear screen

S00 S01 S03 S06 S09 S14 S15 S16 S20 S21 S28 S30 S35 S36 S37 S38 S42 S44 S45 S55 S64 S86 S120 S139 S139 S158 S163

002 002 002 004 007 010 010 010 011 011 012 002 007 007 010 011 007 012 011 007 007 011 005 005 007 011 011

10 16 18 10 8 15 4 4 13 10 18 3 7 11 18 19 11 3 3 6 10 3 17 19 13 15 16

Startschalter Schalter NOT AUS Taster Signalhorn Sitzkontaktschalter links Vibrationsschalter vorne Warnblinkschalter Beleuchtungsschalter StVZO Schalter Arbeitsbeleuchtung vorne Schalter Scheibenwischer vorne Schalter Scheibenwischer hinten Schalter Kabinenheizung Batterietrennschalter Vibrationsschalter klein/gross Vibrationsschalter Schalter Blinker Schalter Kennleuchte Stufenumschalter schnell−langsam Schalter Kabinenluefter Schalter Kabineninnenleuchte Schalter Fahrhebel Schalter Schwimmstellung Schalter Tuer, links Schalter Motordrehzahl Schalter Frequenzverstellung Schalter Frequenzverstellung Schalter Nachtbeleuchtung Schalter Heckscheibenheizung

Starter switch Switch, emergency off Push button, warning horn Switch, seat contact, lh. Switch, vibration, front Switch, hazard light Switch, lighting StVZO Switch, working head lights, front Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, cabin heating Switch, battery disconnect Switch, vibration low/high Switch, vibration Switch, indicator Switch, warning light Speed range selector, fast−slow Switch, cabin ventilator Switch, cabin inside light Switch, travel control lever Switch, float position Switch door, lh. Switch, engine speed Switch, frequency control Switch, frequency control Switch, cabin night lamp switch rear screen heating unit

V01 V02 V03 V04 V06

002 002 002 012 012

7 17 18 8 9

Diode Diode Diode Diode Diode

Diode Diode Diode Diode Diode

X1:1 X1:2 X1:2 X1:3 X1:4 X1:7 X1:8 X1:9 X1:10 X1:37

002 004 010 002 002 002 002 002 002 006

6 9 10 10 10 12 12 5 5 15

WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

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

103A

0 .. 67 OHM 167A 120 OHM 120 OHM 120 OHM 120 OHM 120 OHM 120 OHM 120 OHM 120 OHM MAX. 13A

NOTAUSH

FE5B FE5B FE5B FE5B

Name

28.06.2004 Seis 28.06.2004 Werner


582 700 95

X1:38 X1:39 X1:40 X1:41 X1:41 X1:42 X1:42 X1:43 X1:44 X1:45 X1:46 X1:47 X1:48 X1:49 X1:50 X1:51 X1:52 X1:53 X1:54 X1:55 X1:56 X1:57 X1:58 X1:59 X1:60 X1:61 X1:79 X1:80 X1:82 X1:82 X1:82 X1:82 X1:83 X1:84 X1:85 X1:86 X1:87 X1:88 X1:89 X1:94 X1:94 X1:95 X1:96 X1:97 X1:98 X1:101 X1:102 X1:103 X1:104 X1:105 X1:106 X1:107 X1:108 X1:109 X1:110 X1:111 X1:112 X1:113 X1:114 X1:115 X1:116 X1:117 X1:117 X1:117 X1:117 X1:118 X1:119 X1:120 X1:121 X1:122 X1:123 X1:123 X1:123 X1:124 X1:141 X1:142 X1:142 X1:143 X1:143 X1:143 X1:144 X1:144 X1:145 X1:146 X1:147 X1:148 X1:149 X1:149 X1:149 X1:149 X1:150 X1:151 X1:152 X1:153 X1:154 X1:154 X1:155 X1:156 X1:157

Bl. 006 005 005 005 006 004 006 010 004 004 004 004 004 004 004 004 004 004 004 006 006 006 006 006 006 006 002 005 004 005 006 008 010 010 008 005 005 005 006 005 005 003 003 002 002 002 002 002 002 005 005 005 005 002 002 005 005 006 004 006 006 004 005 005 006 006 004 004 004 004 002 004 004 004 004 004 004 004 004 004 004 004 004 004 006 006 004 005 006 007 006 002 002 007 005 006 002 007 007

