Bomag Mph 122 2 Service Manual-21417B320016.pdf -Bookmark created by https://wimanual.com MPH 122-2 MPH 122-2 MPH 122-2 S S S Soil Stabilizer Asphalt Recycler 1 General 1 General 1.1 Introduction 1.1 Introduction This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and efficient repair and maintenance work. This manual addresses the professionally qualified personnel or the after sales service of BOMAG, and should be of help and assistance in correct and efficient repair and maintenance work. This manual describes the disassembly, dismantling, assembly, installation and repair of components and assemblies. The repair of components and assemblies is only described as this makes sense under due consideration of working means and spare parts... Documentation Documentation For the BOMAG machines described in this manual the following documentation is additionally available: 1 Operating and maintenance instructions 1 Operating and maintenance instructions 2 Spare parts catalogue 3 Wiring diagram* 4 Hydraulic diagram* 5 Service Information Use only genuine BOMAG spare parts. Spare parts needed for repairs can be taken from the spare parts catalogue for the machine. These repair instructions are not subject of an updating service; for this reason we would like to draw your attention to our additional "Technical Service Bulletins". In case of a new release all necessary changes will be included. In the course of technical development we reserve the right for technical modifications without prior notification. Information and illustrations in this manual must not be reproduced and distributed, nor must they be used for the purpose of competition. All rights according to the copyright law remain expressly reserved. These safety regulations must be read and applied by every person involved in the repair These safety regulations must be read and applied by every person involved in the repair BOMAG GmbH Printed in Germany Copyright by BOMAG * The applicable documents valid at the date of printing are part of this manual. General Safety regulations Important notes Important notes These safety regulations must be read and applied by every person involved in the repair These safety regulations must be read and applied by every person involved in the repair Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. Workshop equipment and facilities as well as the use and waste disposal of fuels and lubricants, cleaning agents and solvent as well as gases and chemicals are subject to legal regulations, which are intended to provide a minimum on safety. It is obv... This manual contains headers like "Note", "Attention", "Danger" and "Environment", which must be strictly complied with in order to inform about and avoid dangers to persons, property and the environment. Paragraphs marked like this contain technical information for the optimal economical use of the machine. Paragraphs marked like this contain technical information for the optimal economical use of the machine. Paragraphs marked like this highlight possible dangers for machines or parts of the machine. Paragraphs marked like this highlight possible dangers for machines or parts of the machine. Paragraphs marked like this highlight possible dangers for persons. Paragraphs marked like this highlight possible dangers for persons. Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts. Paragraphs marked like this point out practices for safe and environmental disposal of fuels and lubricants as well as replacement parts. Observe the regulations for the protection of the environment. General General l For repair and maintenance work move the machine on a firm base and shut it down. l For repair and maintenance work move the machine on a firm base and shut it down. l Always secure the machine against unintended rolling. l Secure the engine reliably against unintentional starting. l Mark a defective machine and a machine under repair by attaching a clearly visible warning label to the dashboard. l Block the articulated joint with the articulation lock. l Use protective clothes like hard hat, safety boots and gloves. l Keep unauthorized persons away from the machine during repair work. l Tools, lifting gear, lifting tackle, supports and other auxiliary equipment must be fully functional and in safe condition. l Use only safe and approved lifting gear of sufficient load bearing capacity to remove and install parts or components from and to the machine. l Do not use easily inflammable or harmful substances, such as gasoline or paint thinners for cleaning. l Do not smoke or use open fire and avoid sparks when cleaning or repairing a tank. l When performing welding work strictly comply with the respective welding instructions. Transport work with cranes and lifting tackle Transport work with cranes and lifting tackle Cranes must only be operated by instructed persons who had been trained in handling cranes. Cranes must only be operated by instructed persons who had been trained in handling cranes. l Follow the operating instructions of the manufacturer when working with cranes. l Follow the operating instructions of the manufacturer when working with cranes. l Follow the operating instructions of the operator when working with cranes. l Follow the operating instructions of the operator when working with cranes. l Always comply with the applicable accident prevention instructions when working with cranes and lifting tackle. Precautions and codes of conduct for welding work Precautions and codes of conduct for welding work Welding work must only be carried out by properly trained personnel. Electric shock! Electric shock! Sparks, fire hazard, burning of skin! Infrared or ultraviolet radiation (arc), flashing of eyes! Health hazard caused by welding work on highly alloyed work pieces, metal coatings, paint coatings, plastic coatings, oil containing dirt deposits, grease or solvent residues, etc.! l Check welding equipment and cables for damage before use (also the validity of inspection stickers). l Check welding equipment and cables for damage before use (also the validity of inspection stickers). l Ensure good conductivity between ground cable and workpiece, avoid joints and bearings. l Start the extraction fan before starting work and guide with the progressing work as required. l Always isolate the burner when laying it down (remove possible electrode residues). l Protect cables from being damaged, use cables with insulated couplings. l Ensure sufficient fire protection, keep a fire extinguisher at hand. l Welding work in areas where there is a risk of fire or explosion, must only be carried out with welding permission. l Remove any combustible materials from the welding area or cover such items appropriately. l Name a fire watch during and after welding work. l Place welding rod holders and inert gas welding guns only on properly insulated bases. l Place the inert gas bottles in a safe place and secure them against falling over. l Use a protective screen or hand shield with welding filter, wear welding gloves and clothes. l Switch the welding unit off before connecting welding cables. l Check electrode holders and electric cables at regular intervals. Behaviour in case of faults l In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel. l In case of faults on the welding unit switch of the welding unit immediately