HR70-9,110-9,120-9,140C-9

 



Overview: Chapters • Chapter 1: Machine designation, manufacturer, serial number and measuring units • Chapter 2: Technical speci fi cations Compaction rollers • Chapter 3: Operating elements & displays • Chapter 4: Options • Chapter 5: Maintenance • Chapter 6: Diesel engine and hydraulic system • Chapter 7: Drum drive and rear axle • Chapter 8: Antrieb vibration system • Chapter 9: Electrical system • Chapter 10: Steering system and articulated pendulum joint • Chapter 11: Towing

• Chapter 10: Steering system & Articulated pendulum joint 10.1 Steering system and articulated pendulum joint ........... ........................ ......................... ........................ ......................... ......................... ........................... ........................... ............ 10.2 Steerin Steering g system........... ...................... ....................... ........................ ....................... ....................... ........................ ....................... ....................... .................... .................... ........................ ....................... .................. ....... 10.2.1 10.2. 1 Technica echnicall speci specifi cations s ........... ....................... ........................ ........................ ....................... ....................... ........................ ....................... ....................... ........................ ................... ................. .......... fication 10.2.2 Overview: Steering hydraulics and components ............ ........................ ......................... ......................... ........................ ........................... ........................... .................... ........ 10.3 Articulated pendulum joint ............ ........................ ......................... ......................... ........................ ......................... ......................... ............................ ............................ ......................... ..................... ........ 10.3.1 Installing and dismantling the articulated pendulum joint ............ ......................... ......................... ........................ .......................... .......................... .................... ........

10-2 10-2 10-2 10-3 10-4 10-5

• Kapitel 11: Towing the compaction roller  11.1 Towing the compaction roller ........... ........................ ......................... ........................ ......................... ......................... ........................ ............................ ............................. ......................... .................. ...... 11.1.1 Safety instructions referring to towing the compaction roller ........... ........................ ......................... ........................ .......................... ........................... ................ ... 11.1.2 Precautionary measures to be taken prior to towing ............ ......................... ......................... ........................ ........................... ........................... ........................ .............. .. 11.1.3 Carrying out the towing process ........... ........................ ......................... ........................ ......................... ......................... ........................... ........................... ......................... ..................... ........ 11.1.4 After the towing process ............ ......................... ......................... ........................ ......................... ......................... ........................ ............................ ............................. ......................... .................. ......

Table of contents

VIII

11- 2 11- 2 11- 3 11- 4 11- 5

Issue: 02-10

Chapter 1 Machine designation, manufacturer, serial number and measuring units Contents This chapter provides you with information about: • the machine type, the manufacturer and • the serial number & the type plate • measuring units and conversion tables

1.1 Machine designation, intended use and manufacturer  Designation:

Types:

HYUNDAI compaction roller

HR70C-9HR110C-9HR120C-9HR140C-9

Purpose of use: The HYUNDAI compaction rollers serve to compact soil. Intended use: The HYUNDAI compaction roller may only be used for the purposes and work mentioned in the operating manual. Any other use of the machine for further purposes is considered as misuse and is not permitted.

1.1.1 Manufacturer 

Name of manufacturer:  ATL AS WEYHAUSEN  ATL F. Weyhausen GmbH & Co. KG Maschinenfabrik Address: 27793 Wildeshausen, Visbeker Straße 35 (Germany) Contact: Phone: +49 (0) 4431 981 - 0 Fax: +49 (0) 4431 981 - 139 E-Mail: [email protected] Web: www.atlaswalzen.com

1.1.1A Distributor 

Distributor, Adderss

Hyundai Heavy Industries co., Ltd. 1000, Bangeojin sunhwan-doro, Dong-Gu, Ulsan, 682-792, Korea

1.1.2 HR70C-9: Type plate and serial number  Type plate labelling 2501 XXXX 123456 The serial number (1) features reference numbers X in order to identify specific equipment, the serial number (1) and the drum type. The serial number can be found on the type plate (2) on the right side below the cabin. In addition, it has been punched into the basic frame. Serial number key:

1

2501 XXXX 123456

2

Type: HR70C-9

B2

Current serial number  1

Type plate cabin

Smooth drum

Engine output: 61.5 kW 2200 min-1 2-stage drive: HA Standard Cabin Standard Canopy

Machine designation

B1

1 3

Pad foot drum 1

1

0 1

Issue: 02-10

HR110C-9 /HR120C-9 /HR140C-9:

1.1.3

Type plate and serial number Type plate labelling 2601 XXXX 123456 The serial number (1) features reference numbers X in order to identify specific equipment, the serial number (1) and the drum type. The serial number can be found on the type plate (2) on the right side below the cabin. In addition, it has been punched into the basic frame. Serial number key:

1

2601 XXXX 123456

2

Type plate cabin

Type: HR110C-9 HR120C-9 HR140C-9 Engine output: 96 kW 2200 min-1 103 kW 2400 min-1 4-stage drive: HA Standard HA & ECO Cabin Standard Canopy

Machine designation

1 4

B1

B2

Current serial number  1 2 4

1

Smooth drum

Pad foot drum

2

1 2

0 1

Issue: 02-10

1.1.4 Legal measuring units

Measuring system:

Machine designation

Metric

Inch

25.40 mm

1 in (inch)

1 kg

2.205 lbs

9.81 Nm (1 kpm)

7.233 lbf x ft (pound-force foot)

1.356 Nm (0.138 kpm)

1 lbf x ft (pound-force foot)

1 kg / cm

5.560 lbs

1 bar (1.02 kp/cm2)

14.233 psi (pound-force per square inch lb/in2)

0.070 bar (0.071 kp/cm 2)

1 psi (lb/in2)

1 liter

0.264 Gallon (Imp.) / 0.220 Gallon (US)

3.785 liters

1 Gallon (US)

4.456 liters

1 Gallon (Imp.)

1609.344 m

1 mile

0° C (Celsius)

+ 32° F (Fahrenheit) / 273.15 Kelvin

1 5

Issue: 02-10

1.1.5 Tightening torques (in Nm) for screws & bolts Standard metric ISO thread DIN 13, sheet 13 Dimensions

Maschine designation

8.8

10.9

12.9

M4

2.8

4.1

4.8

M5 

5.5

8.1

9.5

M6

9.5

14

16.5

M7

15

23

28

M8

23

34

40

M10

46

68

79

M12

79

115

135

M14

125

185

215

M16

195

280

330

M18

280

390

460

M20

390

560

650

M22

530

750

880

M24

670

960

1100

M27

1000

1400

1650

M30

1350

1900

2250

M33

1850

2600

3000

M36

2350

3300

3900

M39

3000

4300

5100

1 6

Issue: 02-10

Standard metric ISO thread DIN 13, sheet 13 8.8

10.9

12.9

M 8x1

Dimensions

24

36

43

M 9 x 1 

36

53

62

M10 x 1

52

76

89

M10 x 1.25

49

72

84

M12 x 1.25

87

125

150

M12 x 1.5

83

120

145

M12 x 1.5

135

200

235

M14 x 1.5

205

300

360

M16 x 1.5

310

440

520

M18 x 1.5

290

420

490

M20 x 1.5

430

620

720

M22 x 1.5

580

820

960

M24 x 1.5

760

1100

1250

M24 x 2

730

1050

1200

M27 x 1.5

1100

1600

1850

M27 x 2

1050

1500

1800

M30 x 1.5

1550

2200

2550

M30 x 2

1500

2100

2500

M33 x 1.5

2050

2900

3400

M33 x 2

2000

2800

3300

M36 x 1.5

2700

3800

4450

M36 x 3

2500

3500

4100

M39 x 1.5

3450

4900

5700

M39 x 3

3200

4600

5300

i Machine designation

NOTE! Friction coef ficient: μ total = 0.12 for screws and nuts without post-treatment as well as phosphated nuts. Tighten by hand!

1

7

Issue: 02-10

Chapter 2 Technical speci fications Compaction rollers Contents This chapter provides you with information about: • the technical specifications of the compaction rollers and the Diesel engines • their dimensions • the fill levels of the fluids and lubricants

2.1 Technical specif ications 2.1.1 Operating data with smooth drum

HR70-9

HR110-9

HR120-9

HR140-9

General data: Service weight

7100 kg

11200 kg

12000 kg

13900 kg

 Axle load, front

3800 kg

6100 kg

6900 kg

8000 kg

 Axle load, rear

3300 kg

5100 kg

5100 kg

5900 kg

22.40 kg/cm

29.00 kg/cm

32.80 kg/cm

38.00 kg/cm

1.8 / 0.8 mm

1.8 / 0.8 mm

1.8 / 0.6 mm

1.9 / 0.7 mm

30 / 40 Hz

30 / 38 Hz

30 / 40 Hz

30 / 40 Hz

120 / 90 kN

220 / 150 kN

240 / 140 kN

280 / 180

Drum width

1700 mm

2100 mm

2100 mm

2100 mm

Drum diameter

1250 mm

1500 mm

1500 mm

1500 mm

Drum thickness

20 mm

25 mm

30 mm

30 mm

0-10 km/h

0-12.5 km/h

0-12.5 km/h

0-12.5 km/h

+/- 12°

+/- 12°

+/- 12°

+/- 12°

45% / 50%

43% / 48%

45% / 48%

40% / 45%

106 dB

106 dB

106 dB

106 dB

Compaction performance: Static linear load  Amplitude high / low Frequency at high / low amplitude Centrifugal force at high / low ampl. Drum:

Drive / Transmission: Speed  Angular movement Gradeability with / without vibration Noise level: Sound power level LWA  Technical specifications

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Issue: 02-10

with pad foot drum

HR70C-9

HR110C-9

HR120C-9

HR140C-9

General data: Service weight

7250 kg

11200 kg

12000 kg

13900 kg

 Axle load, front

4200 kg

6100 kg

6900 kg

8000 kg

 Axle load, rear

3150 kg

5100 kg

5100 kg

5900 kg

Compaction performance: Static linear load  Amplitude high / low

/

/

/

/

1.8 / 0.8 mm

1.8 / 0.8 mm

1.8 / 0.6 mm

1.9 / 0.7 mm

30 / 40 Hz

30 / 38 Hz

30 / 40 Hz

30 / 40 Hz

120 / 90 kN

220 / 150 kN

240 / 140 kN

280 / 180

1700 mm

2100 mm

2100 mm

2100 mm

Drum diameter

11400 mm

1390 mm

1390 mm

1390 mm

Drum thickness

15 mm

25 mm

30 mm

30 mm

0-10 km/h

0-12.5 km/h

0-12.5 km/h

0-12.5 km/h

+/- 12°

+/- 12°

+/- 12°

+/- 12°

45% / 50%

43% / 48%

48% / 52%

40% / 45%

Sound power level LWA

106 dB

106 dB

106 dB

106 dB

Technical specifications

2 3

Frequency at high / low amplitude Centrifugal force at high / low ampl. Drum: Drum width

Drive / Transmission: Speed  Angular movement Gradeability with / without vibration Noise level:

Issue: 02-10

with pad foot drum

HR70C-9

HR110C-9

HR120C-9

HR140C-9

General data: Service weight

7250 kg

11200 kg

12000 kg

13900 kg

 Axle load, front

4200 kg

6100 kg

6900 kg

8000 kg

 Axle load, rear

3150 kg

5100 kg

5100 kg

5900 kg

Compaction performance: Static linear load  Amplitude high / low

/

/

/

/

1.8 / 0.8 mm

1.8 / 0.8 mm

1.8 / 0.6 mm

1.9 / 0.7 mm

30 / 40 Hz

30 / 38 Hz

30 / 40 Hz

30 / 40 Hz

120 / 90 kN

220 / 150 kN

240 / 140 kN

280 / 180

1700 mm

2100 mm

2100 mm

2100 mm

Drum diameter

11400 mm

1390 mm

1390 mm

1390 mm

Drum thickness

15 mm

25 mm

30 mm

30 mm

0-10 km/h

0-12.5 km/h

0-12.5 km/h

0-12.5 km/h

+/- 12°

+/- 12°

+/- 12°

+/- 12°

45% / 50%

43% / 48%

48% / 52%

40% / 45%

106 dB

106 dB

106 dB

106 dB

Frequency at high / low amplitude Centrifugal force at high / low ampl. Drum: Drum width

Drive / Transmission: Speed  Angular movement Gradeability with / without vibration Noise level: Sound power level LWA Technical specifications

2 3

Issue: 02-10

2.1.2 HR70C-9: Dimensions

HR70C-9 A B D H H1 L R R1 W W1

W R1 α

W1 B R

α

H H1 D

A L

smooth drum 2720 mm 1850 mm 375 mm 2723 mm 1250 mm 5032 mm 3900 mm 5600 mm 1700 mm 1700 mm + / - 30°

pad foot drum 2720 mm 1850 mm 375 mm 2728 mm 1140 mm 5032 mm 3900 mm 5600 mm 1700 mm 1700 mm + / - 30°

2.1.3 HR110C-9/HR120C-9/HR140C-9: Dimensions

HR110C-9/120C-9/140C-9 A B D H H1 L R R1 W W1

W R1

α W1 B R

α

smooth drum 3195 mm 2270 mm 490 mm 2920 mm 1500 mm 5757 mm 4860 mm 7015 mm 2090 mm 2100 mm + / - 30°

pad foot drum 3195 mm 2270 mm 490 mm 2920 mm 1390 mm 5757 mm 4860 mm 7015 mm 2090 mm 2100 mm + / - 30°

H H1 D

A L Technical speci fications

2 5

Issue: 02-10

Tires  Standard...  ...with smooth drum  ...with pad foot drum

HR70C-9 16.9 - 24 16.9 - 24 TR

HR110C-9 /HR120C-9/HR140C-9 23.1 - 26 23.1 - 26 TR

Fill levels Fuel tank (in liters)  Hydraulic oil tank (in liters)

HR70C-9  167 l 68 l

HR110C-9/HR120C-9/HR140C-9 300 l 106 l

Diesel engine    Make  Nominal output (kW / HP)

HR70C-9 Perkins 1104C-44  61.5 / 84

HR110C-9 96 / 130

HR120C-9 Deutz TCD 2012 L4 96 / 13

HR140C-9 103 / 140

Speed Speed (km/h)

HR70C-9  0 - 10

HR110C-9/HR120C-9/HR140C-9 0 - 12.5

2.1.4 Roll-over protection system The cabin of the compaction roller corresponds to the stipulations of standard ISO 3471 (1994). It has been tested in accordance with the currently valid acceptance test specifications for roll-over protection systems (ROPS) and a ROPS authorization has been issued.

CAUTION!  Any modifications of the cabin are permitted only after a written form of approval has been issued by F. Weyhausen within the scope of the certification tests. Otherwise, the ROPS certifi cate loses its validity. No liability will be assumed for any modifications of the cabin (drilling/welding) carried out without prior explicit approval of the manufacturer!  Technical specifications

2 6

Issue: 02-10

Chapter 3 Operating elements & displays

Contents This chapter provides you with information about: • the layout of the control elements & displays • the functions of the control levers • switches and circuitries referring to roller operation

3.1 Control elements and displays

HR70C-9

HR110 /120/140C-9

Control elements & displays

3 2

Issue: 02-10

3.1.1 Displays on the dashboard Symbol Function Forward motion

Light indicates forward motion

Reverse motion

Light indicates reverse motion

ECO Speed (Optional feature)

 Activation of the ECO Speed mode

Parking brake

 Activation of the parking brake. Diesel engine can only be started with the parking brake applied (activated) LED (yellow) indicates preheating process of the Diesel engine (ignition lock position I) and goes out as soon as the required starting temperature has been reached

Preheat

Control elements & displays

Description

Charge control

Lights up on starting the Diesel engine but has to go out as soon as it has started

Brake pressure

Light warns of an insuf ficient hydraulic oil pressure of the brake system

Diesel engine oil temperature

If this symbol lights up, stop the compaction roller and let the Diesel engine idle until the engine oil has cooled down!

Diesel engine oil pressure

If this symbol lights up during roller operation, immediately stop the Diesel engine and turn it off!

Coolant level Diesel engine

Light warns of an insuf ficient coolant level in the cooling circuit

Dual display Accumulation of dirt: fuel filter / air filter 

If the corresponding display lights up, determine the cause and clean or replace the filter 

3 3

Issue: 02-10

3.1.2 Dashboard: Displays related to roller operation Symbol

Function

Description

High Amplitude

Light indicates that a high amplitude has been set by means of the selector switch on the panel of switches next to the control lever 

Low Amplitude

Light indicates that a low amplitude has been set by means of the selector switch on the panel of switches next to the control lever 

Drum drive

Light indicates that overmodulation of the hydraulic engine at the drum has been activated by means of the switch on the panel of switches next to the control lever.

Rear axle drive

Light indicates that overmodulation of the hydraulic engine at the rear axle has been activated by means of the switch on the panel of switches next to the control lever.

Function

Description

Parking brake

 Activates / deactivates the parking brake (1).

Horn

Rocker switch for the horn (2).

3.1.3 Steering column switches Symbol

3

Functions: Ignition lock

1

2

Control elements & displays

Emergency stop push-button

3 4

Ignition off  Ignition on Engine start

In an emergency which calls for an immediate stop of the compaction roller, push the emergency stop push-button (3). Issue: 02-10

3.1.4 HR70C-9: Control lever (joystick) and panel of switches in the right armrest

0 KA GA

Function

Description

Control lever (Joystick)

The joystick in the right armrest serves to control the functions related to roller operation. • Joystick moved forwards: Foward travel • Joystick moved backwards: Reverse travel

Button on the joystick

The button serves to activate / deactivate vibration (on / off)

Selector switch vibration mode (soil compaction)

Selector switch Diesel engine speed

Overmodulation (HA control)

Control elements & displays

3 5

• • •

Central (middle) position ( 0) = Vibration off  Rear pressed down ( KA) = Surface compaction (low amplitude) Front pressed down ( GA) = Deep compaction (high amplitude)

Serves to activate or deactivate the 2nd roller operation stage (the availability of this option depends on the speci fic type) • Front pressed down ( Rabbit) = 1st stage: vibration mode • Rear pressed down ( Turtle) = 2nd stage: vibration & drive mode Overmodulation drum drive on / off 

Issue: 02-10

3.1.5 HR110C-9 /HR120C-9 /HR140C-9: Control lever (joystick) and panel of switches in the right armrest

Red

 Yellow

Function

Description

Control lever (joystick)

The joystick in the right armrest serves to control the functions regarding roller operation. • Move the joystick forwards for forward motion. • Move the joystick backwards for reverse motion.

1.1

Joystick buttons

2.2 Blue Green

Selector switch vibration mode

0 GA

Control elements & displays

• • •

KA

2.3

The colors and the ergonomic design of the joystick buttons render it particularly easy to activate a number of functions: green = Neutral position (Diesel engine idle speed) blue = drive mode red = drive & work mode yellow = ECO Speed (if this optional feature is not available for your machine, actuation of this button just reduces the Diesel engine speed; working is not possible) For information on ECO Speed, see chapter Options. The red (vibration on/off ) button (1.1) can be found on the front side of the joystick.

Overmodulation (HA Control)

3 6

Central (middle) position (0) = Vibration off  Rear pressed down (KA) = Surface compaction (low amplitude) Front pressed down (GA) = Deep compaction (high amplitude)

Overmodulation hydraulic motor drum On / Off  (2.2) Overmodulation hydraulic motor rear axle On / Off  (2.3)

Issue: 02-10

3.2 Compaction roller functions 3.2.1 HR70C-9: Functions of the hydraulic HA control The hydraulic HA control serves to operate the compaction roller on level grounds or on slopes, either with or without vibration.

Notes on the hydraulic HA control

i

NOTE! • • • •

Overview: Benefi ts of the hydraulic HA control Automatic adjustment of the traction drive to different types of soil No intervention on the part of the driver required. Ideal adaptation to any type of ground, maximum traction on the axle. Continuous traction control at the axle.