Pf. 15 2 2 3 16 2 17 4 3 2 8 14 15 16 16 12 12 13 13 4 6 6 5 5 5 5 10 16 17 13 16 15 5 4 15 16 13 14 16 3 4 19 19 16 18 16 18 16 18 6 2 5 5 6 6 3 4 17 11 15 14 11 2 6 17 14 2 4 12 13 10 12 13 18 16 18 19 15 19 19 15 16 9 9 17 2 10 12 2 3 17 16 16 3 11 10 18 9 9

Benennung WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

title 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 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 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

TYP

Name

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582 700 95

X1:158 X1:159 X1:15A X1:15E X1:160 X1:161 X1:162 X1:163 X1:164 X1:165 X1:166 X1:167 X1:168 X1:168 X1:169 X1:16A X1:16E X1:170 X1:171 X1:172 X1:173 X1:174 X1:175 X1:176 X1:177 X1:178 X1:179 X1:17A X1:17E X1:180 X1:181 X1:182 X1:183 X1:184 X1:185 X1:186 X1:187 X1:188 X1:189 X1:18A X1:18E X1:190 X1:195 X1:196 X1:197 X1:197 X1:198 X1:199 X1:19A X1:19E X1:200 X1:200 X1:201 X1:202 X1:203 X1:205 X1:206 X1:207 X1:208 X1:209 X1:210 X1:211 X1:212 X1:213 X1:214 X1:21A X1:21E X1:22A X1:22E X1:23A X1:23E X1:24A X1:24E X1:25A X1:25E X1:26A X1:26E X1:27A X1:27E X1:28A X1:28E X1:29A X1:29E X1:301 X1:302 X1:303 X1:304 X1:305 X1:306 X1:307 X1:309 X1:30A X1:30E X1:310 X1:311 X1:312 X1:313 X1:314 X1:315

Bl. 004 006 002 002 006 006 006 012 012 012 012 012 002 012 012 002 002 012 004 004 004 004 004 004 004 004 003 004 004 003 003 003 003 003 003 003 006 006 006 010 010 006 006 006 006 006 006 006 010 010 006 006 006 006 006 006 006 006 006 007 007 007 007 007 007 010 010 010 010 010 010 010 010 010 010 010 010 002 002 002 002 005 005 010 010 010 010 010 010 010 010 002 002 010 010 010 010 010 010

Pf. 10 7 10 10 7 7 7 3 5 3 4 10 8 10 7 14 14 7 2 2 2 2 4 5 5 4 2 7 7 3 3 5 2 2 19 4 16 17 16 2 2 19 7 6 6 7 4 3 15 15 3 4 4 4 4 11 11 11 11 18 14 14 16 19 19 10 10 12 12 6 6 8 8 18 18 5 5 16 16 18 18 2 2 5 5 9 15 18 18 18 2 19 19 2 7 7 17 19 2

Benennung WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

title 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 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 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

TYP

Name

28.06.2004 Seis 28.06.2004 Werner


582 700 95

X1:315 X1:315 X1:316 X1:316 X1:316 X1:319 X1:31A X1:31E X1:320 X1:321 X1:322 X1:323 X1:323 X1:324 X1:324 X1:32A X1:32E X1:34A X1:34E X1:35A X1:35E X2:47 X2:48 X2:49 X2:50 X2:51 X2:53 X2:54 X2:55 X2:56 X2:57 X2:57 X2:58 X2:59 X2:60 X2:60 X2:61 X2:62 X2:63 X2:63 X2:64 X2:65 X2:66 X2:66 X2:67 X2:68 X2:69 X2:70 X2:70 X2:71 X2:73 X2:74 X2:75 X2:76 X2:77 X2:78 X3:1 X3:1 X3:2 X3:3 X3:4 X3:5 X3:6 X3:7 X3:8 X3:9 X3:10 X3:11 X3:12 X3:13 X3:14 X3:17 X3:18 X4:A X4:B X4:C X4:D X4:E X4:F X4:G X4:M X4:N X6:1 X6:2 X7:1 X7:2 X8:1 X8:2 X9:1 X9:2 XS XS X10:2 X10:3 X14:A X14:B X15:1 X15:2 X16:1

Bl. 010 010 010 010 010 010 007 007 010 010 010 010 010 010 010 008 008 004 004 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 009 009 008 009 008 008 008 008 008 008 008 008 009 008 008 008 008 008 008 008 010 011 011 002 010 010 011 011 011 012 012 012 012 012 012 011 011 008 008 008 008 008 009 009 009 009 006 006 006 006 005 005 004 004 002 011 005 005 004 004 004 004 004