and have it repaired by expert personnel. l In case of failure of the extraction system switch the system off and have it repaired by expert personnel. Maintenance; waste disposal l Replace damaged insulating jaws and welding rod holders immediately. l Replace damaged insulating jaws and welding rod holders immediately. l Replace the welding wire reels only in de-energized state. What to do in case of accidents; First Aid l Keep calm. l Keep calm. l Call first air helpers. l Report the accident. l In case of an electric accident: Interrupt the power supply and remove the injured person from the electric circuit. If breathing and heart have stopped apply reactivation measures and call for an emergency doctor. Operation of high-voltage systems Operation of high-voltage systems The rules and statutory regulations valid in the corresponding do apply in addition to the notes given here. The rules and statutory regulations valid in the corresponding do apply in addition to the notes given here. The high-voltage system must only be operated and serviced by qualified and authorized personnel. The high-voltage system must only be operated and serviced by qualified and authorized personnel. Before starting operation the operator must check the proper condition of the system. Possibility of injury or even death caused by electric shock: Possibility of injury or even death caused by electric shock: l if persons come into contact with live parts, l if persons come into contact with live parts, l if persons come into contact with live parts, l in case of faulty insulation of live parts, l in case of faulty insulation of live parts, l inadequate, unsuitable insulation, l inadequate, unsuitable insulation, l if melted parts flake off in case of short circuits. l if melted parts flake off in case of short circuits. Old oils Old oils Prolonged and repetitive contact with mineral oils will remove the natural greases from the skin and causes dryness, irritation and dermatitis. Moreover, used engine oils contain potentially hazardous contaminants, which could cause skin cancer. Appr... l Wear protective clothes and safety gloves, if possible. l Wear protective clothes and safety gloves, if possible. l If there is a risk of eye contact you should protect your eyes appropriately, e.g. chemistry goggles or full face visor; a facility suitable for rinsing the eyes should also be available. l Avoid longer and repetitive contacts with oils. In case of open incisions and injuries seek medical advice immediately. l Apply protective cream before starting work, so that oil can be easier removed from the skin. l Wash affected skin areas with water and soap (skin cleansers and nail brushes will help). Lanolin containing agents will replace natural skin oils that were lost. l Do not use gasoline, kerosene, diesel, thinner or solvents to wash the skin. l Do not put oil soaked cloths into your pockets. l Avoid clothes getting soiled by oil. l Overalls must be washed at regular intervals. Dispose of non-washable clothes environmentally. l If possible degrease components before handling. It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Old oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities. It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Old oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities. Hydraulics Hydraulics l Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. l Always relieve the pressure in the hydraulic system before disconnecting any lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. l Always make sure that all screw fittings have been tightened properly and that hoses and pipes are in mint condition before pressurizing the system again. l Hydraulic oil leaking out of a small opening can hardly be noticed, therefore please use a piece of cardboard or wood when checking for leaks. When injured by hydraulic oil escaping under pressure consult a physician immediately, as otherwise this ... l Do not step in front of or behind the drums, wheels or crawler tracks when performing adjustment work in the hydraulic system while the engine is running. Block drums, wheels or crawler tracks with wedges. Reattach all guards and safety installations after all work has been completed. It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities. It is strictly prohibited to drain off oil into the soil, the sewer system or into natural waters. Oil oil must be disposed of according to applicable environmental regulations. If in doubt you should consult your local authorities. Fuels Fuels Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. Repair work shall only performed by appropriately trained personnel or by the after sales service of BOMAG. Follow the valid accident prevention instructions when handling fuels. The following notes refer to general safety precautions for danger free handling of fuel. Fuel vapours not only are easily inflammable, but also highly explosive inside closed rooms and toxic; dilution with air creates an easily inflammable mixture. The vapours are heavier than air and therefore sink down to the ground. Inside a workshop ... l Fire extinguishers charged with FOAM, CO l Fire extinguishers charged with FOAM, CO 2 l The vehicle battery must always be disconnected, BEFORE work in the fuel system is started. Do not disconnect the battery while working on the fuel system. Sparks could cause explosion of the fuel fumes. l Wherever fuel is stored, filled, drained off or where work on fuel systems is carried out, all potential ignition sources must be extinguished or removed. Search lights must be fire proof and well protected against possible contact with running out... Hot fuels Hot fuels Please apply the following measures before draining of fuel to prepare for repair work: l Allow the fuel to cool down, to prevent any contact with a hot fluid. l Allow the fuel to cool down, to prevent any contact with a hot fluid. l Vent the system, by removing the filler cap in a well ventilated area. Screw the filler cap back on, until the tank is finally emptied. Synthetic rubber Synthetic rubber Many O-rings, hoses, etc. are made of synthetic material, a so-called fluorocarbon elastomer. Under normal operating conditions this material is safe and does not impose any danger to health. However, if this material becomes damaged by fire or extreme heat, it may decompose and form highly caustic hydrofluoric acid, which can cause severe burns in contact with skin. l If the material is in such a state it must only be touched with special protective gloves. The protective gloves must be disposed of according to applicable environmental regulations immediately after use. l If the material is in such a state it must only be touched with special protective gloves. The protective gloves must be disposed of according to applicable environmental regulations immediately after use. l If the material has contacted the skin despite these measures, take off the soiled clothes and seek medical advice immediately. In the meantime cool and wash the affected area of skin over a sufficient time with cold water or lime water. Poisonous substances Poisonous substances Some of the fluids and substances used are toxic and must under no circumstances be consumed. Skin contact, especially with open wounds, must be avoided. These fluids and substances are, amongst others, anti-freeze agents, hydraulic oils, fuels, washing additives, refrigerants, lubricants and various bonding agents. Engine Engine Do not work on the fuel system while the engine is running. (Danger to life!) Do not work on the fuel system while the engine is running. (Danger to life!) Once the engine has stopped wait approx. 