Deactivating the HA control By means of the HA control, traction drive gliding and spinning of the drums can be prevented... •

... whenever driving the compaction roller across heavy terrain causes the drums or/and the wheels to sink into the ground or

•

... whenever slopes (inclinations) cause an increase in the tractive resistance If slippery grounds or extreme inclinations make driving the compaction roller impossible, the HA control reduces the engine speed until the machine comes to a stop.

2.2

In certain situations, overmodulation of the HA control may be required, e.g. •

when starting the compaction roller with the drum/wheels sunk into the ground or

•

while driving at a carefully set speed.

In order to do so, actuate the corresponding switch ( 2.2) to deactivate the HA control at the drum. The maximum driving torque is established at the roller drum.

WARNING! If, even with the overmodulation activated, the required thrust cannot be established, do not continue operation on the slope in question and back up.

HA control

3 7

Issue:

02-10

3.2.2 HR110C-9/HR120C-9/HR140C-9: Functions of the hydraulic HA control The hydraulic HA control serves to operate the compaction roller on level grounds or on slopes, either with or without vibration.

Notes on the hydraulic HA control

i

NOTE! • • • •

Overview: Benefi ts of the hydraulic HA control Automatic adjustment of the traction drive to different types of soil No intervention on the part of the driver required. Ideal adaptation to any type of ground, maximum traction on the axle. Continuous traction control at the axle.

Deactivating the HA control By means of the HA control, traction drive gliding and spinning of the drums can be prevented... •

... whenever driving the compaction roller across heavy terrain causes the drums or/and the wheels to sink into the ground or

•

... whenever slopes (inclinations) cause an increase in the tractive resistance If slippery grounds or extreme inclinations make driving the compaction roller impossible, the HA control reduces the engine speed until the machine comes to a stop.

2.2

2.3

•

In certain situations, overmodulation of the HA control may be required, e.g.

•

when starting the compaction roller with the drum/wheels sunk into the ground or

•

while driving at a carefully set speed.

In order to do so, actuate the corresponding switches ( 2.2 for overmodulation of the drum or 2.3 for overmodulation of the rear axle) to deactivate the HA control. The maximum driving torque is established at the roller drum.

WARNING! If, even with the overmodulation activated, the required thrust cannot be established, do not continue operation on the slope in question and back up. HA Control

3 8

Issue: 02-10

3.2.3 Maximum gradeability of the compaction rollers

Degree%

   n  e    i    l   c    n    i

   n  e    i    l   c   d  e

  e   p   o    l    S

  o    i    t   a   r   n   o    i    t   a   n    i    l   c   n    I

Type

with compaction, in %

without compaction, in %

HR70C-9

45

50

HR110C-9

43

48

HR120C-9

45

48

HR140C-9

40

45

See table on the left for information on the % / degree gradeability ratio.

Slopes

3 9

Issue: 02-10

Chapter 4 Options

Contents This chapter provides you with information about: • conversion from a smooth to a pad foot roller drum • converting and adjusting the scrapers • benefits and installation of a compaction measurement system • ECO Speed

4.1 Converting from a smooth roller drum to a pad foot roller drum (Optional feature) Safety instructions referring to work with the compaction roller  1

i

NOTE! Obligation to inform yourself! • Inform yourself of all issues related to the operation of the compaction roller. • In order to carry out the conversion from smooth roller drum to pad foot roller drum, a crane disposing of a minimum lifting capacity of 8 tons is required.

Converting from a smooth roller drum to a pad foot roller drum In order to operate the compaction roller with a pad foot drum (1), you can order a retrofit kit containing three pad foot segments as an optional feature from the manufacturer.

Labeling of the pad foot segments Each of the three pad foot segments (2) is individually labeled next to the split pad feet (3)

2

i

NOTE! In order to mount the 3 pad foot segments on a smooth roller drum, observing the following instructions is of vital importance! • Make sure you maintain the correct sequence! • Pay close attention to the labeling (3) of the segments (2) and the correlation of the serial numbers. • Only the corresponding segments (2) and identical serial numbers match up for this particular compaction roller.

3

Converting from

smooth roller drum to

pad foot roller drum

4 2

Issue: 02-10

4.1.1 Mounting the pad foot segments on a smooth roller drum Dismantling the attached parts of the smooth roller drum 4 5

•

Prior to starting work, put struts under the roller frame to support it.

•

Remove the front and rear scrapers ( 4) from the smooth roller drum ( 5).

•

Make sure the roller frame is securely fastened by appropriate tie-down equipment ( 6) before lifting it by means of a crane. The lifting height is suf ficient if a pad foot segment can be placed under the smooth roller drum ( 5).

•

Use a high pressure washer to clean the smooth roller drum (5).

4 6

HA-Regelung

Converting from

3-7

smooth roller drum to

pad foot roller drum

4 3

Ausgabestand: 02-10

Issue: 02-10

4.1.2 Mounting the pad foot segments •

2.1

7

2.2

Use a crane to lift the first segment ( 2.1) at the lifting lug (7) and to place it onto a transport vehicle at the lifting lugs. Drive the transport vehicle under the smooth roller drum (5), put down the

2.3

segment (2.1) and adjust its position. Lower the roller frame by means of the crane and place the smooth roller drum (5) on the segment (2.1). Remove the tie-down equipment. •

 Advance the compaction roller until the smooth roller drum (5) rests only on the rear edge (8) of the

•

Lift the second segment (2.2) at the lifting lug (7). Place it on the top of the smooth roller drum (5),

first segment (2). adjust it and connect it to the first segment (2.1) by bolting them together at the junctions (9).

5

•

Use clamps (10) to attach the loose edge of the second segment to the smooth roller drum (5).

•

Make sure there is enough space between the mounted segments and the roller frame.

8

2 10 9

10

5

HA-Regelung 2.1 Converting from

smooth roller drum to

pad foot roller drum

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Issue: 02-10

2.2

•

Back up the compaction roller until the bare part of the surface of the smooth drum (5) points upward, rendering it possible to mount the third segment (2.3).

•

them together at the junctions (9).

9 5

•

Tighten all screws at the junctions evenly (9) along the entire width of the roller (B).

•

Repeatedly drive the compaction roller forward and backward so the segment junctions point

2.3

9.1

 Attach the third segment (2.3). Connect it to the first (2.1) and the second segment (2.2) by bolting

upward. •

Check all screw connections at the junctions (9) and tighten them.

•

 Tightening torques:

•

195 Nm for HR70C-9

•

660 Nm for H110C-9/HR120C-9/HR140C-9

10

10

9 10 2.1

5

B

HA-Regelung

Converting from

3-7

smooth roller drum to

pad foot roller drum

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Issue: 02-10

4.1.3 Mounting the scrapers for the pad foot roller drum •

Install the corresponding pad foot scrapers ( 11) in order to use the drum as a pad foot roller ( 6).

11 Checking the segment connections

i

NOTE! •  After approx. 10 hours of operation, check all screws at the segment connections again (9). If necessary, tighten them. •

Tightening torques: • 195 Nm for HR70C-9 • 660 Nm for H110C-9/HR120C-9/HR140C-9 .

11

6 11 6

11

Converting from

smooth roller drum to

pad foot roller drum

4 6

Issue: 02-10

4.2 Compaction measurement system (optional feature) •

1

•

If your compaction roller is equipped with a compaction measurement device (optional feature), the oscillation and acceleration of the drum are measured. The respective values are established by a sensor (1) and forwarded to a computer ( 2). The computer transfers the values to a display in the cabin. The representation on the display enables the driver to inform him-/herself of the current values concerning the degree of compaction and vibration at all times.

i

NOTE! • The compaction measurement system establishes values and provides information on the degree of compaction. • It does not interfere with the operational processes of the compaction roller.

1 Sensor at the drum 2 Compaction measurement system with documentation (data storage).

2

Compaction measurement system

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Issue: 02-10

4.2.1 Variants of the compaction measurement system Compaction measurement system with documentation (display, recording & data storage):

2

•

In addition to displaying the current information regarding vibration and compaction, this type of measurement system (2) is able to gather, record and save all the respective information available, once operation of the vehicle has started.

•

The memory capacity allows you to record approx. a week‘s (i.e. 40 hours‘) operation data at construction sites.

•

The data is recorded per track, which ensures reliable recordings even for complex construction measures and intricate maneuvering.

•

The data thus retrieved can be transferred to a personal computer and evaluated by means of the corresponding software.

i

NOTE! From an economic point of view, the most relevant advantages of compaction measurement with storage function are: quality enhancement of the operation as a result of controlled compaction and the comprehensible documentation of the compaction results both for the building contractor and the client.

Analysis and evaluation of the data:

Compaction measurement system

•

The data of the entire construction project can be graphically displayed and printed as an overview.

•

 Areas of the image that contain values which are smaller than a set default value are marked in red.

•

The overview can be gradually enlarged in order to represent certain parts in greater detail.

•

Not only can each compaction roller track be marked separately, but it is possible to display and print the individual tracks as line diagrams.

•

With the aid of a movable cursor, the compaction results achieved by different tracks and passes can be compared.

•

The compaction values can easily be calibrated with the results of selective standard test runs.

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Issue: 02-10

Compaction measurement system with digital display:

3

 An easy-to-install measurement system (3, with digital display only, no documentation) which serves to inform the driver of the degree of soil compaction. The display with track and pressure function shows the relative degree of compaction of the soil while it is being compacted by the vibration roller drum. The Display: • Informs you of the current compaction result (BIG mode) as well as the compaction process, with the present position of the roller drum in the track and its relation to the default compaction value (TRACK mode). • A zoom function serves to gradually enlarge the display of smaller values. The relative degree of compaction: •

The more the soil is compacted, the higher the respective value.

•

As soon as a suf ficient degree of compaction has been reached, it appears as a stable/ xed value (bar graph and numerical value).

Jump: •

Warning (bar graph and numerical value): Operation on soil which has been compacted too much can cause the vehicle to jump and result in material damage.

Amplitude: •

Vertical oscillation of the drum in mm.

Frequency: •

Current frequency of the vibration system in Hz.

Speed: •

Display in km/h

Track: •

Compaction measurement system

Display of the compaction process per track, the current position (in m) and the default value (shown as a dashed line).

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Issue: 02-10

4.2.2 Installing the sensors and connecting them to the compaction measurement system Installing the sensor at the roller drum: HR70C-9: • Weld the sensor bracket onto the center of the side plate (distance between the top holes: 10 mm).

1 1

• Screw on the sensor (1); point upwards.

fix

it by means of Loctite 243. The arrow on the sensor ( 1) must

HR110C-9/HR120C-9/HR140C-9:

HR110 /120/140C-9

HR70C-9

• Install vertically, above the center of the axle, threaded holes M6 (distance to the upper edge: 18 mm, distance between the drill holes: 84 mm). • Screw on the sensor (1); point upwards.

fix

it by means of Loctite 243. The arrow on the sensor ( 1) must

Laying the sensor wiring to the cabin:

4

5

Compaction measurement system

Lay the sensor cables (4) along the hydraulic hoses and into the cabin from below.  Attach the sensor cable to the compaction measurement system at the upper connection. The power supply cable of the middle connection at the compaction measurement system needs to lead into the side console of the cabin. Establish the plug connection (5) for the power supply.

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Issue: 02-10

4.2.3 Installing the speed sensor at the axle •

Compaction roller HR70C-9: Installation of a speed sensor is not possible for HR70C-9.

HR110 /120/140C-9

Compaction roller HR110C-9 /HR120C-9/HR140C-9: • For compaction roller types HR110-9, HR120-9 and HR140C-9, the speed sensor ( 6) is to be installed at the axle, at the speed connection.

6

WARNING! •

•

Prior to screwing in the speed sensor, check whether a tappet (7) of the engine speed disk in the axle is positioned right in front of the drill hole of the speed sensor (6). If you insert the speed sensor too far, it might collide with the tappet ( 7)!

7 6

Compaction measurement system

4 11

Issue: 02-10

Adjusting the speed sensor: • • • • •

Screw the speed sensor (6, without the plug) into the threaded hole until its surface touches the tappet (7). Rotate the speed sensor (6) in the opposite direction by half a turn. Keep turning the speed sensor until the milled groove B is parallel to the running direction. Use a counter nut to lock the speed sensor (6) in this position. Lay the sensor cable and connect it to the plug (8) in the engine compartment.

6 7 B M13

0.5 - 1.5 mm

8

Compaction measurement system

4 12

Issue: 02-10

4.2.4 Establishing the connections at the compaction measurement system •

The connections at the compaction measurement system ( 2,3) are established by means of plug adapters (9).

•

Be sure to allocate them properly.

3 9

Drum sensor  connection Power supply connection

Printer or PC connection with corresponding software

Compaction measurement system

4 13

Issue: 02-10

4.3 ECO Speed function (optional feature) With the ECO Speed function, the compaction roller can be operated at a reduced Diesel engine speed while the compaction frequency remains at the previously set level.

4.3.1 Activating and deactivating the ECO Speed function Switch

1.5

Function ECO Speed (Optional feature, not available in all machines)

Description • •

• • • •

ECO Speed

4 14

Button ECO Speed (1.5) With the ECO Speed function, the compaction frequency remains constant while the Diesel engine speed is reduced.  Activate this function by pushing the ECO Speed (1.5) button. The Diesel engine speed is reduced by 400 min-1. The frequency of the activated vibration remains at a constant level.  Actuate the button ECO Speed (1.5) again to deactivate the function.

Issue: 02-10

4.3.2 Overview: Components of the ECO Speed system The ECO Speed system is composed of the following elements:

1 2

1 Vibration pump with proportional solenoids 2 Control unit in the cabin 3 Printed circuit board 4 Additional cable set (order no. ZGBR-00746) Printed circuit board / control unit ECO Speed (not shown) 5 Rexroth control box

3 5

ECO Speed

4 15

Issue: 02-10

Chapter 5 Maintenance

Contents This chapter provides you with information about: • the required service and maintenance work • filling the tires • checking the tire inflation pressure • changing the tires

5.1 Maintenance measures 5.1.1 Safety instructions referring to maintenance work

WARNING! Obligation to inform yourself! Be sure to take all safety precautions and to observe all instructions regarding the operation of the compaction roller when carrying out maintenance work!

WARNING! Obligation to inform yourself! Read the safety instructions and warnings in the operating and maintenance manual before starting any maintenance work and follow them! Do not activate! Maintenance work in progress!

WARNING! Use signs and warning notices to point out that maintenance work is being carried out.

WARNING! Prevent the compaction roller from unintentionally starting by removing the ignition key from the ignition lock.

Maintenance work

5 2

Issue: 01-10

5.1.2 Safety precautions to be taken prior to maintenance work Securing the compaction roller before taking any maintenance measures:

1

2

3

Stop the Diesel engine and secure it against unintentional activation by pulling out the ignition key. •

 Activate (apply) the parking brake.

•

Secure the wheels at the rear axle by means of wheel chocks.

•

In case the maintenance work needs to be carried out in the work zone, be sure to create a safe working environment.

•

Ensure the compaction roller`s stability.

•

Protect the work area against moisture and dirt.

•

Check whether the hydraulic system is depressurized.

•

For work at the roller drum, the drum frame or the steering system, always insert the anti-buckling device (1) between the drum frame and the rear end and secure it ( 2).

•

Use only tools that are mentioned and recommended in the operating and maintenance manual.

After completing the maintenance work:

Maintenance work

•

 Ascertain that the compaction roller is in a safe operating condition.

•

Check the hydraulic system of the compaction roller for leaks after starting it.

•

Test the roller functions

•

Do not resume operation of the compaction roller before thoroughly checking the vehicle.

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Issue: 02-10

5.1.3 HR70C-9: Maintenance overview 1 1 Engine compartment 2 Diesel engine 3 Hydraulic pump assembly 4 Battery 5 Hydraulic tank

2

6 Vibration drive 7 Drum drive 3 4

6 7

Maintenance

5 4

Issue: 02-10

5.1.4 HR110C-9/HR120C-9/HR140C-9: Maintenance overview 1 Engine compartment

1

2 Diesel engine 3 Hydraulic pump assembly 4 Battery 5 Hydraulic tank

5

6 Vibration drive 2

7 Drum drive

4 3

6 7

Maintenance

5 5

Issue: 02-10

5.1.5 Maintenance instructions referring to the initial operation Delivery receipt:

NOTE! Make sure all checks and maintenance measures required for the initial operation are carried out in the presence of the customer and his/her staff. Obtain a written con firmation.

i •

 Ascertain the completeness of the delivery (incl. all accessories & the documentation).

•

Make a note of any damage found. Refer to the chapter Note of delivery and veri fication of inspections in the operating manual for information on the default maintenance intervals and maintenance certi ficates.

Testing the operating state of the vehicle:

NOTE! Carry out the maintenance work described below in the presence of the operating staff (i.e. the driver) and the service staff of the customer. Refer to the corresponding sections of the operating and maintenance manual.

i Checking the fill levels:

Check whether the following fill levels correspond to the required levels as stated in the maintenance manual: Engine oil level Hydraulic oil level Fill level in the drum drive Fill level in the vibration drive Checking the tire in flation pressure

Screw connections:

Check all screw connections Use a a torque wrench to tighten the wheel nuts (tightening torque: 500 Nm).

Hydraulic system: Initial operation

Check the hydraulic hoses and screw connections for leaks. 5 6

Issue: 02-10

5.1.6 Instruction and demonstration at the machine

i

NOTE! Perform the instruction in the presence of the operating staff (i.e. the driver) and the service staff of the customer. Make sure that it is understood and that the individuals in question will read and comprehend the operating & maintenance manual . Hand out the documents related to the machine and point out their importance.

Vehicle documents and operating manual:

Explain the structure and the contents of the operating and maintenance manual. Be sure to refer to the safety instructions and stress the importance of observing them. Explain the operation and the functions of the compaction roller, based on the instructions in the operating and maintenance manual.

i Operating elements and displays (cabin):

NOTE! Bear in mind that, after your initial instruction and demonstration, the operating & maintenance manual will be the only resource for obtaining information on the operation of the vehicle.

When giving the operation staff instructions related to the driver`s compartment, adhere to the sequence provided by the operating and maintenance manual: Begin by explaining the adjustment of the driver`s seat. Explain the functions of the switches, the buttons and the symbols of the dashboard and the steering column. Provide information on the joystick buttons and the corresponding symbols on the dashboard. Point out the connections between certain functions, e.g. the parking brake and engine start. Functions of the control lever for work with the compaction roller. Point to the specifications of the required hydraulic - , gear- and engine oil types.

Instruction

5 7

Issue: 02-10

Working with the machine:

Soil compaction options Vibration modes Roller drum types Operation on slopes

Driving the machine:

Transporting the compaction roller. Refer to the corresponding instructions in the operating and maintenance manual when explaining the towing process.

Maintenance work:

Filling the tires with water. Checking the tire in flation pressure. After the initial operation and demonstration, eliminate any leaks and check the functions of the brake system and the electrical equipment. Provide information on maintenance measures and intervals. Point out that the use if supplies and substances other than the ones approved by the manufacturer inevitably leads to the immediate expiry of the warranty.

Instruction

5 8

Issue: 02-10

5.1.7 Check list 1st inspection after 50 operating hours Diesel engine:

NOTE! In addition to the measures stated here, refer to the operating manual of the Diesel engine manufacturer and observe the instructions.

i Checking the fill levels:

Check the engine oil level. Check the hydraulic oil level. Check the fill levels of the wheel drives at the rear axle. Check the fill level in the housing of the rear axle. Replace the breathers of the rear axle. Check the oil level at the vibration drive. Check the tire inflation pressure and the water level in the tires.