Pf. 7 17 2 7 19 6 18 18 8 18 19 6 18 8 19 2 2 9 9 5 5 18 18 19 17 18 8 7 8 7 2 10 9 10 9 13 15 16 13 18 14 14 14 14 11 12 12 15 18 13 11 11 10 10 11 11 11 10 10 19 10 12 2 2 2 3 3 4 4 7 10 6 6 14 14 14 14 15 18 18 16 15 13 14 15 14 5 5 11 11 19 20 6 6 10 10 13 13 12

Benennung WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS SETCKER KABINE/ROPS STECKER ROPS/SD STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. STECKER VIBRATION GRO STECKER VIBRATION GRO STECKER VIBRATION KLE STECKER VIBRATION KLE STECKER WASSERABSCHEI STECKER WASSERABSCHEI STECKER RÜCKFAHRALARM STECKER RÜCKFAHRALARM Steckdose Steckdose STECKER TAUCHROHRGEBE STECKER TAUCHROHRGEBE STECKER SITZKONTAKT STECKER SITZKONTAKT STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE VOR

title 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−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS Con cabin/ROPS conn. ROPS/SR conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. conn. vibration big conn. vibration big conn. vibration small conn. vibration small connector water separator connector water separator conn. backupalarm conn. backupalarm Socket Socket connector fuel level sensor connector fuel level sensor connector seat contact switch connector seat contact switch connectoe driving pump back connectoe driving pump back connector driving pump front

TYP

Name

28.06.2004 Seis 28.06.2004 Werner


582 700 95

X16:2 X17:1 X17:2 X17:3 X17:4 X18:1 X18:2 X19:1 X19:2 X20:1 X20:2 X20:3 X20:4 X21:1 X21:2 X22:1 X22:2 X22:3 X22:4 X25:2 X25:3 X25:4 X26:1 X26:2 X26:3 X26:4 X26:5 X26:6 X26:7 X26:8 X26:9 X26:10 X26:11 X26:12 X27:1 X27:2 X27:3 X27:4 X27:5 X27:6 X27:7 X27:8 X27:9 X27:10 X27:11 X27:12 X28:1 X28:2 X28:3 X28:4 X28:5 X28:6 X29:1 X29:2 X29:3 X29:4 X29:5 X29:6 X29:7 X29:8 X30:1 X30:2 X30:3 X30:4 X30:5 X30:10 X30:11 X30:12 X30:13 X30:14 X30:15 X30:17 X30:22 X30:23 X30:24 X30:25 X31:1 X31:2 X31:3 X31:4 X31:5 X31:6 X31:7 X31:8 X31:9 X31:10 X31:11 X31:12 X31:13 X31:14 X31:15 X31:16 X31:17 X31:18 X31:19 X31:20 X31:21 X31:22 X31:23

Bl. 004 012 012 012 012 012 012 012 012 012 012 012 012 005 005 006 006 006 006 007 007 007 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003

Pf. 12 3 3 4 5 10 10 7 7 7 7 7 7 4 4 16 17 17 16 11 11 10 8 8 2 9 2 9 7 3 7 4 9 12 11 6 10 5 11 9 10 2 5 10 10 10 16 13 13 14 16 17 14 14 15 15 17 17 18 17 5 5 8 7 7 2 2 3 3 2 7 6 5 6 6 6 16 17 17 12 14 15 17 13 13 8 8 7 7 9 9 11 10 10 10 6 6 6 11

Benennung STECKER FAHRPUMPE VOR STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER THERMOFÜHLER STECKER THERMOFÜHLER STECKER EISSCHUTZ HKL STECKER EISSCHUTZ HKL STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER KÜHLMITTEL STECKER KÜHLMITTEL ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug 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−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−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor

title connector driving pump front conn. blower conn. blower conn. blower conn. blower conn. sender temp. conn. sender temp. conn. anti−ice air−cond. conn. anti−ice air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. connector coolant sensor connector coolant sensor connector vibration sensor connector vibration sensor connector vibration sensor connector vibration sensor connector switch speed ranges connector switch speed ranges connector switch speed ranges connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor 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 EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine

TYP

Name

28.06.2004 Seis 28.06.2004 Werner


582 700 95

X31:24 X31:25 X32:A X32:B X32:G X32:H X32:K X32:L X33:1 X33:2 X33:3 X33:4 X33:5 X33:6 X33:7 X33:8 X34:A X34:B X34:C X34:D X34:G X34:H X34:J X34:N X34:P X34:R X35:1 X35:2 X35:3 X35:4 X35:5 X35:12 X35:15 X35:16 X35:17 X35:18 X35:19 X35:20 X35:21 X35:22 X35:23 X35:24 X35:25 X35:26 X35:27 X35:28 X35:29 X35:30 X35:31 X35:33 X35:34 X35:35 X35:37 X35:38 X35:40 X35:41 X35:46 X35:47 X35:48 X35:49 X35:53 X35:54 X35:55 X35:56 X35:57 X35:58 X35:59 X35:60 X35:61 X35:64 X35:65 X35:66 X35:67 X35:68 X36:A X36:B X37:A X37:B X38:A X39:1 X39:2 X39:3 X39:4 X40:1 X40:2 X40:3 X40:4 X41:1 X41:2 X41:3 X41:4 X41:5 X41:6 X41:7 X41:8 X42:1 X42:2 X42:3 X42:4

Bl. 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 004 004 004 004 004 004 006 003 002 005 006 006 006 004 004 004 004 006 006 006 006 006 006 006 006 004 006 004 004 004 006 004 004 004 004 006 004 004 006 006 004 004 006 004 004 004 004 004 004 004 004 004 006 004 004 004 004 004 002 002 002 002 002 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 008 008 008 008

Pf. 11 12 2 3 3 3 2 2 19 18 18 19 18 19 17 20 14 16 12 13 10 11 3 5 14 2 4 12 16 11 10 3 10 10 18 11 11 4 3 10 5 11 8 16 15 2 4 9 5 13 5 17 5 2 11 11 15 16 14 12 12 9 18 7 7 8 8 8 17 13 18 19 19 19 4 5 10 12 12 9 10 10 9 9 10 10 9 8 8 8 8 11 11 11 11 18 18 19 18

Benennung EMR−Stecker Motor EMR−Stecker Motor EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOSS E−KAS ST. ZÜNDSCHLOSS E−KAS STECKER STARTER E−KAS STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21

title EMR−connector engine EMR−connector engine EMR−diagnosis EMR−diagnosis EMR−diagnosis 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 connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector supply e−box supply e−box connector ignition switch, e−box connector ignition switch, e−box connector starter, e−Box connector 1 steering unit connector 1 steering unit connector 1 steering unit connector 1 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21

TYP

Name

28.06.2004 Seis 28.06.2004 Werner


582 700 95

X42:5 X42:6 X42:7 X42:8 X43:1 X43:2 X44:1 X44:3 X44:4 X44:5 X44:7 X44:9 X44:14 X44:15 X44:23 X44:26 X44:27 X44:28 X44:29 X44:30 X44:31 X44:32 X44:33 X44:35 X44:36 X44:37 X44:38 X44:41 X44:46 X44:47 X44:53 X44:54 X44:55 X44:56 X44:57 X44:58 X44:59 X44:60 X44:65 X44:66 X44:67 X44:68 X47:A X47:B X47:C X48:1 X48:2 X48:3 X48:4 X49:1 X49:2 X49:3 X49:4 X50:1 X50:2 X50:3 X51:1 X51:2 X51:3 X52:1 X52:2 X53:B X53:C X53:H X53:L X53:M X54:1 X54:2 X54:3 X54:4 X54:6 X54:11 X54:12 X55:1 X55:2 X55:3 X55:4 X56:1 X56:2 X56:3 X56:4 X57:1 X57:2 X57:3 X57:4 X57:5 X57:6 X57:8 X57:9 X57:10 X57:11 X57:12 X57:13 X57:14 X57:15 X57:16 X57:17 X57:18 X57:19

Bl. 008 008 008 008 006 006 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 007 007 007 006 006 006 004 004 012 012 012 012 012 012 012 012 012 012 012 012 011 011 011 011 011 011 011 011 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003

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

Benennung STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER SCHALTER ARML STECKER SCHALTER ARML MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN ST. PLATTENFREQ. ST. PLATTENFREQ. ST. PLATTENFREQ. ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU STECKER DRUCKSENSOR STECKER DRUCKSENSOR STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor

title conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21 connector switch arm rest connector switch arm rest MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker conn. sender PLEIGER conn. sender PLEIGER conn. sender PLEIGER conn. sender front conn. sender front conn. sender front conn. sender front conn. sender rear conn. sender rear conn. sender rear conn. sender rear conn. plate−freq. conn. plate−freq. conn. plate−freq. connector 1 steering wiring connector 1 steering wiring connector 1 steering wiring connector pressure sensor connector pressure sensor conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller connector wiper rear connector wiper rear connector wiper rear connector wiper rear conn. wiper front conn. wiper front conn. wiper front conn. wiper front 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