1 minutes for the system to depressurize. The systems are under high pressure. (Danger to life!) Keep out of the danger zone during the initial test rung. Danger caused by high pressure in case of leaks. (Danger to life!) When performing work on the fuel system make sure that the engine cannot be started unintentionally during repair work. (Danger to life!) l Maintenance and cleaning work on the engine must only be performed with the engine stopped and cooled down. Make sure that the electric system is switched off and sufficiently secured against being switched on again (e.g. pull off ignition key, att... l Maintenance and cleaning work on the engine must only be performed with the engine stopped and cooled down. Make sure that the electric system is switched off and sufficiently secured against being switched on again (e.g. pull off ignition key, att... l Observe the accident prevention regulations for electric systems (e.g. -VDE-0100 l Cover all electric components properly before wet cleaning. Air conditioning system Air conditioning system Work on air conditioning systems must only be carried out by persons who can provide sufficient evidence of their ability (proof of professionalism) and only with the appropriate technical equipment. Work on air conditioning systems must only be carried out by persons who can provide sufficient evidence of their ability (proof of professionalism) and only with the appropriate technical equipment. l Always wear goggles and protective clothing when performing maintenance and repair work on air conditioning systems. Refrigerant withdraws heat from the environment when evaporating, which can cause injury by freezing when in contact with skin (boi... l Always wear goggles and protective clothing when performing maintenance and repair work on air conditioning systems. Refrigerant withdraws heat from the environment when evaporating, which can cause injury by freezing when in contact with skin (boi... l Perform maintenance and repair work on air conditioning systems only in well ventilated rooms! Escaping refrigerant vapours will mix with the ambient air and displace the oxygen required for breathing (danger of suffocating). l Smoking is prohibited when performing maintenance and repair work on air conditioning systems! Toxic breakdown products may be generated if refrigerant comes into contact with heat. l Refrigerant should always be extracted and removed by flushing with nitrogen before starting welding or soldering work near components of the air conditioning system. The development of heat may cause the refrigerant to develop toxic and highly cor... l Pungent smell! The toxic substances, which are responsible for the pungent smell, must not be inhaled, since this may cause damage to the respiratory system, the lung and other organs. Extract toxic breakdown products with a suitable extraction sys... l When blowing out components with compressed air and when flushing with nitrogen the gas mixture escaping from the components must be extracted via suitable extraction facilities (workshop extraction systems). Handling pressure vessels Handling pressure vessels l Since the fluid container is pressurized, the manufacture and testing of these pressure vessels is governed by the pressure vessel directive. The pressure vessels must be repetitively tested by an expert as specified in TRB 532 Inspection by Expert... l Since the fluid container is pressurized, the manufacture and testing of these pressure vessels is governed by the pressure vessel directive. The pressure vessels must be repetitively tested by an expert as specified in TRB 532 Inspection by Expert... l Secure pressure vessels against tipping over or rolling away. l Do not throw pressure vessels! Pressure vessels may thereby be deformed to such an extent, that they will crack. The sudden evaporation and escape of refrigerant releases excessive forces. This applies also when snapping off valves on bottles. Bott... l Refrigerant bottles must never be placed near heating radiators. Higher temperatures will cause higher pressures, whereby the permissible pressure of the vessel may be exceeded. l Do not heat up refrigerant bottles with an open flame. Excessive temperatures can damage the material and cause the decomposition of refrigerant. l Do not overfill refrigerant bottles, since any temperature increase will cause enormous pressures. It is strictly prohibited to release refrigerant into the atmosphere during operation, maintenance and repair work and when taking air conditioning systems into or out of service. It is strictly prohibited to release refrigerant into the atmosphere during operation, maintenance and repair work and when taking air conditioning systems into or out of service. Battery Battery l Always wear goggles and protective clothing to service or clean batteries! Battery acid can cause severe injury by cauterization when coming in contact with skin. l Always wear goggles and protective clothing to service or clean batteries! Battery acid can cause severe injury by cauterization when coming in contact with skin. l Work only well ventilated rooms (formation of oxyhydrogen gas). l Do not lean over the battery while it is under load, being charged or tested (danger of explosion). l Keep ignition sources away from the battery. Burning cigarettes, flames or sparks can cause explosion of the battery l Use battery chargers etc. only in strict compliance with the operating instructions. l After an accident with acid flush the skin with a sufficient amount of water and seek medical advice. l Do not allow children access to batteries. l When mixing battery fluid always pour acid into water, never vice-versa. Special safety regulations Special safety regulations l Use only genuine BOMAG spare parts for repair and maintenance work. Genuine spare parts and original accessories were specially developed, tested and approved for the machine. l Use only genuine BOMAG spare parts for repair and maintenance work. Genuine spare parts and original accessories were specially developed, tested and approved for the machine. l The installation and use of non-genuine spare parts or non-genuine accessories may therefore have an adverse effect on the specific characteristics of the machine and thereby impair the active and l Unauthorized changes to the machine are prohibited for safety reasons. l Do not perform any cleaning work while the engine is running. l If tests on the articulated joint need to be performed with the engine running, do not stand in the articulation area of the machine (danger of crushing!). l If tests must be performed with the engine running do not touch rotating parts of the engine (danger of injury!). l Always ensure an adequate supply of fresh air when starting in closed rooms. Exhaust gases are highly dangerous! l Refuel only with the engine shut down. Ensure strict cleanliness and do not spill any fuel. l Always ensure an adequate supply of fresh air when refuelling in closed rooms. l Dispose of used filters in accordance