Screw connections:

Check the screw connections of the engine mounting at the Diesel engine. HR70C-9: Tighten the connecting bolts basic frame / rear axle ( 600 Nm) HR110 /120/140C-9: Tighten the screw connections at the rear axle ( 550 Nm) Tighten the screw connections at the articulated pendulum joint. Check all other screw connections (see operating and maintenance manual for information on further tightening torques)

Diesel engine:

Replace the air filter cartridge of the Diesel engine. Clean the air filter housing, if necessary. Tighten the fastening screws of the air intake system. Tighten the fastening screws of the exhaust system/muf fler. Follow the instructions in the operating manual of the Diesel engine manufacturer in order to carry out any maintenance work related to the Diesel engine!

Hydraulic system:

Replace the oil filter cartridge at the pump assembly. Check all hydraulic hoses and screw connections for leaks. Check the ventilation filter at the hydraulic tank.

Check list 1st Inspection

5 9

Issue: 02-10

5.1.8 Table of lubricants  Greasing point

Lubricant

Viscosity

Diesel engine

 API classification

SAE 10 W

 Arctic climate

CG 4/CH 4

SAE 20 W - 20

Equivalent standard

Temperate climate

SAE 30

Tropical climate

SAE 40

 All climes

SAE 15 W - 40

New machine

ISO VG 32

Pay particular attention to the specifications referring to operation with temperatures below 0° C. Be sure to preheat the hydraulic oil sufficiently.

Hydraulic oil

 ATL AS Spezial 46

New machine ISO VG 46 ISO VG 68

Table of lubricants

5 10

Issue: 02-10

5.2 Maintenance work 5.2.1 Maintenance work related to the Diesel engine Illustration

Maintenance work: Fuel system Weekly or at intervals of 100 operating hours: Check the fuel-water separator:

1

• • •

2

The fuel-water separator (1) is attached to the stiffener wall of the cabin. Open the engine hood. Drain the fuel-water separator ( 1) via the drain screw below the separator.

50 operating hours after the initial operation and subsequently, at intervals of 500 operating hours or annually

HR70C-9

Den Kraftstoff-Vor lter überprüfen und austauschen: •

 At intervals of 500 operating hours or once every 12 months, replace the filter cartridges of the preliminary fuel filters (2).

•

HR70C-9: Open the engine hood. HR110/120/140C-9: Open the cover (3) with the ventilation grills (on the right, in the direction of motion).

• •

In order to collect the leaking oil, place on oilpan under the fuel filter. Screw off both filter housings (cartridges) and dispose of them in an eco-friendly way, in accordance with waste disposal key 150299 (EU). Slightly lubricate the sealing surfaces of the new filter cartridges.  Attach the filter cartridges. Screw them on by hand. Let the Diesel engine turn via the starter. Open the fuel ventilation plug and ventilate the fuel system. For a detailled description of the ventilation procedure, refer to the Perkins (for engine type 1104 C-44) or Deutz operating manuals (for engine type TCD 2012 L4).

3 HR110 /120/140C-9 2

1

• • • •

Maintenance work

5 11

Issue: 02-10

Illustration

Maintenance work: Engine oil system 50 operating hours after the initial operation and subsequently, at intervals of 500 operating hoursen und austauschen:

HR70C-9 2 Oil change:

WARNING! Environmental protection ! The engine oil must not penetrate the ground, pollute water or leak into the sewer system. Be sure to collect it in sufficiently dimensioned receptacles and dispose of it in an eco-friendly way.

1

3

• • • •

4

•

Start the Diesel engine and let it run until it has reached operating temperature. Stop the Diesel engine and pull out the ignition key. Underneath the exterior oil drain plug, place a sufficiently dimensioned receptacle to collect the waste oil. Screw out the oil drain plug ( 3). Pull out the oil dipstick (1) and drain the oil. Dispose of the waste oil in accordance with EU waste disposal key 130202. Fit the oil drain plug ( 3) with a new O-ring and screw it back in. Replacing the oil filter:

HR110/120/140C-9

•

Unscrew and remove the filter housing (cartridge, 150299.

• •

Slightly lubricate the sealing surface of the new filter  cartridge.  Attach the oil filter cartridge and screw it on by hand.

2 1

4). Dispose of it in accordance with EU waste disposal key

Adding oil:

2

• • • •

Fill a sufficient amount of engine oil (approx. 10 liters) into the Diesel engine via the ller neck ( 2).  After adding oil, loosen the cap and let the Diesel engine run via the starter. Check the oil level at the oil dipstick. If necessary, add more oil. Start the Diesel engine and let it idle until it has warmed up.

4 3

Maintenance work

12

Issue: 02-10

Illustration

Maintenance work: Cooling system To be carried out if the warning lamp lights up or after repair work:

HR70C-9

WARNING! Risk of burns caused by hot coolant!  Before you open the lid of the cooler, make sure that the Diesel engine and the cooling system have cooled down.

2 •

HR70C-9:

Open the engine hood.

 

HR110 /120/140C-9: Open the cover with the ventilation grills (1) (on the right, in the direction of motion).

•

Carefully screw off the cover of the combination cooler (2).

•

Check the coolant level. If coolant needs to be added or after repair work, the following mixing ratio is required: • Capacity of the cooling system: approx. 15 liters (l).

HR110 /120/140C-9

Mixing ratio: 40% coolant for 1 liter of water, i.e. 0.6 l of water and 0.4 l of coolant.

1

2 4 2

Illustration

Maintenance work: Checking the V-be V-belt lt

50 operating hours after the initial operation and subsequently, subsequently, at intervals of 500 operating hours Check the V-belt V-belt tension and check the V-belt V-belt for signs of damage:

WARNING! Never check the V-belt tension with the Diesel engine running! Turn off the Diesel engine and pull out the ignition key.

i HR70 HR 70C-9 C-9

0 /120/ 140C-9 HR110 HR11  /120/140 C-9

Illustration

NOTE! Refer to the operating manual of the Diesel engine manufacturer for instructions regarding V-belt tensioning and replacement: Perkins for engine type 1104 1104 C-44 Deutz for engine type TCD 2012 L4

Maintenance work: Replacing the combustion air fil filter  ter 

50 operating hours after the initial operation and subsequently, subsequently, at intervals of 500 operating hours

i

NOTE! If the respective lamp on the dashboard indicates an accumulation of dirt at the air fi filter lter for the combustion air of the Diesel engine,clean or replace the air fi filter. lter.  After a maximum of fi five ve cleanings by means of compressed air, replace the fi filter lter cartridge. Wash the interior of the air fi filter lter housing and clean it; if necessary,vacuum it.

WARNING! Damage to t he Diesel engine! Damage Never attempt to clean the air fi filter lter by blowing air into it!

Wartungsarbeiten

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Ausgabestand: 01-10

Maintenance work

5 14

Issue: 02-10

5.2.2 Hydraulic system Illustration

Maintenance work: Changing the hydraulic oil and the oil filter 

50 operating hours after the initial operation and subsequently, subsequently, at intervals of 500 operating hours 4

i

NOTE! Prior to carrying out any maintenance work at the hydraulic system, be sure to consult the Table of lubricants for lubricants  for information on the specifi speci fications cations of the required hydraulic hydraulic oils.

3 Slightly loosen the oil filter cartridge (3 ( 3) by means of a tension band or a similar tool, but do not not screw  screw it off yet.

i 2 1

NOTE! In order to prevent the contents of the suction pipe from leaking, stop loosening the filter cartridge as soon as a suction sound is audible. The air intake causes the oil in the suction pipe to flow back into the tank.

•

 As soon as the suction sound stops, unscrew the oil filter cartridge and dispose of it in an eco-friendly way. EU waste disposal key: 150299 (EU).

•

Use clean oil to lubricate the sealing of the filter head (4 ( 4).

•

Lubricate the new oil filter cartridge (3 ( 3) with clean hydraulic oil.

•

Attach the new oil filter cartridge and screw it on by hand.

i

NOTE! Do not not use  use a tension band to screw on the filter cartridge!

Checking the hydraulic oil level:

Maintenance work

• •

Screw off the oil filler neck with the oil dipstick ( 1) and check the oil level. If necessary, add hydraulic oil.

•

Clean the ventilation head ( 2).

•

In case you need to add hydraulic oil, refer to the Table of lubricants for lubricants  for the required oil speci fications. 5 15

Issue: 02-10

Illustration

Maintenance work: Hydraulic oil change at intervals of 2000 operating hours (i.e. if you need to change the type of oil)

i

NOTE! Take the compaction roller to a workshop in order to carry out the oil change.

WARNING! Environmental protection ! Environmental The hydraulic oil must not penetrate the ground, pollute water or leak into the sewer system. Collect it in suf ficiently ficiently dimensioned dimensioned receptacles. Dispose of it in accordance with EU waste disposal key 130202. • • • •

Start the Diesel engine and let it run until the hydraulic oil has warmed up. Stop the Diesel engine and remove the ignition key. Place an oilpan under the hydraulic tank. Unscrew the oil fi filler ller neck with the oil dipstick.

i • • • • •

NOTE! Be sure to take the amount of hydraulic oil to be drained into account and to use a suf fi suf ficiently ciently dimensioned oilpan to collect the leaking oil.

Screw off the oil drain plug. Remove the oil dipstick and drain the hydraulic oil. Dispose of the waste oil in accordance with EU waste disposal key 130202 130202.. Replace the oil fi filter lter cartridge, see instructions above. Fit the oil drain plug with a new O-ring and screw it in.  Add hydraulic hydraulic oil via the fi filter. lter.

CAUTION! Be sure to exercise extreme cleanliness when fi lling in hydra hydraulic ulic oil! Inform yourself of the type of hydraulic oil in the hydraulic system, see Table of lubricants. • • • •

Maintenance work

 Add hydraulic hydraulic oil via the oil oil fi filler ller neck. Start the Diesel engine and let it run until the hydraulic oil has warmed up. Stop the Diesel engine and pull out the ignition key. Check the hydraulic oil level again.

5 16

Issue: 02-10

5.2.3 Rear axle Illustration

Maintenance work: Check the oil level in the wheel drives 50 operating hours after the initial operation and subsequently, at intervals of 500 operating hours:

•

i

NOTE! Prior to carrying out work at the rear axle, secure the compaction roller against rolling. Activate (apply) the parking brake and put wheel chocks under the tires.

WARNING! 1

Environmental prot ection! The axle oil may not penetrate the ground, pollute water or leak into the sewer system.

1

Checking the oil level in the wheel drives: • • • • •

 Advance the compaction roller until the oil drain plug ( 1) is in the middle position, i.e. «3 or 9 o`clock» (see ill. on the left, 2). Screw off the oil drain plug ( 1). The oil level must be visible underneath the opening or tangible with a finger. In case you need to add axle oil, be sure to refer to the speci fications in the Table of lubricants. Screw the oil drain plug ( 1) back in.

500 operating hours after the initial operation and subsequently, at intervals of 1500 operating hours: 2

12

Changing the oil in the wheel drives: 9

3

6

• • • •

If the oil in the wheel drives needs to be changed, advance the compaction roller until the oil drain plug ( 1) is in the lowest position («6 o`clock», see ill. on the left, 3). Place a suitable receptacle under the wheel drive. Screw off the oil drain plug ( 1) and drain the oil. Screw the oil drain plug ( 1) back in and add axle oil, see instructions above.

3

Maintenance work

5 17

Issue: 02-10

Illustration

Maintenance work: Checking the oil level at the rear axle 50 operating hours after the initial operation and subsequently, at intervals of 500 operating hours:

2 • 3 2

i

NOTE! Prior to carrying out work at the rear axle, secure the compaction roller against rolling. Activate (apply) the parking brake and put wheel chocks under the tires.

WARNING! Environmental prot ection! The axle oil may not penetrate the ground, pollute water or leak into the sewer system. Checking the oil level in the axle housing: • • •

Unscrew the filler screw (2) from the axle housing. The oil level must be visible underneath the opening or tangible with a finger. Screw the filler screw (2) back in.

500 operating hours after the initial operation and subsequently, at intervals of 1500 operating hours: Changing the oil in the axle housing :

3 3 3

• • • • • • •

Place a suf ficiently dimensioned oilpan under the three oil drain plugs ( 3). Screw out the oil drain plugs ( 3) and drain the axle oil. Dispose of the waste oil in accordance with waste disposal key 130202 (EU). Screw the oil drain plugs ( 3) back in. Be sure to refer to the Table of lubricants with regard to the required axle oil speci fications. Fill new axle oil into the axle housing via the filler screws (2). Tighten the filler screws (2).

Wartungsarbeiten

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Ausgabestand: 02-10

Maintenance work

5 18

Issue: 02-10

Illustration

Maintenance work: Checking and replacing the breather  

50 operating hours after the initial operation and subsequently, at intervals of 500 operating hours: 1

Maintenance work

1

• • •

Carry out a visual inspection to check the rear axle for oil leaks. Replace the breather ( 1) on the axle. The breathers are part of the maintenance kits (see spare parts list).

5 19

Issue: 02-10

5.2.4 HR70C-9: Maintenance work at the drum drive Illustration

Maintenance work: Checking the oil level in the drum drives, changing & adding oil 50 operating hours after the initial operation and subsequently, at intervals of 500 operating hours:

HR70C-9

i

NOTE! Prior to carrying out work at the drum drive, secure the compaction roller against rolling. Activate (apply) the parking brake and put wheel chocks under the tires.

1

WARNING! Environmental prot ection! The axle oil may not penetrate the ground, pollute water or leak into the sewer system.

i •

 Y • • • •

2 3

The filler screw (1), the control screw (2) and the oil drain plug (3) are located on the left side, next to the traction motor. Screw out the control screw (2) to check the oil level. Gear oil needs to leak from the drill hole. If necessary, add gear oil at the plug ( 1) until oil starts leaking from the control screw (2). Screw the plug back in. Whenever you need to add oil, refer to the Table of lubricants for the required gear oil specifications.

500 operating hours after the initial operation and subsequently, at intervals of 1500 operating hours: •

• • • • •

Maintenance work

NOTE! Prior to carrying out maintenance work related to the components of the roller drum, refer to the Table of lubricants for information on the required gear oil speci fications.

Changing oil in the transmission/gear box: Unscrew the oil drain plug ( 3). Dispose of the waste oil in an appropriate eco-friendly way. Screw the oil drain plug (3) back in. Remove the filler screw ( 1) and the control screw (2) and fill in gear oil from the top, until oil starts leaking from the control screw (2).  Attach and tighten the filler screw (1) and the control screw (2) again.

5 20

Issue: 02-10

5.2.5 HR110C-9/HR120C-9/HR140C-9: Maintenance work at the drum drive Illustration

Maintenance work: Checking the oil level in the drum drives, changing & adding oil 50 operating hours after the initial operation and subsequently, at intervals of 500 operating hours:

HR110 /120/140C-9

i

1

NOTE! Prior to carrying out work at the drum drive, secure the compaction roller against rolling. Activate (apply) the parking brake and put wheel chocks under the tires.

WARNING! Environmental prot ection! The axle oil may not penetrate the ground, pollute water or leak into the sewer system.

i • • •

 Y

• •

NOTE! Prior to carrying out maintenance work related to the components of the roller drum, refer to the Table of lubricants for information on the required gear oil speci fications.

 Advance the compaction roller until the labeling (1) at the gear flange is visible and points upward. The filler and the oil drain screw ( 2, 3) are both situated on the inner gear side  Y. If the labeling (1) is in the correct position, the control screw (2) is on the left side and the drain screw ( 3) points downward. Remove the filler screw (2) from the gear box. The oil level should be tangible with a finger underneath the opening. If required, add the necessary amount of gear oil. Be sure to consult the Table of lubricants for information on the speci fications of the required gear oil.

500 operating hours after the initial operation and subsequently, at intervals of 1500 operating hours:

3

Maintenance work

2

• • • •

Oil change at the gear box:  Advance the compaction roller until the control screw ( 2) is in its lowest position. Screw out the control screw and drain the oil.  Advance the compaction roller until the control screw is in the middle position («3/ 9 o`clock»). Fill in gear oil and screw in the control screw ( 2).

5 21

Issue: 02-10

5.2.6 Maintenance work at the vibration drive Illustration

Maintenance work: Checking the oil level at the vibration drive, changing & adding oil

50 operating hours after the initial operation and subsequently, at intervals of 500 operating hours: HR70C-9

i

1

NOTE! Prior to carrying out work at the vibration drive, secure the compaction roller against rolling. Activate (apply) the parking brake and put wheel chocks under the tires.

WARNING! Environmental prot ection! The axle oil must not penetrate the ground, pollute water or leak into the sewer system.

1

4.2

HR110/120/140C-9 4

  • • • •

HR70C-9:  Advance the compaction roller until the control screws (1) are in the lowest and top position. Remove the lower control screw. Oil needs to leak from the threaded hole. If no oil escapes from the opening, add oil via the upper control screw until it starts leaking from the bottom screw. Be sure to consult the Table of lubricants for information on the specifications of the required oil. Screw the control screws (1) back in.

• • • • • • •

HR110C-9 /HR120C-9 /HR140C-9:  Advance the compaction roller until the inspection glass (4) is in the lowest position («6 o‘clock») (4.1). This implies that the filler screw (4) is in the top position («12 o‘clock»). If, in this position, the gear oil level does not correspond to the illustration ( 4.2), oil needs to be added. Be sure to consult the Table of lubricants for information on the specifications of the required oil. Remove the filler screw (4) from the housing.  Add oil until the correct oil level is reached, see illustration. Screw the filler screw (4) back in.

4.1

Maintenance work

5 22

Issue: 02-10

5.2.7 Maintenance work at the ventilation system Illustration

Maintenance work: Replacing the filter units of the ventilation system

500 operating hours after the initial operation and subsequently, at intervals of 500 operating hours or in case of a high accumulation of dirt: 1

Never use water jets or a high-pressure washer to clean the ventilation slots (1). Instead, always clean the ventilation slots by means of a heavy-duty vacuum cleaner. Open the cover (2) of the filter unit and replace the filter unit.

2

5.2.8 Note regarding maintenance work related to the electrical installation For information on maintenance work related to the electrical installation, see chapter Electrical system.

5.2.9 HR70C-9: Perkins Diesel engine maintenance schedule at intervals of ... operating hours (max. permissible period of time) 8 or   daily

250 or every 6 months

500 or every 12 months

1000

2000

3000

X

Check the coolant level. X

Check the coolant concentration. At intervals of 2 years, replace the anti-freeze agent. In case corrosive agent is used instead of anti-freeze agent, replace it at intervals of 6 months. Be sure you use the correct quantity.

X

Check the condition and the tension of the drive belt. X

Replace the drive belt of the generator.

X

Drain the water from the preliminary filter (in case your vehicle is equipped with this feature). X

Replace the fuel filter element. X

X

Check the engine oil level. Replace the engine oil ( fill it in slowly, be sure to add the correct quantity. For a load factor above 40% or the use of engine oil that does not correspond to the required speci fications, adjust the intervals accordingly. Please consult your local Perkins representative for information on the calculation of the load factor.

X

Replace the engine oil filter. Clean the air filter and empty the dust collector of the air filter, if a high accumulation of dust is caused by the operating conditions.

X

Replace the air filter and empty the dust collector of the air filter (normal operating conditions). X

Clean the turbine and the compressor housing of the turbo charger. To be carried out by speci fically trained staff only!

X

Check the valve play. If necessary,l adjust it. To be carried out by speci fically trained staff only!

X

Maintenance work

Check the functioning of the injection nozzles. To be carried out by speci fically trained staff only!

X

X

X

Requir ed measur es

Check all hoses and connections. X

Replace the breathers.

X

Check the starter and the generator. To be carried out by speci fically trained staff only!

X

Make sure the wiring of the electrical system is in good condition and check for signs of wear & tear. Check for engine damage and leaks (repair, if necessary).