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing

Bl. 003 003 003 003 003 003 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 008 008 008 008 008 009 009 009 009

Pf. 6 6 6 11 11 12 17 7 2 2 7 17 19 7 2 2 7 19 18 18 6 6 19 19 8 8 19 19 18 16 16 17 18 18 18 18 16 17 19 20 14 14 14 14 14 15 14 16 15 17 17

Benennung

X57:20 X57:21 X57:22 X57:23 X57:24 X57:25 X58:2 X58:3 X58:5 X58:6 X58:6 X58:6 X59:2 X59:3 X59:5 X59:6 X59:6 X59:6 X60:1 X60:2 X60:3 X60:4 X61:1 X61:2 X61:3 X61:4 X62:1 X62:2 X62:3 X62:4 X62:5 X62:6 X62:7 X62:8 X62:9 X62:10 X62:11 X62:12 X62:13 X62:14 X72:1 X72:2 X74:1 X74:2 X74:3 X74:4 X74:5 X75:2 X75:7 X76:1 X76:2

Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN ST. PROP.−PUMPE PLATT ST. PROP.−PUMPE PLATT STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER SUB−D STECKER BCM INT SUB−D STECKER BCM INT STECKER VERS. BCM STECKER VERS. BCM

connector engine connector engine connector engine connector engine connector engine connector engine Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO BL Con. STVZO BL Con. STVZO BL Con. STVZO BL Con. STVZO BR Con. STVZO BR Con. STVZO BR Con. STVZO BR con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. plate−pump con. plate−pump con. printer con. printer con. printer con. printer con. printer con. SUB−D BCM con. SUB−D BCM con. Power−sup. BCM con. Power−sup. BCM

title

Y04 Y07 Y08 Y14 Y15 Y16 Y17 Y30 Y31 Y92 Y93 Y98 Y112 Y113 Y122 Y123 Y137 Y138 Y140 Y141 Y142 Y143 Y144 Y145

006 006 006 012 012 004 004 004 004 006 006 007 006 006 007 007 003 012 008 008 007 007 007 007

17 15 13 14 7 13 12 15 16 7 6 14 4 3 16 17 10 10 10 11 18 18 19 20

Magnetventil Bremse Magnetventil Vibration vorne gross Magnetventil Vibration vorne klein Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Fahrtrichtung vorwaerts Magnetventil Fahrtrichtung rueckwaerts Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Lenkung vorne rechts Magnetventil Lenkung vorne links Magnetventil Vibrationsfrequenz, hinten Magnetventil Lenkung (Y1) Magnetventil Lenkung (Y2) Magnetventil Platten heben Magnetventil Platten senken EMR Verstellung Magnetveentil Heizung Magnetventil Erreger auf Magnetventil Erreger ab Magnetventil Plattenverschieben Links Magnetventil Plattenverschieben rechts Magnetventil Platten Schwimmstellung Magnetventil Platten (Priorität)

Solenoid valve, brake Solenoid valve, vibration, front, high Solenoid valve, vibration, front, low Fuel pump, heating unit Magnetic clutch, air conditioning compr. Solenoid valve, travel direction forw. Solenoid valve, travel direction backw. Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, steering, front rh. Solenoid valve, steering, front lh. Solenoid valve, vibrat.freq.,rear Solenoid valve, steering (Y1) Solenoid valve, steering (Y2) Solenoid valve, lift plates Solenoid valve, let down plates EMR adjustment Solenoid valve, heating unit solenoid valve exciter up solenoid valve exciter down solenoid valve, plate displace left solenoid−valve, plate displace right solenoid−valve, plate swimming−position solenoid−valve, plate (priority)

TYP

MAX. 1.8A 0.4 .. 1.2A 0.4 .. 1.2A 3,5A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A 1A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A

9 9 109

582 700 95

X36 X37

X38 X1:301… X1:324 X1:79 … X1:214

A80

X1:1 … X1:61

Nur bei StvzO only acc. To StvZO illumination

A02

K11

K05

K16

K06

K09

K43 K48 K61

B57

K57 K56

X32:1-12

Gez.: 28.06.2004 Name: Seis Gepr.: 28.06.2004 Name: Werner

X34:1-19

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CAN 1 A34 Fahrsteuerung

CAN 2

EMR + Fahrhebel

CAN 1

LCD + Datensammler + OPUS 21

A83 Messtechnik Steuerung

CAN 3


BCM

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from: 1

Connector overview BW 177...226 DH/BVC-4

Ers. f.:

Blatt Nr.: 301

Replaces:

Sheet No.: 301

582 700 95

BW216 219DH 4 Service Training

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