with applicable environmental regulations. l When performing repair and maintenance work collect oils and fuels in suitable containers and dispose of in compliance with applicable environmental regulations. l Do not heat up oils higher than 160 �C because they may ignite. l Wipe off spilled or overflown oil using suitable cleaning means and dispose of in accordance with applicable environmental regulations. l Dispose of old batteries according to applicable environmental regulations. l There is a danger of scalding when draining off engine or hydraulic oil at operating temperature! Allow engine and hydraulic system to cool down to a sufficient level. l Do not exceed the max. permissible tire pressure. The values specified in the table apply for screws: General repair instructions General General l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly. l Before removing or disassembling parts, assemblies, components or hoses mark these parts for easier assembly. l Before assembling and installing parts, assemblies or components oil or grease all movable parts or surfaces as required and in compliance with the compatibility of materials. The values specified in the table apply for screws: Electrics General General Due to the fast technical development electric and electronic vehicle systems become more intelligent and more comprehensive day by day, and can hardly be dispensed with in hydraulic and mechanical vehicle systems. Diagnostics according to plan Well structured trouble shooting procedures can save time and money. Random tests have revealed that purely electronic components or control units only very rarely are the actual cause of failures: l In approx. 10 % of the examined cases the problems were caused by control units. l In approx. 10 % of the examined cases the problems were caused by control units. l In approx. 15 % sensors and actuators were the cause of the problems. By far the highest proportion of all faults could be traced back to wiring and connections (plugs, etc.). General: l Before changing any expensive components, such as control units, you should run a systematic trouble shooting session to eliminate any other possible fault sources. Knowledge in basic electrics is required for this purpose. If a fault was diagnosed... l Before changing any expensive components, such as control units, you should run a systematic trouble shooting session to eliminate any other possible fault sources. Knowledge in basic electrics is required for this purpose. If a fault was diagnosed... l Check for good cable and ground contacts, therefore keep all mechanical transition points between electric conductors (terminals, plugs) free of oxide and dirt, as far as this is possible. l Always use the machine related wiring diagram for testing. If one or more faults were detected, these should be corrected immediately. l Do not disconnect or connect battery or generator while the engine is running. l Do not operate the main battery switch under load. l Do not use jump leads after the battery has been removed. l Sensors and electric actuators on control units must never be connected individually or between external power sources for the purpose of testing, but only in connection with the control unit in question. l It is not permitted to pull plugs off while the voltage supply is switched on (terminal 15 "ON")! Switch the voltage supply "OFF" first and pull out the plug. l Even with an existing polarity reversal protection incorrect polarity must be strictly avoided. Incorrect polarity can cause damage to control units! l Plug-in connectors on control units are only dust and water tight if the mating connector is plugged on! Control units must be protected against spray water, until the mating connector is finally plugged on! l Unauthorized opening of control electronics (Microcontroller MC), modifications or repairs in the wiring can cause severe malfunctions. l Do not use any radio equipment or mobile phones in the vehicle cab without a proper aerial or in the vicinity of the control electronics! Electrics and welding Electrics and welding Before starting welding work you should disconnect the negative battery pole or interrupt the electric circuit with the main battery switch, disconnect the generator and pull the plugs off all control units in order to protect the electrical system o... Before starting welding work you should disconnect the negative battery pole or interrupt the electric circuit with the main battery switch, disconnect the generator and pull the plugs off all control units in order to protect the electrical system o... l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch. l Disconnect the minus pole of the battery or interrupt the electric circuit with the main battery switch. l Isolate the generator and all control units from the electric circuit. l Always fasten the earth clamp of the welding unit in the immediate vicinity of the welding location. l When choosing the location for the earth clamp make sure that the welding current will not pass through joints or bearings. The values specified in the table apply for screws: Battery Rules for the handling of batteries When removing a battery always disconnect the minus pole before the plus pole. When installing the battery connect the minus pole after the plus pole to avoid short circuits. Fasten the terminal clamps with a little force as possible. Always keep battery poles and terminal clams clean to avoid high transition resistances when starting and the related development of heat. Make sure the battery is properly fastened in the vehicle. The values specified in the table apply for screws: Generator Before removing the generator you must disconnect the ground cable from the minus pole of the battery while the ignition is switched off. Do not disconnect the generator while the engine is running, because this may cause extremely high voltage peaks... When disassembling the battery cable, the B+-nut underneath on the generator side may also be loosened. This nut must in this case be retightened. When connecting e.g. the battery cable to the terminal of the generator you must make sure that the polarity is correct (generator B+ to the + pole of the battery). Mixing up the polarities by mistake causes short circuit and damage to the rectifier ... The generator can only be operated with the battery connected. Under special conditions emergency operation without battery is permitted, the lifetime of the generator is in such cases especially limited. Plus and minus cables must be disconnected during rapid charging of the battery or electric welding on the vehicle. When cleaning the generator with a steam or water jet make sure not to direct the steam or water jet directly on or into the generator openings or ball bearings. After cleaning the generator should be operated for about 1 - 2 minutes to remove any de... The values specified in the table apply for screws: Starter motor So-called jump starting (using an additional external battery) without the battery connected is dangerous. When disconnecting the cables from the poles high inductivities (arcs, voltage peaks) may occur and destroy the electrical installation. For purposes like e.g. purging the fuel systems, starters may be operated for maximum 1 minute without interruption. Then you should wait for at least 30 minutes (cooling down) until trying again. During the 1 minute starting period this process shou... Starter motors must not be cleaned with high pressure steam cleaning equipment. The contacts on starter terminals 30, 45, 50 must be protected against unintended shorting (jump protection). When replacing the starter the ring gear on the engine flywheel must be checked for damage and its number of teeth - if necessary replace the ring gear. Always disconnect the battery before starting assembly work in the starter area of the engine or on the starter itself. The values specified in the table apply for screws: Hydraulic system Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG. Repair work on hydraulic elements shall only performed by appropriately trained personnel or by the after sales service of BOMAG. Please note Please note Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system. Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system. l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal. l Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal. l Before loosening hoses, pipe lines etc. relieve all pressure from the system. l During repair work keep all openings closed with clean plastic plugs and caps. l Never run pumps, motors and engines without oil or hydraulic oil. l When cleaning hydraulic components take care not to damage any fine machine surfaces. l Chemical and rubber soluble cleansing agents may only be used to clean metal parts. Do not let such substances come in contact with rubber parts. l Rinse of cleaned parts thoroughly, dry them with compressed air and apply anti-corrosion oil immediately. Do not install parts that show traces of corrosion. l Avoid the formation of rust on fine machined caused by hand sweat. l Use new O-rings or seal rings for reassembly. l Use only hydraulic oil as sliding agent when reassembling. Do not use any grease! l Use only the specified pressure gauges. Risk of damaging the pressure gauges under too high pressure. l Check the hydraulic oil level before and after the work. l Fill in only clean oil as specified in the maintenance instructions. l Check the hydraulic system for leaks, if necessary find and rectify the cause. l Before taking new hydraulic components into operation fill these with hydraulic oil as specified in the operating and maintenance instructions. l After changing a hydraulic component thoroughly flush, refill and bleed the complete hydraulic system. l Perform measurements at operating temperature of the hydraulic oil (approx. 40 �C). l After changing a component perform a high and charge pressure test, if necessary check the speed of the exciter shaft. l The operating pressure of the exciter shaft to a great extent depends on the base under the vibrating drum. On hard ground place the drums on a suitable base and check the drum pressure. Do not activate the vibration on a hard, concreted base, dang... l After the completion of all tests perform a test run and then check all connections and fittings for leaks with the engine still stopped and the hydraulic system depressurized. Before commissioning Before commissioning l Fill the housings of hydraulic pumps and motors with hydraulic oil. Use only hydraulic oils according to the specification in the maintenance instructions. l Fill the housings of hydraulic pumps and motors with hydraulic oil. Use only hydraulic oils according to the specification in the maintenance instructions. l After changing a component flush the hydraulic system as described in the flushing instructions. Taking into operation Taking into operation l Bleed the hydraulic circuits. l Bleed the hydraulic circuits. l Start up the hydraulic system without load. l Check the hydraulic oil level in the tank, if necessary top up with hydraulic oil as specified in the operating and maintenance instructions or drain oil off into a suitable container. After taking into operation After taking into operation l Check fittings and flanges for leaks. l Check fittings and flanges for leaks. l After each repair check all adjustment data, system pressures, rotational speeds and nominal values in the hydraulic system, adjust if necessary. l Do not adjust pressure relief valves and control valves to values above their specified values. The values specified in the table apply for screws: Air conditioning system Chemicals Chemicals The chemicals Work on air conditioning systems must only be carried out by persons who: l have proven to have sufficient expert knowledge, l have proven to have sufficient expert knowledge, l have the necessary equipment to undertake such tasks, l are reliable and l are not any directives regarding their activities when carrying out inspection and maintenance work acc. to � 4 section 2 of the chemical The inspection and maintenance tasks, including leak tests and possible repair activities, must be recorded in the operating instructions together with information about the refrigerant quantities used and regained, whereby the operator is obliged to... Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system. Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system. l Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections. l Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any connections. l During repairs on refrigerant lines and components, these must be kept closed, as far as this is possible, to prevent the system from being contaminated by air, moisture and dirt. The operational safety of the system can only be assured as long as ... l Connections, screw fittings and their immediate surrounding areas must be cleaned before removal. l Before loosening hoses, pipe lines etc. relieve all pressure from the system. l During repair work keep all openings closed with clean plastic plugs and caps. l All parts to be reused should be cleaned with a gasoline free solvent and blow-dried with clean compressed air or dried with a lint-free cloth. l Before opening all components should have warmed up to ambient temperature, to avoid that damp air is drawn into the component by the difference in temperatures. l Damaged or leaking parts of the air conditioning must not be repaired by welding or soldering, but must generally be replaced. l Do not fill up refrigerant, but extract existing refrigerant and refill the system. l Different types of refrigerant must not be mixed. Only the refrigerant specified for the corresponding air conditioning system must be used. l Refrigerant circuits with refrigerant type R134a must only be operated with the compressor oil l Used compressor oil l Due to its chemical properties compressor oil l Compressor oil l All O-rings l When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil l A too high compressor oil l Use new O-rings or seal rings for reassembly. l Always used 2 spanners to work on pipes l Tighten screw fittings with the specified torque. l Check all pipes l Do not leave the refrigerant circuit unnecessarily open to the atmosphere. l In case of a repair on the refrigeration system you should first evacuate the air conditioning system for at least 45 minutes to remove any moisture from the system, before you start to refill. Moisture bonded in the compressor oil l Compressor valves must only be opened after the system has been properly sealed. l The use of leak detection spray is not permitted. If such substances are used the WARRANTY will become null and void. l If the air conditioning system had been opened for repair work, a new drier should be installed in the refrigerant circuit. l After completion of repair work screw locking caps (with seals) on all valve connections service connections. l Before start up of the air conditioning system after a new filling: - Turn the compressor approx. 