5 24

Issue: 02-10

5.2.10 HR110C-9 /HR120C-9 /HR140C-9: Deutz Diesel engine maintenance schedule Prior to the operation of new  / refurbished engines

replace

Required measures

X

X

Lubricant (Intervals dependent on field of application)

X

X

Oil filter cartridge (at each change of lubricants)

X

Fuel filter cartridge

after .... operating hours (maximum permissible period of time)

X

10 or daily

250

500

1000

6000

once a year 

12000

every 2 years

check

X

clean

X

Lubricant fill level; add, if required

X X

X

Flexible fuel over flow conduits

X X X

X

X

X

X

X

Injection valve

Preliminary fuel cleaner

X

Coolant (additive concentrate)

X

Coolant pump

X

Coolant pump

X

Air intake filter (according to maintenance display) X

X X

   

X

X

X

X

Coolant (additive concentrate)

X

Air intake filter (according to maintenance display) Charge air cooler (drain lubricant/condensed water)

X

Charge air cooler (drain lubricant/condensed water)

X

X

Battery and cable connections

X

X

Engine control, warning system

X

Valve play (adjust, if necessary)

X

X

X

X

X

X

X X X

V-belt (tension or replace, if necessary) X

V-belt (tension or replace, if necessary)

X

Pressure retention valve at the injection pump

X

Crank case pressure ventilation valve

X

Crank case pressure ventilation valve

X

X X

Maintenance work

X

Preliminary fuel cleaner

X X

X

Flexible fuel over flow conduits (replace completely)

X

X

X

X

X X

to be carried out by trained service staff only

X

5 25

Issue: 02-10

5.3 Tires at the rear axle 5.3.1 Water filling in the tires of the rear axle •

In order to improve the propulsional properties of the tires at the rear axle, on delivery, they arefilled with water and an additive composed of magnesium chloride which serves as antifreeze.

i

NOTE!  • Magnesium chloride is commercially available granulated salt with a 47% share of dry substance which can be purchased at (chemical) wholesale. • In countries where the exterior temperatures never fall below 0º C, the tires can be filled with industrial water, without any additives.

Filling procedure: Water and antifreeze additive

1

2

•

Lift the compaction roller at the rear axle by means of a sufficiently dimensioned hydraulic jack.

•

Turn the tire (1) until the charge valve (2) is in the top position.

•

Slowly unscrew the valve core (3).

•

Screw a hose line ( 4) onto the charge valve.

•

The saline solution (see Preparation of the saline solution below) can be poured into the tire (1) by means of a container placed above the tire or via a special pump.

•

The filling procedure (5) must be interrupted repeatedly because the tire needs to be bled. In case the tire is not suf fiently filled after pouring in the saline solution, add industrial water to establish the required level.

•

Tires at the

3

4

5

3

axle

i

NOTE! Preparation of the saline solution: • Mix magnesium chloride and water at a weight ratio of 1:1 in a clean container. Stir until the salt has completely dissolved. •  Always add the salt to the water, never vice versa.

Filling procedure: Pure water  •

In order to fill the tires with water, use industrial water.

•

The filling procedure is identical to the one with antifreeze additive, see instructions above. 5 26

Issue: 02-10

5.3.2 Empyting the tires 1

2

6

•

Lift the compaction roller at the rear axle by means of a suf ficiently dimensioned hydraulic jack.

•

Turn the tire (1) until the charge valve (2) is in the lowest position.

•

Slowly unscrew the valve core (3).

•

Due to the overpressure in the tire, the water will be driven out of the tire, down to the level of the charge valve (6).

•

Extend the vent pipe of the composite valve (7) by means of a thin rubber hose (9).

•

In order to remove the remaining quantity of water from inside the tire, screw the composite valve (7) onto the charge valve (2) and charge with compressed air (8).

•

The compressed air drives the remaining water out of the tire via the rubber hose (9) until it finally leaks from an opening at the side of the composite valve.

•

 As soon as the tire is empty, attach the valve core (3) and ll the tire (1) with compressed air. Prescribed pressure: 1.1 bar to 1.6 bar  (for standard tires).

8 3

7

3

Tires at the

axle

5 27

issue: 02-10

5.3.3 Filling procedure: Using the “Hanauer Maus” In order to fill or empty a tire by means of the so-called “Hanauer Maus”, carry out the following

1

instructions:

2

•

Use a sufficiently dimensioned hydraulic jack to lift the compaction roller at the rear axle.

•

Turn the tire (1) until the charge valve (2) is in the top position.

•

Slowly screw off the valve core (3).

•

Screw the fill valve ( 10) into the charge valve (2).

•

Screw a hose line ( 4) onto the fill valve (10).

•

The air escapes from the tube and the opening at the side of the fill valve ( 10).

i 3

10

Twist off the fill valve ( 10) and tighten the valve core (3).  At the end of the filling procedure, unscrew the fill valve ( 10) and screw in the valve core (3). Fill the tire (1) with compressed air until the required pressure of 1.1 bar to 1.6 bar  (for standard tires) has been established.

3

4

Tires at the

• • •

NOTE! The filling procedure is complete as soon as a constant jet of water exits the opening.

axle

5

28

Issue: 02-10

5.3.4 Checking the tire inflation pressure DANGER!

1

Risk of injuries!   Antifreeze may leak from the tire while its pressure is being checked! This can lead to chemical burns. Wear protective clothing to protect your skin!

2

•

Check the tire pressure once a week: Type of tires

min. pressure

max. pressure

Note!

Standard tires

1.1 bar

1.6 bar

With water filling

Special tires

1.6 bar

2.0 bar

With water filling

Checking the tire pressure: •

In order to check the tire inflation pressure, the charge valve ( 2) needs to be in the top («12 o`clock») position. Move the compaction roller forward and backward to establish this position of the tires (1).

•

Unscrew the safety cap of the charge valve.

•

Squeeze the filler valve until there is no saline solution (or water) leaking from the valve ( 2) any more.

WARNING! Material damage!   Always empty the tires and make sure no water or saline solution can leak from the charge valve before checking the tire inflation pressure. Moisture destroys the tire gauge. • •

 Attach the gauge and check the tire inflation pressure. If necessary, adjust the tire pressure.

5.3.5 Mounting the tires WARNING! Material damage!  • Have tires replaced or mounted by an authorized HYUNDAI dealer or a trained expert only. • In order to prevent the tire from sliding on the wheel rim, the tire must not be mounted with the aid of lubricants. • Tires at the

axle

Tightening torque of the wheel nuts ( 2): 500 Nm. 5 29

Issue: 02-10

Chapter 6 Diesel engine and hydraulic system

Contents This chapter provides you with information about: • the technical specifications of the Diesel engine • the entire hydraulic system

6.1 Diesel engine NOTE!  Obligation to inform yourself!  Please refer to the operating manual of the Diesel engine manufacturer (i.e. Deutz or Perkins) for information related to the Diesel engine. The manual is part of the vehicle documentation.

i 6.1.1 Technical specifications Diesel engine Compaction roller type Make

HR70C-9 Perkins 1104C-44

Type Nominal output

HR110C-9

HR120C-9

HR140C-9

Deutz TCD 2012 L4

Deutz TCD 2012 L4

Deutz TCD 2012 L4

four-stroke Diesel engine with charging and direct injection 61.5 kW (84 HP)

96 kW (130 HP)

96 kW (130 HP)

103 kW (140 HP)

2400

2300

2300

2500

10 l

10 l

10 l

Max. engine speed (min -1) Engine oil (with filter)

8l

Cooling

liquid-cooled/cooling protection

Diesel tank capacity (liters)

167 l

300 l

300 l

300 l

6.1.2 Maintenance overview Diesel engine

i

Diesel engine

6-2

NOTE!  Obligation to inform yourself!  For information on the required maintenance work, refer to the corresponding chapter of the operating and maintenance manual . In addition, be sure to consult the maintenance schedule in the operating manual of the Diesel engine manufacturer (Deutz or Perkins)!

Issue: 02-10

6.2 Hydraulic system

i

NOTE! Obligation to inform yourself! For information about the hydraulic system, the drum drive and the rear wheels as well as the vibration and the steering system, refer to the respective chapters of this document and the operating & maintenance manual.

6.2.1 Technical specifications hydraulic system Type

HR70C-9

HR110/120/140C-9

Hydraulic oil tank capacity (in liters)

68

106

Hydraulic oil filter

Filter cartridge, integrated in the pump assembly

Filter cartridge, integrated in the pump assembly

 ATLAS Spezial 46 or  ISO VG32/46/68. See table of lubricants.

 ATLAS Spezial 46 or  ISO VG32/46/68. See table of lubricants.

Specif ications Hydraulic oil

6.2.2 Maintenance work hydraulic system

i

Hydraulic system

6 3

NOTE! Obligation to inform yourself! Please refer to the chapters on maintenance in this document and the operating & maintenance manual for information on maintenance work related to the hydraulic system.

Issue: 02-10

6.2.3

Hydraulic circuit diagram: Entire hydraulic system HR70C-9    t    i   n   u   e   v    i   r    d   m   u   r    D

490 bar 

26 - 30 bar 

460 bar 

370 bar  300 bar 

PS MB

MB

Diesel

engine Traction motor 

300 bar  MA MA

490 bar 

460 bar 

460 bar 

370 bar 

300 bar 

240 bar 

180 bar 

240 bar 

25 bar 

Steering cylinder 

  r   o    t   o   m   n   o    i    t   a   r    b    i    V      V

6.2.4

Hydraulic circuit diagram: Entire hydraulic system HR110/120/140C-9    t    i   n   u   e   v    i   r    d   m      u      r       D

 490 bar 

460 bar 

26-30 bar 

 370 bar  320 bar 

Diesel   Traction   motor 

engine

490 bar 

460 bar  460 bar 

370 bar  

  r   o    t   o   m   n   o    i    t   a   r    b    i    V      V

320 bar 

240 bar 

240 bar  180 bar 

25 bar 

Steering cylinder 

Chapter 7 Drum drive and rear axle

Contents This chapter provides you with information about: • the drum and its drive unit • the drum functions • trouble shooting • the default values • an overview of the measuring points • an overview of the options for adjustments • installing and dismantling the drum

7.1 Drum and rear axle 7.1.1 Technical specifications drum with smooth roller drum

HR70C-9

HR110C-9

HR120C-9

HR140C-9

Drum: Dr um width

1700 mm

2100 mm

2100 mm

2100 mm

Drum diameter 

 1250 mm

1500 mm

1500 mm

1500 mm

Drum thickness

20 mm

25 mm

30 mm

30 mm

with pad foot roller drum

HR70C-9

HR110C-9

HR120C-9

HR140C-9

Drum: Dr um width

1700 mm

2100 mm

2100 mm

2100 mm

Drum diameter 

1140 mm

1390 mm

1390 mm

1390 mm

Drum thickness

15 mm

25 mm

30 mm

30 mm

7.1.2 Technical specifications rear axle with standard tires Type and manufacturer 

Drum and rear axle

HR70C-9

HR110C-9

HR120C-9

HR140C-9

DANA Spicer 602/112/ 105-100

DANA Spicer 602/112/ 105-100

DANA Spicer 602/112/ 105-100

DANA Spicer 602/112/ 105-100

Standard tires with drum

16.9-24

23.1-26

23.1-26

Special tires with pad foot roller drum

16.9-24 TR

23.1-26 TR

23.1-26 TR

7 2

23.1-26 23.1-26 TR

Issue: 02-10

7.1.3 Overview: Drum

5

1

2

3

5 1 Drum 2 Drum drive 3 Vibration drive 4

4 Vibration system 5 Gear box drum

Drum and

axle

7 3

Issue: 02-10

7.1.4

Overview Drive Hydraulics Drum HR70C-9, HR110/120/140C-9

HR70C-9

HR110 /120/140C-9

1

1

2

3

2 = HP oil system A & B = Control oil system PS = Tank line

1 A

T

Drum drive

A

  m   u   r    D

  e   n    i   g   n   e    l   e   s   e    i    D

Fixed displacement pump Control pressure

Brake

B

T

1 Drive adjustment pump Variable displacement pump Drive

2 Control lever  B

3 Drum drive motor 

7.1.5

Overview Drive Hydraulics Rear Axle HR70C-9, HR110/120/140C-9 HR70C-9

Brake

3

A

B = HP oil system A & B = Control oil system PS = Tank line

T

  e   n    i   g   n   e    l   e   s   e    i

HR110/120/140C-9 Brake

A

A

B Fixed displacement pump Control pressure

   D

Variable displacement pump Drive

B

T

7.1.6

HR70C-9:Drive unit - Sequence of functions 4

1

2

•

• •

•

• •

R

V 3

Roller operation can be started after starting of the Diesel engine and a sufficient operating time to allow the hydraulic oil to reach its operating temperature (about 50° C). Release the parking brake (3); the pilot lamp in the dashboard must go out. Switch the speed selector switch (4) to stage 1 or 2 dependent on the required roller operation. Switch the vibration system on, as required, using the button (2) on the control lever. Move the control lever (1) to the front or rear. The solenoid valve for the traveling direction forward V or reverse R switches. • The control pressure PS reaches the displacement disk of the variable displacement pump. • The variable displacement pump swivels to the selected direction and the oil flow reaches the drum and rear axle drive units. = HD oil system A & B = Control oil system PS = Tank line

T

V

R

HP MA

A

  e   n    i   g   n   e    l   e   s   e    i    D

  e    l   x   a   r   a   e    R

  m   u   r    D

T X1

X2

B MB

T

7.1.7

HR110/120/140C-9: Drive unit - Sequence of functions •

1.3

1

V • •

•

1.2

R

•

3

Roller operation can be started after starting of the Diesel engine and a sufficient operating time to allow the hydraulic oil to reach its operating temperature (about 50° C). Release the parking brake (3); the pilot lamp in the dashboard must go out. Press the blue (1.2) or red (1.3) button for the Diesel engine speed. • Blue button (1.2) Travel without roller operation. • Blue button (1.3) Roller operation, with or without vibration, slope travel. Move the control lever (1) to the front or rear. The solenoid valve for the traveling direction forward V or reverse R switches. • The control oil pressure for the control oil pump reaches the displacement disk of the variable displacement pump for the drum/rear axle drive unit. • The variable displacement pump swivels to the selected direction and the oil flow reaches the drum and rear axle drive units.

= HD oil system A a. B = Control oil system PS = Tank line T

V

R

HP MA

A

  e   n    i   g   n   e    l   e   s   e    i

Brake   e    l   x   a   r   a   e    R

   D

X1

X2

B MB

  m   u   r    D

T

T

7.1.8 Trouble shooting: What to do if the compaction does not start Failure / Problem

Causes and actions to be taken

The vehicle does not move in the desired • direction

•

Defective contact in the eletrical system

The solenoid valve fails to switch

•

The cable connections or the plug-in connections may be loose or defective.

• • • •

Check the power supply to the solenoid valve: Is the solenoid valve charged? If so, does the solenoid head switch? In case it does, repeatedly change the direction of motion by means of the joystick. In case it does, but there is still no thrust, check the valve function, see the sections referring to the travel and vibration pump.

•

• The compaction roller remains stationary

•

The drum loses ground contact (i.e. jumps)

Drum and

axle

The parking brake has not been deactivated.  A warning sound is started.

•

Deactivate the parking brake and actuate the  joystick.

•

Electrical fault related to deactivating the parking brake. See chapter Electrical installation.

•

If, in spite of carrying out the measures above, the compaction roller still does not move, check the position of the relief valve in the hand pump block.

The emergency actuation for the brake has not been • reversed.

The solenoid valve for determining the direction of motion may be defective, see instructions above.

•

Insuf ficient charge pressure. Check the pressure at measuring point PS.

•

The HP valves have not been closed and tightened after a towing process.

•

Check the high pressure A and B at measuring points MA/MB.

•

The ground is too hard.

•

The compaction limit of your vehicle has been reached. Stop the compaction process.

7 8

Issue: 02-10

Failure / Problem

Causes and actions to be taken

The drum or the wheels starts slipping on slopes or on wet grounds.

•

a) The drum keeps skidding, with the rear wheels stopped. b) Wheelspin of the rear wheels, but the drum stops spinning.

Drum and rear axle

The HA control function serves to prevent the drive from slipping

In certain situations, such as

• setting the compaction roller into motion with the a) if there is a risk of the drum or/and the rear wheels drum or the rear wheels sunk into the ground sinking into the ground while driving along heavy terrain or  b) whenever inclinations (driving on slopes) increase • driving at a carefully set, ne-tuned speed, the driving resistance. it may be necessary to override the HA control. If the driving resistance on slippery or wet grounds In order to do so, deactivate the HA control of the drum or operation on extreme slopes prevents you from or the rear axle by means of the corresponding switresuming operation, the HA control reduces the ches („Overmodulation hydraulic motor drum / rear engine speed until the compaction roller comes to axle“, see the respective chapter). a stop.  As a result, the maximum driving torque is set at the drum and the rear wheels (in accordance with the selected switch settings).

7 9

Issue: 02-10

7.1.9

Speeds, hydraulic measuring and adjustment values for compaction rollers Measurement/Adjustment Diesel engine idling speed min. Supply pressure Diesel engine idling speed max. Supply pressure

Adjustment values HR70C-9

Adjustment values HR110/120C-9

Adjustment values HR140C-9

Measuring point

950 - -1,000 min-1

900 min-1

900 min-1

Diesel engine

26 bar

26 bar

26 bar

HP

-1

2300 - -2,400 min 30 bar 2100 - -2,200 min

Traveling drive forward

460 bar -1

Diesel engine speed max.

2100 - -2,200 min

Traveling drive reverse

2,300 min 30 bar

-1

Diesel engine speed max.

-1

460 bar

2,500 min 30 bar

-1

2,400 min

460 bar

460 bar -1

Diesel engine MA

-1

2,200 min

2,400 min

460 bar

460 bar

7.46 mi/h 50 m in 14s - 16s

Diesel engine HP

-1

2,200 min

6.21 mi/h 50 m in 17s -19 s

Roller speed max.

-1

Diesel engine MB Test track/Stop watch

7.1.10 Overview of the measuring points and prerequisites of measurement HR70C-9

HR110/120/140C-9 HP

HP

MB

a

ATTENTION! To enable measurement of the speeds and hydraulic oil pressures the Diesel engine must have reached its operating pressure and the hydraulic oil 50° C min. in the supply circuit.

d

NOTE! Determining the maximum roller speed: Travel a defined distance of 50 m at a max. roller speed reached before. Measure the time required with stop watch.

MB

MA

MA

7.1.11 Overview: Adjustments at the oil pressure pump of the drum drive HR70C-9

HR110C-9 /HR120C-9 /HR140C-9

HP valve 490 bar 

HP valve 490 bar  B

PS control/charge pressure settings PS control/charge pressure settings

HP valve 490 bar  A

HP valve 490 bar 

Pressure cut-off 460 bar  Pressure cut-off 460 bar 

Drum and

axle

7 11

Issue: 02-10

Chapter 7.2 Installing & dismantling the drum

Contents This chapter provides you with information about: • the roller drum and its drive unit, • the rear axle and its drive unit, • the functions and trouble shooting, • the measuring points and default values. • an overview of the measuring points, • an overview of the adjustment options

7.2.1 Preparing the drum for repair work Preparing the roller for drum removal and installation

1

a  ATTENTION! The drum may only be removed in a workshop. Sufficient crane capacity must be available to lift the drum frame and the drum. • Secure the roller against rolling before starting work. • Pull the ignition key. • Insert the anti-buckling device (1) between the drum frame and the basic frame. • Wedge the rear wheels appropriately. •  Attach the drum frame via lifting gear to a crane. • Lift the drum frame so that the drum and the rubber buffer are released from

load. • Place supports under the drum frame at the front and at the rear. • Place oilpans under the drum drive and under the vibration drive.