10 revolutions by hand using the clutch or V-belt pulley of the magnetic clutch. - Start the engine with the compressor l Never run the compressor with an insufficient amount of refrigerant. The values specified in the table apply for screws: Fuel hoses Fig. 1 All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer lay... All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton hose. If a fuel hose has come loose one must make absolutely sure that the internal Viton layer has not been separated from the reinforced outer lay... The values specified in the table apply for screws: Gaskets and mating surfaces Leaking sealing faces can mostly be traced back to incorrect assembly of seals and gaskets. l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage. l Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, corrosion or other damage. l Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used. l Assemble seals and gaskets only with sealing compound, grease or oil, if this is specifically specified in the repair instructions. l If necessary remove any old sealing compound before assembling. For this purpose do not use any tools that could damage the sealing surfaces. l Sealing compound must be applied thin and evenly on the corresponding surfaces; take care that the compound does not enter into oil galleries or blind threaded bores. l Examine the contact faces for scratches and burrs, remove these with a fine file or an oilstone; take care that no grinding dust and dirt enters into tapped bores or enclosed components. l Blow out lines, ducts and gaps with compressed air, replace any O-rings and seals that have been dislodged by the compressed air. Assembly of radial seals Fig. 2 l Lubricate the sealing lips (2) l Lubricate the sealing lips (2) (Fig. 2) l Slide the seal over the shaft, with the lip facing towards the fluid to be sealed. If possible, use an assembly sleeve (1 If possible, use an assembly sleeve (1 (Fig. 2) to protect the lip from being damaged by sharp edges, threads or splines. l Lubricate the outer rim (arrow 3 l Lubricate the outer rim (arrow 3 (Fig. 2) Fig. 3 l Press or knock the seal into the housing, until it is flush with the housing surface. l Press or knock the seal into the housing, until it is flush with the housing surface. If possible, use a "bell" (1 If possible, use a "bell" (1 (Fig. 3) that the seal will not skew. If you have no proper service tools at hand, use a suitable drift punch with a diameter which is about 0,4 mm smaller than the outer diameter of the seal. Use VERY LIGHT blows with the hammer if no press is available. The values specified in the table apply for screws: Feather keys and keyways Feather keys may only be reused if they are free of damage. Feather keys may only be reused if they are free of damage. Fig. 4 l Clean and thoroughly examine the feather key. l Clean and thoroughly examine the feather key. l Deburr and thoroughly clean the edges of the keyway with a fine file before reassembling. The values specified in the table apply for screws: Ball and roller bearings Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear. Ball and roller bearings may only be reused if they are free of damage and do not show any signs of wear. Fig. 5 l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced. l If a ball or roller bearing of a bearing pair shows defects, both ball or roller bearings need to be replaced. l Remove any lubricant residues from the ball or roller bearing to be examined by washing it with gasoline or any other appropriate degreasing agent. Ensure strict cleanliness. l Check balls or rollers, running surfaces, outer faces of outer races and inner faces of inner races for visible damage. Replace the ball or roller bearing if necessary. l Check the ball or roller bearing for clearance and resistance between the inner and outer races, replace if necessary. l Lubricate the ball or roller bearing with the recommended type of grease before assembly or reassembly. l On greased bearings (e.g. wheel bearings) fill the space between ball or roller bearing and outer seal with the recommended type of grease before assembling the seal. l Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats. l Make sure that shaft and housing are free of burrs before assembling the ball or roller bearing. l Always mark the individual parts of separable ball or roller bearings (e.g. taper roller bearings) to enable correct reassembling. Never assemble the rollers to an outer race that has already been used, replace the complete ball or roller bearing i... Fig. 6 When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1 When assembling the ball or roller bearing to the shaft load must only be applied to the inner race 1 (Fig. 6) When fitting the bearing into the housing load must only be applied to the outer race (2). The values specified in the table apply for screws: Screws and nuts Tightening torque Tighten nuts or screws with the tightening torques specified in the following tables of tightening torques. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions. Tighten nuts or screws with the tightening torques specified in the following tables of tightening torques. Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions. Damaged screws must under no circumstances be used any longer. Recutting threads with thread cutters or taps adversely affects the strength and leak tightness of the screw joint. Damaged or corroded thread pitches can cause incorrect torque value rea... Self-locking nuts must generally be replaced after disassembly. The use of screws with too high strength can cause damage! l Nut of a higher strength can generally be used instead of nuts of a lower strength classification. l Nut of a higher strength can generally be used instead of nuts of a lower strength classification. l When checking or retightening screw joints to the specified tightening torque you should first relieve by a quarter turn and then tighten to the correct torque. l Before tightening you should lightly oil the thread, in order to ensure low friction movement. The same applies for self-locking nuts. l Make sure that no oil or grease will enter into blind tapped bores. The hydraulic power generated when turning in the screw could cause breakage of the effected part. Strength classes, metric screws The strength classes (from 3.6 to 12.9) are specified for all strength classes from a nominal diameter of 5mm. The corresponding identification can be found where allowed for by the shape of the screw. Fig. 7 Identification of screws Example: A screw is identified with 12.9. The first number corresponds with 1 2 l The nominal tensile strength is 12 X 100 N l The nominal tensile strength is 12 X 100 N 2 2 The second number specifies 10-times the ration between lower yield point and nominal tensile strength (yield point ratio). When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation). When exceeding the lower yield point, the material will return to its original shape when being relieved (plastic deformation). When exceeding the upper yield point the material will not restore its original shape after being relieved. l The lower tensile strength is 9 l The lower tensile strength is 9 2 2 However, these values are by no means identical with the tightening torques, which are to be set on a torque wrench. The corresponding calculation requires a higher effort and, in the end, depends on the materials to be bolted together. However, these values are by no means identical with the tightening torques, which are to be set on a torque wrench. The corresponding calculation requires a higher effort and, in the end, depends on the materials to be bolted together. Strength classes of metric nuts Nuts are differentiated by three load groups. Each load group has a special designation system for the strength class assigned, so that the load group can be clearly identified. Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12) Fig. 8 Identification of nuts In a connection with a screw, these nuts 1 (Fig. 8) Nut height above 0.8 d (d = nominal dimension). Strength class of nut Strength class of nut Strength class of associated screw Strength class of associated screw 4 4 3.6, 4.6, 4.8 3.6, 4.6, 4.8 5 5 3.6, 4.6, 4.8 3.6, 4.6, 4.8 5.6, 5.8 6 6 6.8 6.8 8 8 8.8 8.8 9 9 9.8 9.8 10 10 10.8 10.8 12 12 12.8 12.8 Nuts for screw joints with limited load factor (04, 05) The preceding "0" indicates that, due to their low height, nuts 2 (Fig. 8) Nut height below 0,8 d (d = nominal dimension). Nuts for screw joints without specified load factor (11H, 14H, 17H, 22H) This standard contains strength classes (hardness classes) for nuts 3 (Fig. 8) Nut height below 0,5 d (d = nominal dimension). Identification in clock system Fig. 9 Identification of nuts in clock system For small nuts (Fig. 9) l The 12 o'clock position is identified by a dot or the manufacturer's symbol. l The 12 o'clock position is identified by a dot or the manufacturer's symbol. l The strength class is identified by a dash (b). Identification of UNF-threads Fig. 10 Screws The screw head is marked with a stamped in, round cavity 3 (Fig. 10) Nuts An uninterrupted series of stamped in circles parallel to the axis of the nut on a hexagon area (2). Studs and brake rods At the outmost end a short end of the component is reduced to its core diameter (1). Cotter pins Fig. 11 In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly. Cotter pins must be assembled as shown in the illustration, unless specified differently. The values specified in the table apply for screws: Tightening torques The values specified in the table apply for screws: The values specified in the table apply for screws: l black oiled l black oiled l with surface protection A4C l with surface protection DACROMET DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance. DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance. Tightening torques for screws with metric unified thread Tightening torques for screws with metric unified thread Tightening torques for screws with metric unified thread Coefficient of friction m tot. = 0,14 m Screw dimension Screw dimension Tightening torques Nm Tightening torques Nm 8.8 8.8 10.9 10.9 12.9 12.9 M4 M4 3 3 5 5 5 5 M5 M5 6 6 9 9 10 10 M6 M6 10 10 15 15 18 18 M8 M8 25 25 35 35 45 45 M10 M10 50 50 75 75 83 83 M12 M12 88 88 123 123 147 147 M14 M14 137 137 196 196 235 235 M16 M16 211 211 300 300 358 358 M18 M18 290 290 412 412 490 490 M20 M20 412 412 578 578 696 696 M22 M22 560 560 785 785 942 942 M24 M24 711 711 1000 1000 1200 1200 M27 M27 1050 1050 1480 1480 1774 1774 M30 M30 1420 1420 2010 2010 2400 2400 Tightening torques for screws with metric unified fine thread Tightening torques for screws with metric unified fine thread Tightening torques for screws with metric unified fine thread Coefficient of friction m tot. = 0,14 m Screw dimension Screw dimension Tightening torques Nm Tightening torques Nm 8.8 8.8 10.9 10.9 12.9 12.9 M8 x 1 M8 x 1 26 26 37 37 48 48 M10 x 1.25 M10 x 1.25 52 52 76 76 88 88 M12 x 1,25 M12 x 1,25 98 98 137 137 126 126 M12 x 1.5 M12 x 1.5 93 93 127 127 152 152 M14 x 1.5 M14 x 1.5 152 152 216 216 255 255 M16 x 1.5 M16 x 1.5 225 225 318 318 383 383 M18 x 1.5 M18 x 1.5 324 324 466 466 554 554 M20 x 1.5 M20 x 1.5 461 461 628 628 775 775 M22 x 1.5 M22 x 1.5 618 618 863 863 1058 1058 M24 x 2 M24 x 2 780 780 1098 1098 1294 1294 M27 x2 M27 x2 1147 1147 1578 1578 1920 1920 M30 x 2 M30 x 2 1568 1568 2254 2254 2695 2695 Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste) Tightening torques for screws treated with anti-seizure paste OKS 240 Tightening torques for screws treated with anti-seizure paste OKS 240 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive effects. Prevents seizure and corrosion. Screw dimension Screw dimension Tightening torques Nm Tightening torques Nm 8.8 8.8 10.9 10.9 12.9 12.9 M16 M16 169 169 240 240 287 287 M16 x 1.5 M16 x 1.5 180 180 255 255 307 307 M18 M18 232 232 330 330 392 392 M18 x 1.5 M18 x 1.5 260 260 373 373 444 444 M20 M20 330 330 463 463 557 557 M20 x 1.5 M20 x 1.5 369 369 502 502 620 620 M22 M22 448 448 628 628 754 754 M22 x 1.5 M22 x 1.5 495 495 691 691 847 847 M24 M24 569 569 800 800 960 960 M24 x 2 M24 x 2 624 624 879 879 1036 1036 M27 M27 840 840 1184 1184 1520 1520 M27 X 2 M27 X 2 918 918 1263 1263 1536 1536 M30 M30 1136 1136 1608 1608 1920 1920 M30 x 2 M30 x 2 1255 1255 1804 1804 2156 2156 3 3 276 276 388 388 464 464 3 3 308 308 432 432 520 520 Tightening torques for wheel nuts (fine thread) Tightening torques for wheel nuts (fine thread) Tightening torques for wheel nuts (fine thread) Coefficient of friction m tot. = 0,14 m These values result in a 90% utilization of the yield point Thread diameter Thread diameter Tightening torques Nm Tightening torques Nm 10.9 10.9 M12x1.5 M12x1.5 100 100 M14x1.5 M14x1.5 150 150 M18x1.5 M18x1.5 300 - 350 300 - 350 M20x1.5 M20x1.5 400 - 500 400 - 500 M22x1.5 M22x1.5 500 - 600 500 - 600 The values specified in the table apply for screws: l black oiled l black oiled l with surface protection A4C l with surface protection DACROMET The difference between Withworth and UNF The difference between Withworth and UNF DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance. Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified Coarse Thread Tightening torques for screws with UNC thread, Tightening torques for screws with UNC thread, Coefficient of friction m tot. = 0,14 m UNC Unified Coarse Thread Series, American Unified Coarse Thread Screw dimension Screw dimension Tightening torques Nm Tightening torques Nm 8.8 8.8 10.9 10.9 12.9 12.9 1 1 11 11 15 15 19 19 5 5 23 23 32 32 39 39 3 3 39 39 55 55 66 66 7 7 62 62 87 87 105 105 1 1 96 96 135 135 160 160 9 9 140 140 200 200 235 235 5 5 195 195 275 275 330 330 3 3 345 345 485 485 580 580 7 7 560 560 770 770 940 940 1� - 8 1� - 8 850 850 1200 1200 1450 1450 1 1 1 1 1200 1200 1700 1700 2000 2000 1 1 1 1 1700 1700 2400 2400 2900 2900 1 3 1 3 2200 2200 3100 3100 3700 3700 1 1 1 1 3000 3000 4200 4200 5100 5100 Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Thread Tightening torques for screws with UNF thread, Tightening torques for screws with UNF thread, Coefficient of friction m tot. = 0,14 m UNF Unified National Fine Thread Series, American Unified Fine Thread Screw dimension Screw dimension Tightening torques