2

7.2.1.1 Overview Drum Drum HR70C-9 2

1

4

3

5

6

7

8

9

1 Drum 2 Drive system 3 Rubber buffer 

10

130 Nm 215 Nm 105 Nm

d

105 Nm

14

13

4 Bearing housing 5 Cylinder roller bearing 6 Vibration shaft 7 Cylinder roller bearing (drive bearing) 8 Bearing housing 9 Clutch 10Side plate 11 Vibration motor  12Bearing 13Drum drive/gear unit 14Drum drive hydraulic motor 

12 105 Nm

11

  NOTE! Please refer to the table 'Tightening torques' in chapter 1 for tightening torques and screw joints not specified here in the drawing.

Drum HR110 /120/140C-9 1

2

4

3

5

6

7

8

9

10

11

1 2 3 4

Drum Drive system Rubber buffer  Bearing housing

5 Cylinder roller bearing 6 Vibration shaft 7 Cylinder roller bearing (drive bearing) 8 Clutch 9 Bearing housing 10Side plate 11 Vibration motor  12Buffer bracket 13Cylinder roller bearing 14Drum drive/gear unit 15Drum drive hydraulic motor 

d

15

14

13

12

  NOTE! Please refer to the table 'Tightening torques' in chapter 1 for tightening torques and screw joints not specified here.

Drum HR110/120/140C-9 HR110/120/140C-9

34

15 17

1

23 13

33 3

30

22 7 22

5 23 21

15

26 19 11

8 18

29

Items from the installation description

2

7.2.2 Removing the drum Figure

Work to be executed

• Mark the hydraulic connections. • Detach the hydraulic connections connections from the drum drive drive (1) and • •

1

•

2

• •

3

• •

4

from the vibration drive (2). Detach brake connection from gear motor. Be aware of hydraulic oil flowing out. Immediately close the hydraulic hoses and connections in the drives with sealing plugs. Using a crane and lifting hooks lift the drum (4) so far that the rubber buffers are released from load. Remove the bolts between frame and buffer bracket on the vibration drive side. Remove the bolts (3) between frame and adapter on the drum drive side. Using a crane and lifting hooks lift the drum (4) upwards out of the frame.

7.2.3 Dismantling the drum Figure

Work to be executed

• To remove the vibrator shaft lift the drum on the vibration • • • • • •

1

3

2

5

9

• •

4

6

•

7

8

drive side with a crane and place it vertically up. Erect a working platform beside the drum. Turn the bolts (2) out of the side plate (3). Turn forcing screws (1) into two opposite threads until the side plate (3) can be removed. Turn the six cheese-head screws (4) out of the bearing cover (5). Remove the bearing cover (5) with the shaft sealing ring. Turn the bolts (6) out of the bearing housing (8). Loosen the bearing housing using the forcing screws (9). Remove the bearing housing (8). Unscrew the clutch (7) from the shaft.

Figure

Work to be executed

• Turn an eyebolt into the marked tap hole (10). • Using a crane lift the shaft (4) out of the drum.

10 11

• To remove the components on the drum drive side lift the

drum on the vibration drive side with a crane, rotate it through 90° and place it vertically up.

a Observe pollution control criteria! WARNING!

The chamber of the vibration unit cont ains oil. Remove the oil before turning the drum again. 14 13

• Fasten the drum again on the drive side, lift and place it

upright. • Erect a working platform beside the drum. 12 • Turn all bolts (14) out of the bearing housing (13). • Turn the forcing screws (12) in and force the bearing housing

(13) out of the drum.

7.2.4 Removing the bearing Figure

Work to be executed

Removing the bearing housing on the drum drive side: • Deposit the bearing housing (13) on a workbench.

13

• Compress and remove the retainer (15) with circlip pliers

15,19 14 16

Removing the bearing housing on the vibration drive side:

17 20

18

13

(14)l. • Rotate the bearing housing through 180°. • Turn two forcing screws (16) into the tap holes of the bearing housing (13) and force the bearing (17) out of the bearing housing.

8

• Deposit the bearing housing (8) on a workbench. • Compress and remove the retainer (19) with circlip pliers

(14). • Rotate the bearing housing (8) through 180°. • You must beat the bearing (18) out of the bearing housing (8) using a mandrel (29).

Pulling the bearing rings off the shaft journal: 21

22

• Force the inner bearing rings (21) off the journal (22) using a

mandrel.

7.2.5 Installing the bearing Figure

Work to be executed

a Danger of burns by hot components! DANGER!

11

• Some bearings are fitted in heated state, wear

21

gloves for all work.

22

17,18

8,13

Fitting new bearing rings on the shaft journal: • Heat the inner bearing rings (21) in an oil bath to about 100°C

and press them onto the bearing journals (22) of the shaft (11).

Inserting new cylinder rolle r bearings and ret aining rings: • Press new cylinder roller bearings (17,18) into the respective

8,13 15,19

17,18

bearing housings (8, 13) using an hydraulic press and an intermediate plate. • Insert the retaining rings (15, 19) into the respective bearing housings so that they snap in.

Figure

Work to be executed

Inserting a new shaft sealing ring: • Press the shaft sealing ring (23) out of the bearing cover (5).

23

• Slightly grease the sealing lip of the new sealing ring. • Insert new shaft sealing ring (23) with the sealing lip up into

5

24

the bearing cover (5) and force it in up to the stop using a push-in device.

25

Inserting a new drive bearing into the bearing fixture: • Press bearing fixture (26) out of the drive bearing (25) using a

27

26

• •

25

•

26 •

26

8

plate (24). Place new drive bearing (25) on the bearing fixture (26). Press drive bearing (25) onto the bearing fixture (26) up to the stop using a push-in device (27). Insert bearing fixture (26) with the drive bearing (25) into the bearing housing (8) in such a way that the tap holes of the bearing fixture point upwards.. Press bearing fixture (26) into the bearing housing (8) until they make contact using the push-in device (27).

7.2.6 Assembling the drum Figure

Work to be executed

Installing the bearing housing of the drum drive side •  Apply sealing compound Loctite 518 to the sealing face (28)

28

• •

13

• • • •

29

• •

14 13

12

of the drum. Slightly grease O ring (29) and fit it on the bearing housing (13). Put bearing housing (13) on the sealing face (28) on the drum drive side. Using the screws (14) pull the bearing housing (13) in up to the stop. Retighten screws (14) using a torque wrench. Close the forcing holes (12) by means of screws. To install the components on the vibration drive side lift the drum on the drum drive side with a crane, rotate it through 90° and put it down on the drum circumference. Fasten the drum again on the vibration drive side, lift and place it upright. Erect a working platform beside the drum.

Illustr ation

Maintenance measures Installing the vibration shaft and the bearing case on the vibration drive side: • • •

11

• • • •

11

10

• • •

7

8

oil

Screw an eyebolt into the labeled threaded hole ( 10). By means of a crane, insert the vibration shaft ( 11) into the drum.  After inserting it, rotate the shaft to check whether the vibration shaft (11) is properly seated in the bearing case on the drum drive side. Screw out the eyebolt (10). Use 4 screws to install the coupling ( 7) in the bearing case (8) and to screw it onto the shaft.  Apply Loctite 518 to the sealing surface of the drum. Insert the bearing case ( 8) into the vibration drive side, according to the following instructions: Inserting the bearing case (drum drive side): Fill lubricating oil SAE 40 into the opening between the bearing retainer and the shaft. f or HR70C-9: 3.5 liters f or HR110/120/140C-9 : 17 liters

8

29

Installing the drum

7 24

Issue: 02-10

Figure

Work to be executed

Completing the vibration drive side 23

• Slide new v-ring (30) with the sealing lip over the bearing

5 •

30

• • •

• • •

31

32

•

1

2

3 •

7

• •

cover (5) up to the stop. Slightly grease the sealing lip of the v-ring (30), the sealing face of the bearing cover (5) and the shaft sealing ring (23). Using a crane lift the side plate (3) from the eyebolts eyebolts over the guide screws (1) onto the bearing cover (5). Turn the bolts (2) into the side plate (3) and tighten to the appropriate torque.. To install the hydraulic components on the vibration drive side lift the drum on the vibration drive side with a crane, rotate it through 90° and put it down on the drum circumference. Press drive shaft (31) into the bearing housing up to the clutch. Using a depth gauge measure the the dimension from the t he sealing face (32) to the clutch (7). Pull out shaft (31) up to the stop, and measure again, as described before, with the depth gauge. The balance of the two measurements is the bearing clearance. Compaction roller bearing clearances from 0.9 - 2.0 mm. Calibrate the clutch using the depth gauge. Bolt vibration motor 1 to the side plate with the connections pointing towards the grease nipple.

Figure

Work to be executed

Completing the vibration drive side, continued: • Slightly grease O ring (33) to seal the bearing housing/

34

vibration drive and push it onto the drive. • Calibrate the clutch (34) on the vibration drive (2) using the depth gauge. • Bolt vibration drive to the side plate with the connections pointing towards the grease nipple.

33 2

Drum (4) completely assembled and ready for installation in drum frame. 2

4

7.2.7 Installing the drum Figure

Work to be executed

Reinsert the drum (4) into the drum frame after repair or  replacement of components: • Ensure correct assignment of the drum drive side.

4

• Using the crane lower the drum (4)so far that the screw holes

1 A 3

• • •

5

•

34

3

match.  At first, turn in the bolts bolts (3) on the drum drive side. Pretension the buffer brackets on the vibration drive side about 1-2 mm using the forcing screws (5). Insert shims (34) between frame and buffer bracket. Slightly pretighten the bolts (3), then remove the clamping screws (5) and evenly tighten the fastening bolts (3).

Figure

Work to be executed

Completing the hydraulic connections: •  Attach the hydraulic connections according to the marking on

the drives. • Remove sealing plugs from hydraulic connections. •  Attach the hydraulic connections to the drum drive (1) and the vibration drive (2). • Detach brake connection from gear motor.

1

2 • Wedge rear wheels (6). • Start Diesel engine, release parking brake and move drive

lever slightly forwards and backwards to check whether the drum rotates correctly. • Fasten the drum frame to via lifting gear to a crane (2). • Lift the drum frame so far that the supports under the drum frame can be removed. • Perform the roller functions. 6

Chapter 8 Drive unit of the vibration system

Contents This chapter provides you with information about: • the vibration system and its drive unit • the functions and trouble shooting • the measuring and default values • the layout of the measuring points • the options for making adjustments

8.1 Vibration system 8.1.1 Technical specifications

Type Compaction capacity with smooth roller drum: Static linear load  Amplitude high / low Frequency at high / low amplitude Centrifugal force at high / low amplitude in kN Compaction capacity with pad foot roller drum:  Amplitude high / low Frequency at high / low amplitude Centrifugal force at high / low amplitude in kN

HR70C-9

HR110C-9

HR120C-9

HR140C-9

22.40 kg/cm 1.8 / 0.8 mm 30 / 40 Hz 120 / 90

29.00 kg/cm 1.8 / 0.8 mm 30 / 38 Hz 220 / 150

32.80 kg/cm 1.8 / 0.6 mm 30 / 40 Hz 240 / 140

38.00 kg/cm 1.9 / 0.7 mm 30 / 40 Hz 280 / 180

1.8 / 0.8 mm 30 / 40 Hz 120 / 90

1.8 / 0.6 mm 30 / 38 Hz 220 / 150

1.8 / 0.6 mm 30 / 40 Hz 240 / 140

1.9 / 0.7 mm 30 / 40 Hz 280 / 180

2

1

Compaction & vibration

8 2

Issue: 01-10

8.1.2 Overview: Vibration system 2 2

1

4 HR70C-9

3

HR110/120/140C-9

1 Drum 3

2 Vibration modes (Selector switch):

0

KA: low amplitude

0

GA: high amplitude GA KA

Compaction & vibration

3 Vibration system 4 Vibration drive

8 3

Issue: 02-10

8.1.3

Overview: Vibration Hydraulics

2

HR70C-9

HR110/120/140C-9 2

1 2

1

1

4 Vibration

2.1 2.1

= HP oil system A & B = Control oil system PS = Fuel line

T A

A 1 Oil pressure pump - vibration B Oil pressure (variable displacement) pump - vibration

2 Joystick, vibration on (2.1) 3 Vibration mode selector switch 4 Vibration drive unit

B

8.1.4

Sequence of functions - Vibration mode

HR110/120/140C-9

•

•

2.1

2 •

0

3 KA

GA

 After starting roller operation (i.e. the compaction roller moves forward or backwards), you can activate the vibration system as required. Set the selector switch (3) to the desired vibration mode. • Middle position 0: no vibration mode selected • Switch set to position KA = (Y6) low amplitude. •  Switch set to position GA = (Y6) high amplitude. In order to activate or deactivate vibration, press (2.1) on the joystick (see illustration on the left for types HR70C-9 or HR110/120/140C-9). • The corresponding solenoid valve (KA or GA) of the variable oil pressure pump of the vibration system) opens and releases the control oil pressure to the displacement disk of the pump. • The control pressure reaches the displacement disk of the variable oil pressure pump. • The pump swivels, depending on the selected vibration mode, and the oil flow reaches the vibration drive unit. HP

 Y6 T

 Y5

HP

 Vibration

T

A

HR70C-9

2.1 2 = HP oil system A & B = Control oil system PS = Fuel line

B

A B

8.1.5 Trouble shooting: What to do if the vibration does not start Failure / Problem

Causes and actions to be taken

Vibration cannot be activated

•

Electrical fault

• • •

•

Insuf ficient charge pressure

•

Check the charge pressure, make sure it is correct.

•

Hydraulic fault

•

Check the high pressure A & B at the measuring points. Check the coupling between the vibration motor and the shaft.

•

Vibration cannot be deactivated

Rough-running, sluggish vibration

•

•

The vibration on/off button on the joystick is defective.

•

Check the high pressure A & B at the measuring points MA & MB. Check the oil level in the vibration bearing, see maintenance instructions.

Incorrect engine speed •

Vibration generates a high noise level

Vibration system

The vibration on/off  button (2.1) on the joystick may be defective. Check the functions of the vibration mode selector switch on the control panel. Check Relay K04.

•

Incorrect frequencies

•

8 6

Check the vibration system.

Issue: 02-10

8.2 Engine speeds, hydraulic measuring and default values Measurement / Adjustment

Max. Diesel engine speed At a high amplitude: Start-up pressure Operating pressure Frequency

At a low amplitude: Start-up pressure Operating pressure Frequency

Default values HR70C-9 2200 min-1

HR110/120C-9 2200 min-1

HR140C-9 2400 min-1

280-300 bar 220-260 bar 30 Hz (corresponds to 1800 min-1 of the vibration shaft)

330-350 bar 230-280 bar 30 Hz (corresponds to 1800 min-1 of the vibration shaft)

330-350 bar   230-280 bar   30 Hz (corresponds to 1800 min-1 of the vibration shaft)

280-300 bar 150-190 bar 40 Hz (corresponds to 2400 min-1 of the vibration shaft)

330-350 bar   130-180 bar  

 Amplitude at a high frequency

0.7 mm

 Amplitude at a low frequency

1.6 mm

330-350 bar 130-180 bar HR110C-9 : 38 Hz / HR120C-9 : 40 Hz (corresponds to 2280 min-1 / 2400 min-1 of the vibration shaft) HR110C-9 : 1.8 mm HR120C-9 : 0.6 mm 1.8 mm

Run-up time vibration

2 to 3 seconds

2 to 4 seconds

Vibration system

Measuring point / method / tool

8-7

HR140C-9 : 40 Hz (corresponds to 2280 min-1 / 2400 min-1 of the vibration shaft)

Diesel engine HR70C-9: MA HR110/120/140C-9: MB Sirometer /  Adjusting screw V2

HR70C-9: MB HR110/120/140C-9: MA Sirometer /  Adjusting screw V1

HR140C-9 : 0.7 mm HR140C-9 : 1.8 - 1.9 mm 2 to 4 seconds Stop watch

Issue: 02-10

8.2.1 Overview: Measuring points of the vibration hydraulics and required operating conditions HR70C-9

HR110C-9/HR120C-9/HR140C-9 PS MB MB

PS

MA MA

i

NOTE!  Vibration measurement:  A sirometer is required to establish the values regarding vibration, see Using a sirometer .

DANGER! In order to measure the engine speeds and the hydraulic oil pressure, the Diesel engine needs to have reached its operating temperature and the hydraulic oil needs to have reached a minimum temperature of 50° C in the feeding circuit.

Vibration system

8 8

Issue: 02-10

8.2.2 Overview: Adjustments at the oil pressure pump (vibration) HR70C-9

HR110C-9/HR120C-9/HR140C-9  Y6 high frequency

 Y6 high frequency

B

 Y5 low frequency HP valve 370 bar 

B HP valve 370 bar 

 Y5 low frequency

A

setting V1 big amplitude

HP valve 370 bar 

A HP valve 370 bar 

pressure cut-off  320 bar 

pressure cut-off 300 bar 

Engine speed, hydraulic default and measuring values

setting V2 small amplitude

8 9

Issue: 02-10

8.3 Using a sirometer  •

3

• • •

2 2

 A sirometer enables you to measure the engine speed and the frequency at any running e ngine or vibration unit with great accuracy. The TREYSIT sirometer (1) analyses the vibrancy at the drum. The engine speed or frequency (lower scale, 1.1) to be measured is displayed on both scales. The TREYSIT sirometer has been tested and approved by the "Physikalisch-Technische Bundesanstalt" (national metrology institute providing scienti c and technical services) in Braunschweig. With a tolerance of 1-2%, its accuracy is appropriate for the measurements in question.

DANGER! Risk of injuries! The vibration measurement by means of a sirometer may only be carried out with the roller stopped! • • • •

In order to conduct the measurement, position the sirometer (1) on the edge of the drum. Turn the top part of the sirometer to the left so the measuring wire (2) is extended. With the vibration activated, the end of the measuring wire (2) starts to de ect (3).  After recording the furthest de ection (3) of the measuring wire (2), the amount of vibrations per second (in Hz) is displayed on the lower scale (1.1).

1

1.1

Sirometer

8 10

Issue: 02-10

Chapter 9 Electrical system

Contents This chapter provides you with information about: • the electrical system • maintenance work related to the electrical system • fuses, relays and positions of the components • the electric circuit diagrams

9.1 Electrical system ATTENTION! The HYUNDAI compaction rollers dispose of an operating voltage of 12 Volt. Be sure to take this into account when jump-starting the vehicle or replacing components.

WARNING!  Any repair work related to the electrical system may be carried out by trained professional service staff only!

WARNING! Prior to performing any work referring to electrical components of the wiring, disconnect the plus terminal (2) from the battery (1).

9.1.1 Maintenance work referring to the electrical system DANGER! Risk of explosions! Whenever maintenance work related to the electrical system is carried out, keep away sparks and open fire from the battery. Do not smoke!

Illustration

Battery Maintenance work to be carried out on a monthly basis: 2

HR70C-9

•

Check the battery terminals ( 2) for signs of corrosion and dirt.

•

Lubricate the poles and terminals. Required grease: order no. 0830684.

•

Open the cover caps ( 3) of the battery and check the fill level above the cells.

•

Make sure the fill level is suf ficient, i.e. above the cells.

HR110/120/140C-9

CAUTION!

3

Electrical system

 Add distilled water only!

9 2

Issue: 02-10

9.1.2  Overview: Electrical system HR70C-9

Starter  Engine block

 Y5 P03

K10

F18/K11

F17

S04

 Y1  Y2

 Y6

 Y1 = Reverse  Y2 = Forward  Y5 = Low f requency  Y6 = High f requency

M08

Installation in the cover plate of the control console

S07  Y9  Y10

S27

 Y03

S06  Y7

Immersion tube contact

H18

9.1.3 Overview: Electrical system HR110/120/140C-9  Y05  Y06

S09

 Y01

S08

 Y02 P03

K09

 Y1 = Reverse  Y2 = Forward  Y5 = Low f requency  Y6 = High Frequency

S07 H19 F17

K09  Y03  Y07

B03 (Speed Sensor)* H18 *Option

 Y08

9.1.4 Printed circuit board, fuses and relays Printed circuit board •

The printed circuit board (3) constitutes the control center of the electrical system. This is where the fuses and relays of the compaction roller are installed.

• • • • •

5

4

The printed circuit board is to be found under a cover plate (4), next to the driver`s seat (left side). Open the plate (4) covering the printed circuit board (3) and check its condition by a visual inspection. Check all the fuses and relays for damage and dirt.  Always replace defective fuses, see Allocation of the fuses on the printed circuit board. The Rexroth control box (5) for the joystick (reverse/forward motion) is also installed below the cover (4).

3

3

Electrical system

9 5

Issue: 02-10

Allocation of the fuses on the printed circuit board

F1

F3

F2

F4 F5

Electrical system

F6

F7

F8

F9 F10 F11

F12 F13 F14

No.

Ampere

Function

No.

Ampere Function

F1

 30 A

Ignition lock, starter, preheating

F10

15 A

Rotating light, front work lights

F2

 7.5 A

Radio

F11

 15 A

Rear work lights

F3

 25 A

Relay K08, EMR 3

F12

 25 A

Fan (heating unit), air conditioning (optional feature)

F4

 25 A

Time relay rear window heating

F13

7.5 A

Control climate coupling

F5

25 A

Air conditioning (optional feature), heat exchanger 

F14

15 A

Socket, rotating sensor  

F6

 7.5 A

Control lights, fuel gauge, Generator D+

F15

10 A

Emergency off, relay K3, brake, air filter, RC2-2, H03

F7

7.5 A

Gearshift drum, axle

F16

15 A

DRCA-RC2-2, Vibration, joystick, ECO, engine speed control, backup warner, Diesel valve, Diesel pump

F8

15 A

Horn, electrical seat features (optional), rear window control

F17

80 A

Preheating

F9

 15 A

Front and rear wipers

F15 F16

9 6

Issue: 02-10

Fuses and relays in the engine compartment HR70C-9

HR110C-9 /HR120C-9 /HR140C-9

F17 K10

K10

• •

F17

•

Check the fuses (F17) and the relay (K10, preheating relay) in the engine compartment for damage and dirt.  Always replace defective fuses.

Electrical system

•

9 7

Check the fuses (F17) and the relay (K10, preheating relay) in the engine compartment for damage and dirt.  Always replace defective fuses.

Issue: 02-10

Functions of the relays No.

K8

K7 K4 K5

K2

K6

Electrical system

Location

Plan No.

K01 Ignition lock

Printed circuit board

1

K02 Starter, Ignition lock

Printed circuit board

1

Printed circuit board

1

K04 Vibration

Printed circuit board

4

K05 Vibration

Printed circuit board

4

Printed circuit board

4

K07 Diesel engine control

Engine compartment

7

K08 Rear window heating

Printed circuit board

10

K09 Preheating relay

Engine compartment

2

K3

K03

K1

Function

K06

9 8

Parking brake, Emergency-off push-button

Selector switch vibration mode

issue: 02-10

Overview: Switches (see electric circuit for functions) S21

S24

S25

S23

S26

HR110/120/140C-9

S13 S1 HR70C-9

Electrical installatio

S11

S14

9 9

Issue: 02-10

Electric circuit diagrams HR70C-9

0

1

3

2

 

4

5

6

7

8

9 Kl 30 KL 15

Kl50 2.0 F06 F16   1   0  F  -

1

  0 2   3

1

  5   1  F  -

  2

86

30

85

87 87a

  1   1   0  V  -

 e   d  o   i   d   h  c  s   ö  L

5

1

2

-K01

 p  m  A

  6   1  F  -

  0 2   1

4

  8   6   1  R   0

3

2

 R  -

1

 p  m  A

  5 2   1

5

4

-K03

31

2.0 10 11 12 1

2

3

4

5

6

-X8   2   3   4   5   6   7   8   9   0   1   4   4   4   4   3   3   3   3   4   4

7

8

1

2

5

6

7

8

3

4

1

2

3

5

-X1

-X2   0   0   3   3

  0   0   5   5

-X1

 r   b

 t  r

 t  r

 w  s

4

-X1 -X5

1

1

2

-X9

1

-X9

-X4

2

-X5

3

4

-X5

-X5

5

2

-X5

 n  g

  l   b

  1  +  l  D  b

  5   1

  2

  0   1

  6   5

  5   5

  2   5

 r  g   3    l   0   b  H

 t  r   w  s

  l   b   r  g

 r  g    l   b

 t  r   w  s

2

  0   5

S11 3.0

  1   5

  1   2

  7   0   1

 w  s

 t  r   n  g

 t  r   n  g

I     

S13

1 5

M01

2.1

D01

5.6

F16

7   2   5

1

rt

-X9.1

10

2

9

-X9.1

1

T Temp

-S11 + Kl 30

Kl 50

M -M01

Kl 31

B+

W

G31

1

1

2

2

-H01

-G01

1

1

1 2

-H03

K1

2

-S27

D+

2

-Y03 K0

-Y09

1

M -2

2

-Y04

M08

2.3

2.3  r   b

 r   b

Kl 31 Batterie battery

Zündschlo ss ignition lock

Anlasser starter motor

Lichtmaschine alternator

Lichtmaschinenkontrolle status alternator

B re m sv en ti l brake valve

F es ts te ll br e ms e parking brake

Not-Aus emergency stop

Feststellbremse parking brake 07.05.07

Heuer

  Datum

07.05.2007

3.0

 w  s

 t  r

rt

-B01

1

3

 0  

  0   3

-

8

-X4 -X5 -X5

-S01 01 2

7

gr-bl 103

  8  n  g

6

-X5

  9   0   1   2

  5   1

001

2.0

3

1

-K02

9

2.0

 p  m  A

Mehrmengenventil additional fuel valve Dieselpumpe fuel pump

AW-2501 /1070

2.0

Dieselventil fuel valve

0 1.9 1.9 1.9

1

3

2

 

4

5

6

7

8

9

Kl 30

Kl 30

KL 15

KL 15

F16

F16

3.0

F06

1.9

1.9 Kl50 F02

10.2

1

  6   0  F  -

2

 p  m  A   5  ,   7

1.9 3

-X4

5

-X4

7

4

6

-X4

-X4

9

-X9   9   0  H

  9   2

  1   3

 n  g

 w  s

1.3

  5

  9

 s  w   t  r

 s  w   r  g

17

-X9

-X9.1

8

-X4

 +   5   0   1   1

  7   1

  9   1

 r  g

 w  s

17

11

-X9

  l  e  u  F

  6   1  H

9

 M01

22 10

-X9

9

-X4

10

-X4

-X4

-X4

12

12

-X9

  1

  1   1

  7

  2   1

 e  g   s  w

 s  w    i  v

 s  w    i  v

 t  r   s  w

22 10

11

-X9.1

4

-X9

  2   1  H

  0   1  H

 s  w   w  s

11

14

-X4

3

-X9

-X9.1

15

-X4

16

-X4

9

-X5

-X4

17

13

-X9

18

-X4

  3   1  H

  2   0  H   4

  6

 s  w   n  g

 s  w   n  g

12

-X9.1

13

-X4

  1   1  H   3

  4

  i  v

  i  v

4

  3   1

  9

 w  s   n  g

 n  g   w  s

3

-X9.1

13

-X9.1

-X9.1

 t  r

A   7   1  F

1

  7   2  t  r

TK

1

 +

 G

1

1

1

1

1

1

15 L

-H09

2

-H16

2

-H10

-P1

 -

2

-H12

2

-H02

2

-H11

2

-H13

K1

1.5  K1

50

-K10   0   3

1 1

 e  g   1

2

-R02

R01

  2

 r   b

8.4

 t  r   n  g

H

31 R

1.5 K0

K0

P

1

1

1

2

T Temp 2

2

P 2

-S07

-S05

1

P 2

-B02

-S04

S06

4.7

 r   b

 r   b

 r   b

1.9 Kl 31

Kl 31 3.0 Vorglühen preheating

001

2

30

07.05.07

Heuer

Vorglühkontrolle status preheat

  Datum

07.05.2007

Tankanzeige fuel gauge

L uf t fi lt er ve rs ch mu t zu ng air filter clogged

W as s er st an d water level

Öldruck Motor engine oil pressure

Motortemperatur engine temperature

AW-2501 /1070

Bremsdruck brake pressure

0 2.9 2.9 2.9

1

3

2

 

4

5

6

7

8

9

Kl 30

Kl 30

4.0

KL 15

KL 15

4.0

F16

4.0

F16

1

  4   1  F  -

 p  m  A

  5

2   1

A02 RC 2-2

-X25

1

Rex-1

  0   3

  5   1

 L  K

 L  K

27

 t  r  e   i  v  r  e  s  e  r

 e  s  s  a  M

41

42

  7   0   1

  3   0   1

  3   0   1

 t  r   n  g

  l   b   r  g

  l   b   r  g

2

28

 e  s  s  a  M

 D  X  R

 D  X  T

52 51

50

  8   9   5   9   9   9  r   b

 t  r

 s  w   w  s

 n  g

 H

 L

 n  a  C

 n  a  C

17

40

  i  t  o  p  r   h  a  F

39

34

  7  m   9   h  O   i  v   0   2   1

 s  w    i  v

 s  w

35

  3   3

  6   9

  0   0   1

 s  t  r   ä  w   k  c   ü  R

  4   3

 t  r   e  g

 s  w

36

 e   b  a  g   i  e  r   f  t  r  a  t  S

 s  t  r   ä  w  r  o  V

30

31

  5   3

  1   0   1

  2   0   1

 w  s   n  g

 w  s   t  r

  l   b   t  r

29

10 11

-X5

 .  t   k  n  u   f  r  e   d  n  o  S

19

-X4

15

20

18

13 14

-X5

-X4

15

-X5

-X5

21

-X4

22

-X4

16

-X5

Vor

6.1

Rück

6.2

17

-X5

1.9 S11

  1   2   4   4

  3   4

  l   b   t  r

 s  w   e  g

A

H

C

D

B

G

E

F

13

-X29

-X29

14

-X29

1.9

F16

  5   7

 t  r   e  g

XA

 s  w

 w  s   n  g

1  S

XB

 K   4

E

 w  s

  k  r  c  o   ü  V  R

A

P03

  8   0   1

 t  r   r  g

15

  6   7

  4   7

-X24

  4   4

 w  s   t  r

2

3

4

5

6

7

8

9

1

10

-X18

X23 X20- A-2 S-3 E-1 M-4

  2   1

  1   1

  6   1

 w  s   t  r

  l   b   t  r

 t  r   r  g

  5   1  w  s

4

-X34 -X34 1

1 2

-Y1

 r   b

 r   b

2

1 1

2

4 2

-Y2

 r   b

-B03 -X34  r   b

2

 r   b

2.9 Kl 31

Kl 31 4.0 Diagnosestecker DRCA10 diagnosis connector DRCA10

001

 r   b

07.05.07

Heuer

  Datum

07.05.2007

Joystick

Rückwärts reverse

Vorwärts forward

TCD /CFM

AW-2501 /1070

Tacho speed sensor

Steckdose power outlet

0

1

3

2

 

4

5

6

7

8

9

3.9

Kl 30

Kl 30

5.0

3.9

KL 15

KL 15

5.0

3.9

F16

F16 1800

5.0 6.5

2200 6.5

PFE 2501-2601

  1  J  -1

2

3

4

5

6

7

PFE 2601 ECO-Rex2

8

9

  2  J  -

10 11

1

2

3

4

5

6

3

1

7

8

9

10 11

  1  V    1  V  -

2

5

4

-V1

-K05

31

 s   i  a   l  e  r  t  t   i  r   h 87a  c  S

30

15

87

3

1

2

-K04

5

4

-K06

2.9 31 12

-X5

5

19

-X11

-X5

20

-X5

21

-X5

22

  6   1   1

  i  v

 n  g   e  g

20

-X19   1   8

5

6

1

-J03

4

-X29

  l   b

-X11 -X11

12

1

-X3

2

-X3

5

 I  I  O  I

2 6 8 3

1 5 7

10

9

  4   1

  5   1

  l   5   b  -  1  s  w  H

 n  g  6  -  0   l   b  H

 r  g

  5   6

5

 w   6  s   6   r  r  g  g

6

-X11

-X11

31

5.0

Kl 31

5.0

3

-X11

6

-X9.1

2

1

-H06

2

-H14

-S16

2 116  w  s

JX

5.6 1

1 2

6.0

Y05

 r   b

 r   b

2

2.3

K0

K0

6.3

Y06

 r   b

3.9 Kl 31 Vibration Ein/Aus vibration on /off

001

4

  4  w   1  s    l  H   b

1

-H15

2

-X9

15

1

2

6

  6

-X9.1

-X9.1

 w  s   r  g

1

-X11 -X11

-X9

  5

  3   1

5

-X29

15

-X9

 w   5  s   2   r  r  g  g

 s  w   e  g

 s  w   e  g

-X21

11

  4   2

  7   6

  i  v

2

-X5 -X6

  6   2   0   4

1

07.05.07

Heuer

Wahlschalter Vibration vibration mode switch

  Datum

07.05.2007

kleine Frequenz große Amplitude

grosse Frequenz kleine Amplitude

low frequency high amplitude

high frequency small amplitude

grosse Amplitude high amplitude

kleine Amplitude small amplitude

ECO

AW-2501 /1070

0 4.9 4.9 4.9

1

3

2

 

4

5

6

7

8

9

Kl 30

Kl 30

KL 15

KL 15

F16

6.0 6.0

F16

6.0

31

6.0

 m   h  O   0   2   1

Low High

4.9

7.1 EMR 7.1

31

17

-X11

7

-X11

8

2

-X11

7

-X7 -X7 -X7

3

9

10

14

16

-X11 -X11 -X11 -X11 -X11

15

-X6

3

4

5

18

-X11

6

2

-X6

1

-X16

2

-X16

-X15

1

-X15

  6   1   1   3   3

  4   3

  6   1   1

 w  s    l   b

 w  s   n  g

 n  g   e  g

 n  g   e  g

-X29

7

-X6

  3   2

  0   2

 w  s

 t  r   n  g

22

3

X29

 116

 n  g   e  g

 w  s

  8   1  F  -

1

30

86

87a 87

85

  0

2   3

 t  r

D01

 t  r   n  g

 w  s

2

117,83

5

83

10

7  p  m  A

1

-K11

  2   3

1.3

1

  2   6

2 1 0

  4   6

4   8   2

6.0

-X29

  7   1   1

4.3

gn-rt 20

-X13

9

-S22

 t  r

2

-X13  s  w

1 2

-Y10

 w  s

3

-X13  r   b

 r   b

 r   b

4.9 Kl 31

Kl 31 6.0 Drehzahlregelung speed control

001

07.05.07

Heuer

  Datum

07.05.2007

AW-2501 /1070

0

1

3

2

 

4

5

6

7

8

9

5.9 Kl 30

Kl 30

5.9 KL 15

KL 15 F16

5.9 F16

4.9 4.9

3.9

Vor

 

3.9

7.0 7.0 7.0

2300 1800

Rück

Drehzahlregelung

5.9

31

31 7.0 8

-X6 gn-rt 20

5.9

-X21

9

 t  r

  2   7

 t  r   n  g

  l   b   t  r

1

-X21

 w  s

2

J01

-X9

7 2

-H7

Rück

3

J02

-X6

 t  r   r  g

21

-X9.1

-X6

18

19

-X6

  6   3

  9   3

  7   3

 e  g

 n  g

  l   b

16

1

2

17

-X6

9

-X3

10

-X3

  8   1

-X9.1

8

-X21

16

-X29

 w  s   t  r

1

1 4.3

-X29

-X3

8 12

21

  3   7

 s  w

Vor

3

  8   8   0  w  s  H   t  r

 w  s   t  r

-X9.1

8

-X9

  2   3

7

-X29

  2   8

-X21

-X6

  7   7   0   l   b  H   t  r

  l   b   t  r 11

-X29

9

-X9

  1   3

21

gn-rt 98

7

-H8

19

-X29

-X29

  0   8

  8   7

 e  g

 n  g

  l   b

-X21

6

-X21

 t  r

17

  7   7

3

  8   3

18

-X29   9   7  t  r

4

-X21

2

-X21

  i  v

2

3 1

JX

4.7

K0

-X36

1

H19

1 2

K0 8.1

-X36 2  r   b

 r   b

5.9 Kl 31

Kl 31 7.0 vorwärts forward

001

07.05.07

Heuer

  Datum

07.05.2007

rückwärts reverse

Rückfahrsummer backup a lar m

AW-2501 /1070

0 6.9 6.9

1

3

2

 

4

5

6

7

8

9

Kl 30

Kl 30

KL 15

KL 15

6.9 F16

F16

  3   0  F  -

1

8.0 8.0 8.0

 p  m  A   5

2   2

86

30

85

87 87a

-K08

5.3 Low 5.3 High

6.9  31

31 13

-X3

11

12

-X3 -X3

14

-X3

15

-X3

16

17 18

-X3

-X3

19

20

-X3

-X6

6.9 Kl 31

001

Kl 31

07.05.07

Heuer

  Datum

07.05.2007

8.0

20

/1070

8.0

0 7.9 7.9

1

3

2

 

4

5

6

7

8

Kl 30

KL 15

KL 15

F16

7.9

  7   0  F  -

 p  m  A

1 2

  8   0  F  -

  5  ,   7

1

10

-X6

-X6   8   2

 s  w   t  r

  l   b   s  w

7

8

-X29

  8   6

        I

 s  w   t  r

        0

1

  9   6

6 8 9

10

13

-X9

-X6

9.0

F08

9.0

 p  m  A   5

  7   1

  6   1

  l   b   s  w

 w  s   s  w

  l   b   s  w

-X29         I

  0   7

  1   7

        0

 e  g    l   b

 e  g   r  g

-X3

6

-X3

21

14

-X6

  4   1

  2

  9   5

 r  g   t  r

 r  g   t  r

  3

 t  r

 s  w    l   b

-X6

  7   5   l   b

-S17

5 7

2

-H04

8

  8   8

  7   5

10

 e  g    l   b

10

-S18

1

 t  r

1

6 9

-X6

 0  

14

7 2

  l   b   s  w

9.0

15

I     

-X9.1

5

  7   8

  6   8  w  s   t  r

5

  5   0  H

10

-X29

1

-X9.1

-X9

 e  g   r  g

9

16

14

  0   3

 e  g    l   b

  4   0  H

12

-X6

  9   2

5 7 2

16

-X3

  7   2

-X29

4

9.0

F16

31 11

9.0

2   1

31

7.9

9

Kl 30

  l   b

-S14

1

-H05

9

2

1 1

1 2

2

Y08 6.2  r   b

7.9

 r   b

K0

 s  u  n   i  M

2.9  r   b

K1

 s  u   l  P

-H18

M -2

1 2

-M03

Y07

 r   b

 r   b

 r   b

 r   b

Kl 31

Kl 31 Gangumschaltung Achse gear shift axle

001

07.05.07

Heuer

  Datum

07.05.2007

Gangumschaltung Bandage gear shift drum

Signalhorn horn

E-Sitz e-seat

AW-2501 /1070

9.0

0

1

3

2

 

4

5

6

7

8

9

8.9 Kl 30

Kl 30

8.9 KL 15

KL 15

10.0

8.9 F16

F16

10.0

8.9 F08

F08

10.0

  0   1  F  -

8.9

1

1

2   1

2   1

 p  m  1  A  1  F   5  -

 p  m  A

  9   0  F  -

  5

1

 p  m  A   5

2   1

31

31 3

-X10

1

-X10

13

-X10

  1

  0   2

 t  r   w  s

 w  s   t  r

14

7

-X3

-X10

12

-X10

2

8

-X3

-X10

-X10

 e  g

I      I     

I     

I       0  

1

 e  g

1

sw-rt 2

5

  6  ,   5

3

2 1 0 1

  4  ,   3

  8  ,   7

 e  g

 e  g

3

  1   1  ,   9

2 1 0

        I         0

 e  g

7

1 5

sw-rt 1,2 10

2 6 8

9 10

-S20

  l   b   r  g

9

  0   3  .   9   2

  8   2  ,   7   2

 t  r   w  s

 w  s   t  r

-S21

  9   2

  2   3

5

7

2

4

6

8

10

9

3

1

7

5

10

9

9

  6   3

-S23

  l   0   b   1   s  e  w  g

  l   b

  7   2

  6   2

  7   3

 e  g   r  g

1

1

1

1

2

2

2

2

2

  b  a   3   1   3   5   3   5

4

1

-S24

  1   2

 e   l  g   b

 t  r

1

-S25

  2   1   3   2   1   2

 n  g

6

  8   2

1

3

-X31

3

-X31 -X31

2

5

3

2

M -

10   4   2  e  g    l   b

4

5

-X31

6

1

-E7 br

8.9

E3

 r   b

 r   b

 r   b

 r   b

E4  r   b

E1  r   b

E2  r   b

M M06  r   b

2

 r   b

1

M -2 M07  r   b

M04  r   b

M -2

1

M05

 r   b

 r   b

 r   b

Kl 31

31

10.0

Kl 3110.0 Rundumleuchte rotating light

001

10.0

11

  3

 0  

  3   3

10.0

07.05.07

Heuer

  Datum

vorne front

07.05.2007

Abeitscheinwerfer work lights

hinten rear

Wischer hinten rear wiper

Waschpumpe hinten rear washpump

Wischer vorn front wiper

AW-2501 /1070

Waschpumpe vorn front washpump

0

1

3

2

 

4

5

6

7

8

9

9.9 Kl 30

Kl 30

11.0

9.9 KL 15

KL 15

11.0

F16

11.0

9.9 F16 9.9 F08

  2   0  F  -

2.1

 p  m  A

1 2

1

  4   0  F  -

  5  ,   7

 p  m  A

  5 2   2

  2   1  F  -

1

 p  m  A

  5   0  F  -

  5 2   2

1

 p  m  A

  3   1  F  -

  5 2   2

1 2

 p  m  A   5  ,   7

 F02

87a 30

86

T 85

87

-K07

9.9

31

31 11.0 4

-X10

10

5

-X10

-X10

6

7

-X10 -X10

8

9

-X10

1

-X14

2

-X14

  3   1  w  s

 t  r

  6   1

  4   1

 w  s

 w  s

  5   1

I     

 w  s

 0  

 t  r   w  s

-X14

21

-X3

4

-X14

22

-X3

Anschluss Klima

  7   1   2   1

3

  8   1

  9   1

 B

  l   b

  l   b

 s  w

Heizung Lüfterstufen 0 1 2 3 S19

C

Klima

B L

1 5

9

3

7

M

10

H

 w  s

S26

 n  g

 e  g

7 4 1 2  +

7 8 +

2

1

E06

8

9.9

1

3

4

M02

138W

M  r   b

 r   b

 r   b

M02

31

Kl 31

Kl 31 Innenleuchte interior light

001

-R03

R

-A01

 r   b

 r   b

9.9

L

07.05.07

Radio

Heuer

  Datum

07.05.2007

Heckscheibenheizung rear window heating

Heizungsgebläse heater fan

AW-2501 /1070

0 7.9 7.9

1

3

2

 

4

5

6

7

8

Kl 30

KL 15

KL 15

F16

7.9

 p  m  A

1

  7   0  F  -

2

  8   0  F  -

  5  ,   7

1

-X6

20

11

-X3

10

-X6

  9   3

-X6

 n  g

  8   2

 s  w   t  r

  l   b   s  w

8

-X29

19

-X29

-X29

  8   6

        I

 s  w   t  r

  0   8  n  g

        0

1

  9   6

7 2 6 8 9

10

13

-X9

-X6

9.0

F08

9.0

 p  m  A

  5

  7   1

  6   1

  l   b   s  w

 w  s   s  w

  l   b   s  w

-X29         I

  0   7

  1   7

        0

 e  g    l   b

 e  g   r  g

-X3

6

-X3

21

14

-X6

  4   1

  2

  9   5

 r  g   t  r

 r  g   t  r

  3

 t  r

 s  w    l   b

-X6

  7   5

-S17

1 5 7

2

-H04

8

  8   8

  7   5

10

 e  g    l   b

10

-S18

1

 t  r

  l   b

6 9

-X6

 0  

14

7 2

  l   b   s  w

9.0

15

I     

-X9.1

5

  7   8

  6   8  w  s   t  r

5

  5   0  H

10

-X29

1

-X9.1

-X9

 e  g   r  g

9

16

14

  0   3

 e  g    l   b

  4   0  H

12

-X6

  9   2

5

6

-X21

16

-X3

  7   2

7

4

9.0

F16

31 20

9.0

2   1

31

7.9

9

Kl 30

  l   b

-S14

1

-H05

9

2

1

HD Regelung

1

1 2

2

Y08 6.2  r   b

7.9

 r   b

K0

 s  u  n   i  M

2.9  r   b

K1

 s  u   l  P

-H11.19

M -2

1 2

-M03

Y07

 r   b

 r   b

 r   b

 r   b

Kl 31

Kl 31 Gangumschaltung Achse gear shift axle

001

07.05.07

Heuer

  Datum

07.05.2007

Gangumschaltung Bandage gear shift drum

Signalhorn horn

E-Sitz e-seat

/1070

9.0

0

001

1

07 05 07

Heuer

2

  Datum

07.05.2007

3

 

4

5

6

weiss

ws

white

wh

grau

gr

grey

gy

gelb

ge

yellow

ye

rosa

rs

pink

pk

rot

rt

red

rd

grün

gn

green

gn

blau

bl

blue

bl

braun

br

brown

bn

orange

or

orange

og

violett

vi

violet

vt

schwarz

sw

black

bk

türkis

tk

turquoise tq

7

8

/1070

9

Electric circuit diagrams

HR110C-9, HR120C-9, HR140C-9

0

1

3

2

 

4

5

6

7

8

9 Kl 30 KL 15

Kl50 2.0 F06 F16   1   0  F  -

1

  0 2   3   5   1  F  -

  2

86

30

85

87 87a

  1   1   0  V  -

 e   d  o   i   d   h  c  s   ö  L

5

1

2

-K01

1

 p  m  A

  6   1  F  -

  0 2   1

4

  8   6   1  R   0

3

2

 R  -

1

 p  m  A

  5 2   1

5

4

-K03

31

2.0 10 11 12 1

2

3

4

5

6

-X8   4   5   6   7   8   9   0   1   2   3   7   7   7   7   6   6   7   7   7   7

7

8

1

2

5

6

7

8

3

4

1

2

3

5

-X1

-X2   0   0   3   3

  0   0   5   5

-X1

 r   b

 t  r

 t  r

 w  s

4

-X1 -X5

1

1

2

-X9

1

-X9

-X4

2

-X5

3

4

-X5

-X5

5

 n  g

6

-X5

  1   2   6   6

-X5

 n  g

  8   3

  5   1

  9   3

  l   b

 t  r   r  g

  1  +   l  D   b

  2

  3   4

  6   5

  5   5

  2   5

 r  g   3    0   l  H   b

 t  r   w  s

  l   b   r  g

 r  g    l   b

 t  r   w  s

2

  0   5

I     

-X4 -X5 -X5

  1   5

  5   6

  7   0   1

 w  s

 t  r   n  g

 t  r   n  g

1

3

S13

1 M01

5

F16

7

2.1

  2   5

 t  r

1

rt

-X9.1

10

2

9

-X9.1

F16-1 2.4

-S11 +

1 Kl 30

Kl 50

M -M01

Kl 31

B+

W

G31

1

D+

-G01

2

-H01

2

1 2

-H03

-Y03 K0

K1

2.3

2.3

 r   b

 r   b

Kl 31 Batterie battery

Zündschloss ignition lock

Anlasser s ta rt er m ot or

L ic ht ma sc hi ne a lt er na to r

L ic ht ma sc hi ne nk on tr ol le st at us a lt er na to r

Bremsventil b ra ke v al ve

Feststellbremse parking brake

Not-Aus emergency stop

Feststellbremse parking brake 07.05.07

Heuer

  Datum

07.05.2007

3.0

 w  s

rt

-

8

 0  

  0   3

-B01

7

S11 3.0

-S01 01 2

2

gr-bl 103

  5   1

001

2.0

3

1

-K02

9

2.0

 p  m  A

F . W e yh a u s

G m b H & C O . KG

AW-2601 /1110-1140

2.0

0 1.9 1.9 1.9

1.9

1

3

2

 

4

5

6

7

8

9

Kl 30

Kl 30

KL 15

KL 15

F16

F16

3.0

F06

1.9 Kl50 F02

10.2

1

  6   0  F  -

2

 p  m  A   5  ,   7

1.9 3

-X4

5

7

-X4

4

6

-X4

-X4

9

17

-X9

-X9

  9   0  H

1.3

 M01

  7

  9

 s  w   t  r

 s  w   r  g

-X9.1

8

-X4

11

-X9

  l  e  u  F

  6   1  H

 +   5   0   1   1

  7   1

  9   1

 r  g

 w  s

9

rt 53

22 10

-X9

17

9

10

-X4

-X4

11

-X4

12

-X4

12

-X9   2   1  H

  0   1  H

 s  w   w  s

  7   2

  1   1

  9

 e  g   s  w

 s  w    i  v

 s  w    i  v

22 10

  5   3

 w  s

 s  w

 t  r   s  w

11

-X9.1

13

14

-X4

-X9.1

3

-X9

-X4

15

-X4

16

-X5

9

17

-X4

13

-X9

18

-X4

  3   1  H

  4

  8

 s  w   n  g

 r  g    l   b

12

-X9.1

-X4

  2   0  H

  2   1   4   3

4

-X9

  1   1  H   3

  6

  i  v

  i  v

4

  3   1

  1   4

 w  s   n  g

 n  g   w  s

3

-X9.1

13

-X9.1

-X9.1

A   7   1  F  -

1

1

 +

 G

1

1

1

1

1

1

  4   5  t  r

-H09

2

-H16

2

-H10

-P1

 -

2

-H12

2

2

-H02

-H11

2

-H13

2

30

1

K1

1.5  K1

8.4

  3   1

2

87

-K09  s X12

2

 e  g

3

X12

 P  L  H  P  M  I   S   O  n  e   h   ü   l   3  g  r  R  o  V

  7   3

 w   w  s

 w  s

  1  n  e   h   ü   l   3  g  r  R  o  V

 M  E

 n  e   h   ü   l   3  g  r  R  o  V

R01

  2

 M  E

 t  r   n  g

92

1 1

P 2

2

  5 -S07  6

-R02 1.5 K0

K0

4.7

 M  E

1.9

F16-1

 t  r   n  g

77

68

 D  B  O   S   O

 r  e  t   l   i   3   f  t  R   f  M  u  L

 E

 D  B  O   S   O

  3  R  M  E

 r   b

 r  e  t   l   i   f  t   f  u  L

71 X35 1 . 3

70

 L  O  W   S   O  .  t  n  o  K    k  c   3  u  r  R   d   l  M   Ö

S09 . X35 2

 T  P  L  T  T   S   O

  3  R  M  E

 E

2

S06

 r   b

 r   b

1.9 Kl 31

Kl 31 3.0 Vorglühen preheating

001

 r  u  t  a  r  e  p  m  e  T

1

P

07.05.07

Heuer

  Datum

Vorglühkontrolle status preheat

07.05.2007

Tankanzeige fuel gauge

Luftfilter air filter clogged

Wasserstand water level

F . W e yh a u s

Öldruck Motor engine oil pressure

G m b H & C O . KG

Motortemperatur engine temperature

AW-2601 /1110-1140

Bremsdruck brake pressure

0 2.9 2.9 2.9

1

3

2

 

4

5

6

7

8

9

Kl 30

Kl 30

4.0

KL 15

KL 15

4.0

F16

4.0

F16

1

  4   1  F  -

 p  m  A

  5

2   1

A02 RC 2-2

-X25

1

Rex-1

  0   3

  5   1

 L  K

 L  K

27

 t  r  e   i  v  r  e  s  e  r

 e  s  s  a  M

41

42

  7   0   1

  3   0   1

  3   0   1

 t  r   n  g

  l   b   r  g

  l   b   r  g

2

28

 e  s  s  a  M

 D  X  R

 D  X  T

52 51

50

  8   9   5   9   9   9  r   b

 t  r

 s  w   w  s

 n  g

 H

 L

 n  a  C

 n  a  C

17

40

  i  t  o  p  r   h  a  F

39

34

  7  m   9   h  O   i  v   0   2   1

 s  w    i  v

 s  w

35

  3   3

  6   9

  0   0   1

 s  t  r   ä  w   k  c   ü  R

  4   3

 t  r   e  g

 s  w

36

 e   b  a  g   i  e  r   f  t  r  a  t  S

 s  t  r   ä  w  r  o  V

30

31

  5   3

  1   0   1

  2   0   1

 w  s   n  g

 w  s   t  r

  l   b   t  r

29

10 11

-X5

 .  t   k  n  u   f  r  e   d  n  o  S

19

-X4

15

20

18

13 14

-X5

-X4

15

-X5

-X5

21

-X4

22

-X4

16

-X5

Vor

6.1

Rück

6.2

17

-X5

1.9 S11

  1   2   4   4

  3   4

  l   b   t  r

 s  w   e  g

A

H

C

D

B

G

E

F

-X29

13

-X29

14

-X29

1.9

F16

  5   7

 t  r   e  g

XA

 s  w

 w  s   n  g

1  S

XB

 K   4

E

 w  s

  k  r  c  o   ü  V  R

A

P03

  8   0   1

 t  r   r  g

15

  6   7

  4   7

-X24

  4   4

 w  s   t  r

2

3

4

5

6

7

8

9

1

10

-X18

X23 X20- A-2 S-3 E-1 M-4

  7   4

  5   4

  7   5

 w  s   t  r

  l   b   t  r

 t  r   r  g

  5   5  w  s

4

-X34 -X34 1

1 2

-Y1

 r   b

1 1

2

4 2

-Y2

 r   b

2

-B03 -X34

 r   b

 r   b

2

 r   b

2.9 Kl 31

Kl 31 4.0 Diagnose Stecker DRCA10 diagnosis connector DRCA10

001

 r   b

07.05.07

Heuer

  Datum

07.05.2007

Joystick

Rückwärts reverse

Vorwärts forward

F . W e yh a u s

G m b H & C O . KG

TCD /CFM

AW-2601 /1110-1140

Tacho speed sensor

Steckdose power outlet

0

1

3

2

 

4

5

6

7

8

9

3.9

Kl 30

Kl 30

5.0

3.9

KL 15

KL 15

5.0

3.9

F16

F16 1800

5.0 6.5

2300 6.5

PFE 2501-2601

  1  J  -1

2

3

4

5

6

7

PFE 2601 ECO-Rex2

8

9

  2  J  -

10 11

1

2

3

4

5

6

3

1

7

8

9

10 11

  1  V    1  V  -

  5   0  K

2

5

4

-V1

-K05

 +   4   0  K  e  n   h  o   2  x  e  R   O  C  E

31

87

3

1

2

-K04

  1   0   6   2  E  F  P

 s   i  a   l  e  r  t  t   i  r   h 87a  c  S

30

15

5

4

-K06

2.9 31 12

-X5

5

19

-X11

-X5   6   1   1

 n  g    l   b

  i  v

20

 n  g   e  g

-X19

-X5

  i  v

5

6

2

11

12

-X11 -X11

1

-X3

2

-X3

5

-X29  I  I  O  I

 s  w   e  g

2 6 8 3

1 5 7

10

9

-X9

116  w  s

JX

  5   6  w   6  s   6   r  r  g  g

5

  9   4

 r  g

10

  1   5

 n   6  g   0    l   b  H

11

 t   l  o  V

 t   l  o  V

 e   2   d   1  u  t   1   i   l  n p  o m   i A  t  a K  r   b V   i   2  V   1

 e   2   d   1  u  t   2   i   l  n p  o m   i A  t  a G  r   b V   i   2  V   1

5

 r  g

6

15

  6   1

 s  w   t  r

 w  s   t  r

2

1

-H15

6

2

-H06

  2  x  e  R  -

 M  W  P

 e   d  u  t   2   i   l  n p  o m   i A  t  a G  r   b M   i W  V P

 e   d  u  t   1   i   l  n p  o m   i  A  t  a K  r   b  M   i  W  V P

  2  x  e  R  -

-X11

  1

  2

 t  r   n  g

 t  r   n  g

 t  r   n  g

 t  r   n  g

1

2

-H14

  2  x  e  R  -

  5   1  .  L  K   x  e  R

42   5   1  .  L  K   x  e  R

1   0   3  .  L  K   x  e  R  t   l  o  V

 t   l  o  V

  2   1

  2   1

  2   1

  2   1

  2  x  e  R  -

1

 r   b

07.05.07

Heuer

Wahlschalter Vibration vib ra ti on m od e s wi tc h

  Datum

07.05.2007

  2  x  e  R  -

2  D  N  G

Kl 31

5.0

28  D  N  G

 D  N  G

 D  N  G

  1   3

  1   3

 e  s  s  a  M

 e  s  s  a  M

  2  x  e  R  -

  2  x  e  R  -

1 2

6.0

 r   b

2

2.3

K0

K0

6.3

Y06

 r   b

3.9 Kl 31

001

  0   3  .  L  K   x  e  R

5.7

Y05

Vibration Ein/Aus vibration on /off

5.0

 r   b

27

 t   l  o  V

  2  x  e  R  -

A

  5

 t   l  o  V

  2  x  e  R  -

5.0

-X11

  4   2

41

31

3

  3   2

31

 M  W  P

2

-X11

  6   4  w   1  s  -  H   l   b

-X9.1 30

1

4

-X9

  5   1

-X9.1

-X9.1

 w  s   r  g

6

  5   1

 s  H  w

  7   1

 w  s   r  g

1

-X11 -X11

-X9

  l   5   b   1  -

  8   1

  2  x  e  R  -

-S16

15

  5

4

-X29

  2  x  e  R  -

1

2

 w   5  s   2   r  r  g  g

 s  w   e  g

 g  n  u  r  e  u  e  t  s  n  A

 r  g

1

  4   2

  7   6

 V   2   1  .  g  n   i  E

-X21

22

-X5 -X6

37

  1   8

-J03

-X5

21

  6   2

  3

  0   4

20

kleine Frequenz gro ße A mp li tu de

grosse Frequenz kleine Amplitude

low frequency high amplitude

high frequency small amplitude

grosse Amplitude high amplitude

F . W e yh a u s

kleine Amplitude small amplitude

G m b H & C O . KG

ECO

AW-2601 /1110-1140

0 4.9 4.9

1

3

2

 

4

5

6

7

8

9

Kl 30

Kl 30

KL 15

KL 15

F16

4.9

6.0 6.0

F16

6.0

31

6.0

 m   h  O   0   2   1

Low High

4.9

7.1 EMR 7.1

31

17

7

-X11

-X11

8

2

-X11

7

3

9

-X7 -X7 -X7

10

14

16

15

-X11 -X11 -X11 -X11 -X11

-X6

3

4

5

18

-X11

6

2

-X6

-X16

1

2

-X16

-X15

-X15

  6   1   1   9

4.9

  1   1

 s  w   e  g

A

 e  g

  8  s  w    i  v

  0   1   i  v

  2   1

  4   1

  3   1

 w  s    l   b

 e  g    l   b

  l   b   s  w

  6   1   1  n  g   e  g

  7  w  s

4.3   2   2

  4  t   9   1  r   1   2   t  n  n  r  g  g

A

H

C

52

  0   2

 s  w   w  s

 t  r  e   i  v  r  e  s  e  r  t  r  e   i  v  r  e  s  e  R

 s  w

D

B

G

E

F

-X27

  2  x  e  R  -

51  D  X  T

50  D  X  R

17  D  N  G

40  H   N  A  C

39  L   N  A  C

34

36

35

 A

 E

 S

  i  t  o  P

  i  t  o  P

  i  t  o  P

 D  N  G   1   3  D  X  T

  2  x  e  R  -

 D  X  R

  2  x  e  R  -

 e  s  s  a  M

  2  x  e  R  -

 H   N  A  C

  2  x  e  R  -

 L   N  A  C

  2  x  e  R  -

  i  t  o  P

  2  x  e  R  -

  i  t  o  P

  2  x  e  R  -

  i  t  o  P

  2  x  e  R  -

 n  g   e  g

-X29

1

-X6

  3   2

  0   2

 w  s

 t  r   n  g

22

3

X29

gn-rt 20

6.0

1

-X29

 116

48   l   h  a  z   h  e  r  D   f   f  O   n  O   h  e  r  D

  2  x  e  R  -

4.9 Kl 31

Kl 31 6.0 Diagnose Stecker SPC/WEY001 diagnosis connector SPC/WEY001

001

7

07.05.07

Heuer

  Datum

07.05.2007

F . W e yh a u s

G m b H & C O . KG

AW-2601 /1110-1140

0

1

3

2

 

4

5

6

7

8

9

5.9 Kl 30

Kl 30

5.9 KL 15

KL 15 F16

5.9 F16

4.9 4.9

 

3.9

7.0

1800

  0   0   2   1

  k   2  ,   8

Vor

7.0

2300

  0   5   8

3.9

7.0

  0   0   8   1

  k   3  ,   4

  0   0   3   2

  k   2  ,   2

  k   0  ,   1

Rück

Drehzahlregelung

5.9

31

31 7.0 8

-X6 gn-rt 20

5.9

-X21

9

 t  r   n  g

-X21

16

2

-H7

-X6

-X9

 t  r   r  g

21

-X6

 w  s

 s  w

Vor 2

J01

Rück

3

  9   3

  7   3

 n  g

  l   b

16

19

J02

1 4.3

-X3

-X29

-X29

  0   8

  8   7

 n  g

  l   b

3

6

-X21

-X3

3

2

-J04

  0   0   2   1

2

-Jo5

  l  a  r  t  u  e  N

2   i  e   b

1 2

-J06

  l   b   n  g

-X21

 r   b

1

  4   1

 s  w   n  g

 t  r

-X21

 e  g

  5   1

  9   7

4

-X21 1

18

-X29

 e  g

-H8

 t  r

1   0   0   8   1

2

-J07

1

JX

  0   0   3   2

15   1  P  P  A   A   I  r  e   b  e  G

4.7

K0

10

  8   3

17

  7   7

  i  v

2

9

-X6

 e  g

 n  g  t  r

19

-X6

  6   3

-X9.1

1

2

18

  6   6

-X9.1

8

-X21

17

-X29

 w  s   t  r

1 7

-X21

-X29

-X3

8 12

21

  3   7

  l   b   t  r

1

3

  8   8  w  0  s  H   t  r

 w  s   t  r

-X9.1

  2   7

8

-X9

  2   3

7

-X29

  2   8

-X6

  7   7   0   l   b  H   t  r

  l   b   t  r 11

-X29

9

-X9

  1   3

21

gn-rt 118

7

-X36

1

H19

1 2

K0 8.1

  l  a   d  e  P

  3  R  M  E

-X36

14   1  P  P  A  V   5   V  t    l  V  o  V   5   l  a   d  e  P

  3  R  M  E

2  r   b

 r   b

5.9 Kl 31

Kl 31 7.0 vorwärts forward

001

07.05.07

Heuer

  Datum

07.05.2007

rückwärts reverse

Rückfahrsummer backup alarm

F . W e yh a u s

G m b H & C O . KG

AW-2601 /1110-1140

0 6.9 6.9

1

3

2

 

4

5

6

7

8

9

Kl 30

Kl 30

KL 15

KL 15

6.9 F16

F16

  3   0  F  -

1

8.0 8.0 8.0

 p  m  A   5

2   2

86

30

85

87 87a

-K08

5.3 Low 5.3 High

6.9  31

31 13

-X3

11

12

-X3 -X3

14

15

-X3

16

17 18

-X3

-X3

19

20

-X3

-X3

8.0

20

-X6

1   5

  3   6

 w  s   t  r

 t  r   n  g

  1  t  r

P 2

-S08   0   2

  3   2

 t  r   e  g

 s  w    i  v

  4   2

  1   2

  2   2

  i  v

 e  g

 n  g

  5   2

  4   6

 s  w    1   1  i   i  -  -  v  v

 t  r   n  g

  6   2

  1   1  w  s

  2   1

  0   1

 s  w   w  s

 w  s    l   b

 L  H

72  Y  L  g  R  n  M   u  S  r  O  e  u  e  t  s  n  A  s   i  a   l  e  R

  3  R  M  E  -

1  t  t  a  B   V

3  t  t  a  B   V

5  t  t  a  B   V

 t   l  o  V

 t   l  o  V

 t   l  o  V

  2   1

  2   1

  2   1

  3   3   3  R  R  R  M  M  M  E  E  E    -

28   5   1  T   S   I   5   1  e  m  m  e   l  K

  3  R  M  E  -

25   1  :   1  M  O  C   D   B

 e  n   i  L   K

  3  R  M  E  -

62

61

82

60

  2  H   N  A  C   D    2  B  H   N  A  C

  2  L   N  A  C   D    2  B  L   N  A  C

  1  H   N   1  A   C  H    D   N  B  A  C

  1  L   N   1  A   C  L    D   N  B  A  C

 e   d  n  u  K

 e   d  n  u  K

 e  s  o  n  g  a   i  D

 e  s  o  n  g  a   i  D

  3  R  M  E  -

  3  R  M  E  -

  3  R  M  E  -

  3  R  M  E  -

 n  n  a  a  C  C

 e  n   5   i   1  e  e   2   2  L  s  s  o  o  -  -  -  e  n  n  L  H  K  m  m  g  g  a  a  n  n  o  e  D   i   i  a  a  s   l  N  D  D  C  C  I  K  G

G

H

F

M

K

A

2

4

6

  1

  2

  3

 D  A  G

 D  A  G

 D  A  G

57

 D  N  G

 D  N  G

 D  N  G

  1   3

  1   3

  1   3

 m   i

 m   i

 e  s  s  a  M

 e  s  s  a  M

 e  s  s  a  M

 r  e  s  s  a  W

 r  e  s  s  a  W

  d  a  r  G   P

  3   3   3  R  R  R  M  M  M  E  E  E    -

-X 33

64  S  F  W    l  A  e   I  s  e   i  D

 P  O  O  R  D  r   e  S  t   I   l  a   h  c  S

B

Diagnose Stecker

63  S  F  W    l  R  - e  G s  e   i  D

  3  R  M  E  -

  3  R  M  E  -

  3  R  M  E  -

 r   b

6.9 Kl 31

Kl 31 Diagnose Stecker EMR3 diagnosis connector EMR3

001

07.05.07

Heuer

  Datum

07.05.2007

Wasser in Diesel Water in fuel sensor

F . W e yh a u s

G m b H & C O . KG

AW-2601 /1110-1140

8.0

0 7.9 7.9

1

3

2

 

4

5

6

7

8

Kl 30

KL 15

KL 15

F16

7.9

  7   0  F  -

 p  m  A

1 2

  8   0  F  -

  5  ,   7

1

10

-X6

-X6

4

-X3

  7   2

  8   2

 s  w   t  r

  l   b   s  w

7

        I

 s  w   t  r

        0

1

-X9

  9   6

  8   5

  6   1

  l   b   s  w

 w  s   s  w

  l   b   s  w

6 8 9

10

9.0

F08

9.0

 p  m  A   5

-X29

-X9

 e  g   r  g

5

6

-X3

-X3

  5   0  H

10

  4   1

  9   2

 t  r

 s  w    l   b

-X29

        I

  0   7

  1   7

        0

 e  g    l   b

 e  g   r  g

1

-X9.1

14

21

-X6

  8   2

  9   5

 r  g   t  r

 r  g   t  r

-X6

  7   5   l   b

-S17

5 7

2

-H04

8

  8   8

  7   5

10

 e  g    l   b

10

-S18

1

 t  r

1

-X9.1

6 9

-X6

 0  

7 2

  l   b   s  w

9.0

15

I     

14

5

  7   8

14

  0   3

9

  6   8  w  s   t  r

12

-X6

 e  g    l   b

16

5 7 2

-X6

  4   0  H

-X29

  8   6

13

  9   2

8

-X29

16

9.0

F16

31 11

9.0

2   1

31

7.9

9

Kl 30

  l   b

-S14

1

-H05

9

2

1 1

1 2

2

Y08 6.2  r   b

7.9

 r   b

K0

 s  u  n   i  M

2.9  r   b

K1

 s  u   l  P

-H18

M -2

1 2

-M03

Y07

 r   b

 r   b

 r   b

 r   b

Kl 31

Kl 31 Gangumschaltung Achse gear shift axle

001

07.05.07

Heuer

  Datum

07.05.2007

Gangumschaltung Bandage gear shift drum

Signalhorn horn

F . W e yh a u s

G m b H & C O . KG

E-Sitz e-seat

AW-2601 /1110-1140

9.0

0

1

3

2

 

4

5

6

7

8

9

8.9 Kl 30

Kl 30

8.9 KL 15

KL 15

10.0

8.9 F16

F16

10.0

8.9 F08

F08

10.0

  0   1  F  -

8.9

1

1

2   1

2   1

 p  m  1  A  1  F   5  -

 p  m  A

  9   0  F  -

  5

1

 p  m  A   5

2   1

31

31 3

-X10

1

-X10

13

-X10

  1

  0   2

 t  r   w  s

 w  s   t  r

14

7

-X3

-X10

12

-X10

2

8

-X3

-X10

-X10

 e  g

I      I     

I     

I       0  

1

 e  g

1

sw-rt 2

5

  6  ,   5

3

2 1 0 1

  4  ,   3

  8  ,   7

 e  g

 e  g

3

  1   1  ,   9

2 1 0

        I         0

 e  g

7

1 5

sw-rt 1,2 10

2 6 8

9 10

-S20

  l   b   r  g

9

  0   3  .   9   2

  8   2  ,   7   2

 t  r   w  s

 w  s   t  r

-S21

  9   2

  2   3

5

7

2

4

6

8

10

9

3

1

7

5

10

9

9

  6   3

-S23

  l   0   b   1   s  e  w  g

  l   b

  7   2

  6   2

  7   3

 e  g   r  g

1

1

1

1

2

2

2

2

2

  b  a   3   1   3   5   3   5

4

1

-S24

  1   2

 e   l  g   b

 t  r

1

-S25

  2   1   3   2   1   2

 n  g

6

  8   2

1

3

-X31

3

-X31 -X31

2

5

3

2

M -

10   4   2  e  g    l   b

4

5

-X31

6

1

-E7 br

8.9

E3

 r   b

 r   b

 r   b

 r   b

E4  r   b

E1  r   b

E2  r   b

M M06  r   b

2

 r   b

1

M -2 M07

M04

 r   b

 r   b

M -2

1

M05  r   b

 r   b

 r   b

Kl 31

31

10.0

Kl 3110.0 Rundumleuchte rotating light

001

10.0

11

  3

 0  

  3   3

10.0

07.05.07

Heuer

  Datum

vorne front

07.05.2007

Abeitscheinwerfer work lights

hinten rear

Wischer hinten rear wiper

Waschpumpe hinten rea r w as hp um p

F . W e yh a u s

G m b H & C O . KG

Wischer vorn fr on t w ip er

AW-2601 /1110-1140

Waschpumpe vorn front washpump

0

1

3

2

 

4

5

6

7

8

9

9.9 Kl 30

Kl 30

11.0

9.9 KL 15

KL 15

11.0

F16

11.0

9.9 F16 9.9 F08

  2   0  F  -

 p  m  A

1 2

1

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  Datum

07.05.2007

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F . W e yh a u s

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F . W e yh a u s

G m b H & C O . KG

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9

Chapter 10 Steering system & Articulated pendulum joint Contents This chapter provides you with information about: • the steering system and the steering hydraulics • the components of the articulated pendulum joint • installing and dismantling the articulated pendulum joint

10.1

Steering system and articulated pendulum joint ATTENTION! The articulated pendulum joint and the steering system constitute a single unit. Articulation of the front drum determines the turning angle of the compaction roller.

10.2

Steering system •

Hydraulic cylinders serve to effect the steering motions by retracting and extending.

•

The steering hydraulics is powered by a hydraulic pump at the Diesel engine.

•

The steering orbitrol (control block) is located underneath the steering column.

•

The turning motion of the steering wheel controls the oil flow in the control block and causes the hydraulic cylinder at the articulated pendulum joint to retract and extend.

•

The bigger the steering motion, the higher the turning angle (max. +/- 30 degrees).

10.2.1 Technical speci cations Measurement / Setting Operating pressure steering system Pressure control valve

Steering system & articulated pendulum joint

10 2

Default values 180 bar  180 bar  

Issue: 02-10

10.2.2 Overview: Steering hydraulics and components 1 Diesel engine 2 Hydraulic pump, steering 3 Steering orbitrol 4 Steering cylinder  5 Hydraulic oil tank

1

5 2 3

1

4

4 3

5

4

4

Steering system & articulated pendulum joint

10 3

Issue: 02-10

10.3

Articulated pendulum joint

1

2

•

The articulated pendulum joint constitutes the link between the drum (front) frame and the basic (rear) frame of the compaction roller.

•

The articulated pendulum joint serves to bend and pivot the drum frame.

3

1 HR HR110/120/140C-9

2 4

2 HR70C-9

1 Basic (rear) frame 2 Steering cylinder  3  Articulated pendulum joint 4 Drum (front) frame

4

Steering system & articulated pendulum joint

10 4

Issue: 02-10

10.3.1 Installing and dismantling the articulated pendulum joint

ATTENTION! 5

•

In order to replace an articulated pendulum joint, take the compaction roller to a workshop, as this work may only be performed by trained service staff.

•

Make sure that the crane to be used disposes of an appropriate lifting capacity before lifting the components.

Preparations to be carried out before dismantling and installing an articulated pendulum joint •

Prior to starting work, secure the compaction roller to prevent it from rolling.

•

Pull out the ignition key.

•

 Apply the parking brake.

•

Insert the anti-buckling device (5) between the drum (front) frame and the basic (rear) frame.

•

Secure the wheels by means of wheel chocks.

•

Slightly lift the drum frame.

•

Place supports (6) both under the front part of the basic frame and underneath the articulated pendulum joint.

6 6

Steering system & articulated pendulum joint

10 5

Issue: 02-10

Dismantling the steering cylinders of the articulated pendulum joint •

Prior to removing the articulated pendulum joint, dismantle the steering cylinders (2).

•

Unscrew the safety screws (2.1) from the steering bolts (2.2) and press the bolts upwards, out of the cylinder fork and the articulated pendulum joint (3)

3

2

2.1 2.2

2

Steering system & articulated pendulum joint

10 6

Issue: 02-10

Dismantling the articulated pendulum joint

3

•

Position a lift truck with a pallet under the articulated pendulum joint.

•

Lift the pallet so it is located right underneath the articulated pendulum joint.

•

Unscrew the screws (3.1) of the connection between the basic (rear) frame and the articulated pen-

1

dulum joint (1/3). •

3

Remove the screws (3.2) from the connection between the drum (front) frame and the articulated pendulum joint (2/3).

1

•

Use the lift truck to lower the disconnected articulated pendulum joint (3) to the ground.

4 3 3 3.2

3.1

3 4

Steering system & articulated pendulum joint

10 7

Issue: 02-10

Replacing and installing an articulated pendulum joint

ATTENTION! 3

•

Any repair work related to the articulated pendulum joint may only be performed by trained service staff, using special tools at the place of manufacture.

•

Always replace the entire articulated pendulum joint.

1

3 1

•

To carry out the installation, put the new articulated pendulum joint (3) onto the pallet of the lift truck and position the pallet underneath the drum area.

•

By means of the lift truck, lift the articulated pendulum joint to a height which enables you to establish the screw connections (3.2) between the articulated pendulum joint (3) and the drum frame (4).

•

By means of the crane, slightly lower the drum frame and align the ange of the articulated pendulum joint (3) with the basic frame (1).

•

Establish the screw connections (3.1) between the articulated pendulum joint (3) and the basic frame (1).

•

Tighten all screws crosswise and to the correct torque (see table of tightening torques).

3

3.1

4

3 3 4

3 Steering system & articulated pendulum joint

10 8

3.2

Issue: 02-10

Chapter 11 Towing the compaction roller

Contents This chapter provides you with information about: • towing the compaction roller 

11.1

Towing the compaction roller 

11.1.1

Safety instructions referring to towing the compaction roller  CAUTION! Precautionary measures to be taken prior t o towi ng the compaction roller! • The precautionary measures related to towing as well as the towing process itself may only be carried out by experienced individuals who have undergone the appropriate training required for this type of work. • Make sure the towing vehicle disposes of the required trailer load capacity / tractive force! • The overall weight of the compaction roller needs to be taken into account (see chapter Technical specifications).

WARNING! The compaction roller may only be towed if its emergency steering is in working order.

WARNING! Material damage! The preparations at the travel hydraulics and the parking brake must be completed prior to towing the compaction roller. Set the towing vehicle in motion very slowly and carry out the towing process at a low speed.

Towing

11 2

Issue: 02-10

11.1.2 Precautionary measures to be taken prior to towing Securing the compaction roller 

DANGER! Risk of death!  Use the wheel chocks to prevent the compaction roller from rolling, since there is no braking effect after releasing the parking brake and the HP valves! •

Place wheel chocks under the wheels.

WARNING! Operation on slopes! If the compaction roller is parked on a slope and needs to be towed, make sure that the rear wheels and the drum are adequately secured!

HR70C-9: 4 mm socket head wrench HR110/120/140C-9: 5 mm socket head wrench

1

Releasing the parking brake and the HP valves

WARNING! Risk of death!  If the compaction roller is not properly secured against rolling, you must not carry out any of the work described below!

Opening the HP valves at the travel pump •

In order to tow the compaction roller, short-circuit the hydraulic circuit between the traction pump and the hydraulic traction motors.

•

 Access the HP valves from the left side of the engine compartment (in the direction of motion).

•

Type 70:

•

Types 110/120/140 : Loosen the socket head screw by 3 turns. Note that there is no counter nut for the socket head screw!

2

In order to loosen the HP valves ( 1) and (2), use the socket head wrench to screw in the adjusting spindles until they are level with the valve housing.

Deactivating (releasing) the parking brake 6 3

•

In order to tow the compaction roller, you need to release the parking brake in the rear axle and in the drum via the hand pump (5).

•

4 5

The hand pump (5) is installed in the engine compartment (on the left side, in the direction of motion).

•

Put a pipe extension into the pump actuation (3).

•

Close the relief valve (4).

•

Build up pressure by manually pumping, which releases the parking brake und causes the corresponding light on the dashboard (brake pressure, 6) to go out.

•

11.1.3 Carrying out the towing process

 Remove the pipe extension.

WARNING! Material damage! • The preparations at the travel hydraulics and the parking brake must be completed prior to towing the compaction roller. • The compaction roller may only be towed if its emergency steering is in working order. • Set the towing vehicle in motion very slowly and carry out the towing process at low speed. The compaction roller may only be to wed within a closed off work zone and not further than is absolutely necessary in order to remove it from the immediate danger / work zone!

Towing

•

First of all, secure the compaction roller against rolling by establishing the connection with the towing vehicle.

•

Remove the wheel chocks and any additional safety equipment used for preventing the compaction roller from rolling.

•

The towing distance is to be kept as short as possible. 11 4

Issue: 02-10