Nm Tightening torques Nm 8.8 8.8 10.9 10.9 12.9 12.9 1 1 13 13 18 18 22 22 5 5 25 25 35 35 42 42 3 3 45 45 63 63 76 76 7 7 70 70 100 100 120 120 1 1 110 110 155 155 185 185 9 9 155 155 220 220 260 260 5 5 220 220 310 310 370 370 3 3 385 385 540 540 650 650 7 7 620 620 870 870 1050 1050 1� - 12 1� - 12 930 930 1300 1300 1600 1600 1 1 1 1 1350 1350 1900 1900 2300 2300 1 1 1 1 1900 1900 2700 2700 3200 3200 1 3 1 3 2600 2600 3700 3700 4400 4400 1 1 1 1 3300 3300 4600 4600 5600 5600 2 BOMAG Stabilizer 2 BOMAG Stabilizer BOMAG Stabilizer MPH 122 MPH 122 The BOMAG MPH 122 is the economical solution for universal use in stabilization of non-bearing soils and recycling of road pavements needing repair. It has proven itself over years in tough applications all around the globe. Day in and day out it proves its capabilities on a large number of construction sites. From small constructions, which can be completed within a few days, up to large-scale construction sites, which will take more than just a few months to be finishe... Range of applications Range of applications In the field of stabilization the MPH 122 is employed to improve and reinforce existing soil materials by mixing in lime, fly ash or cement. In recycling applications the machine is used to cut and pulverize old, damaged black top and road pavements.... The pulverized material in then mixed with binder "In-Place" and finally reused as a new bonded bearing course. Application optimized dosing systems for water, bitumen emulsion and foam bitumen extend the range of application for the MPH 122, making ... Fig. 12 Extended range of applications in recycling by injection of bitumen emulsion or foam bitumen. Many application related details make the MPH122 a unique machine. Optimal view over the entire work area and excellent manoeuvrability due to the combination of articulated and rear axle steering, together with powerful rotor and travel drives, ensu... The universally usable rotor with rotor speeds that can be freely selected under load, can be matched to the requirements of any construction task. The variable mixing compartment of the rotor will automatically adapt to any cutting depth, irrespecti... Perfect adaptation to the application Perfect adaptation to the application Versatility Versatility l Universal rotor for use in soil stabilization and recycling. l Universal rotor for use in soil stabilization and recycling. l High flexibility in application due to variable rotor speed. l Simple and efficient tool change on site due to quick change system for cutting chisels and chisel adapters as well as bolted edge segments. l Cross-slope of rotor by + l Milling close to borders on both sides due to the specially designed rotor hood side plates. l All-wheel drive with high drive torques ensures optimal traction. l Efficient use of machine due to automatic power regulation with integrated overload protection. High reliability High reliability l Powerful, water-cooled turbocharged diesel engine of latest design, compliant with the latest legal requirements. l Powerful, water-cooled turbocharged diesel engine of latest design, compliant with the latest legal requirements. l Amply dimensioned hydraulic pumps and motors ensure optimal function, even under extreme load conditions. l Torsion resistant frame and robust heavy-duty wheel drives as basic prerequisite for high reliability of the machine. Fig. 13 Small turning radius and cross-slope adjustment of rotor via oscillating articulated joint. Optional equipment for maximum flexibility in application Optional equipment for maximum flexibility in application Extended range of applications Extended range of applications For applications in road recycling and soil stabilization there are various bitumen injection systems available, alongside a water dosing system. With these systems the corresponding additives can be dosed and injected into the mixing chamber of the ... Water dosing system Water dosing system The separate water spray bar supplies the necessary water to the bearing course material, in order to achieve the optimal moisture content for compaction. In automatic mode the system adds the required water quantity in dependence on the actual worki... Bitumen dosing system Bitumen dosing system The BOMAG bitumen dosing system is available in the following designs: l Emulsion system l Emulsion system l Foam bitumen system, which can also be used for adding bitumen emulsion. Fig. 14 Formation of foam bitumen The components of the corresponding system type are completely mounted on the machine. All bitumen conducting pipes are warmed up by a thermal oil heating. All injection nozzles and expansion chambers are protected inside the heat insulated spray bar... The basic version is equipped with emulsion and foam bitumen systems for manual dosing control, whereby the desired bitumen flow quantity for a certain working speed must be adjusted as a fixed value. Both systems are also available with computer con... Rotors Rotors The MPH 122 is equipped with a universal rotor of 2330 mm working width and welded chisel adapters as standard. Various rotor variants are optionally available: l Universal rotor with 2530 mm working width. l Universal rotor with 2530 mm working width. l Universal rotor with replacement adapter system for both working widths � for quick replacement of upper adapter section without the need of torch cutting and welding. l Stabilizer rotor with flat chisels and 2330 mm working width. In order to reduce downtimes and running costs all available rotor variants are equipped with the approved simple replaceable edge segments. 3 Technical data 3 Technical data Technical data Fig. 15 Dimensions in mm Dimensions in mm A A B B B1 B1 H1 H1 K K L L MPH 122-2 MPH 122-2 5815 5815 2810 2810 2790 2790 3420 3420 510 510 9050 9050 The right for technical modifications remains reserved The right for technical modifications remains reserved MPH 122-2 MPH 122-2 Weights Weights Operating weight (CECE) Operating weight (CECE) kg kg 20950 20950 Front axle load (CECE) Front axle load (CECE) kg kg 14164 14164 Rear axle load (CECE) Rear axle load (CECE) kg kg 6786 6786 Max. operating weight Max. operating weight kg kg 28000 28000 Dimensions Dimensions Track radius, inner Track radius, inner mm mm 3500 3500 Travel characteristics Travel characteristics Travel speed (1) Travel speed (1) km km 0 � 2.7 0 � 2.7 Travel speed (2) Travel speed (2) km km 0 � 12 0 � 12 Max. gradability (depending on soil) Max. gradability (depending on soil) % % 40 40 Drive Drive Engine manufacturer Engine manufacturer Deutz Deutz Type Type TCD 2015 V06 TCD 2015 V06 Cooling Cooling Water Water Number of cylinders Number of cylinders 6 6 Rated power ISO 9249 Rated power ISO 9249 kW kW 360 360 Rated power SAE J 1995 Rated power SAE J 1995 hp hp 482 482 Rated speed Rated speed rpm rpm 2100 2100 Electrical equipment Electrical equipment V V 24 24 Drive system Drive system hydrostatic hydrostatic Wheels driven Wheels driven All wheel drive All wheel drive Tires Tires Tire size, front Tire size, front 28 LR 26 28 LR 26 Tire size, rear Tire size, rear 620 620 Brakes Brakes Service brake Service brake hydrostatic hydrostatic Parking brake Parking brake Spring accumulator Spring accumulator Steering Steering Type of steering Type of steering Articulated + rear Articulated + rear Steering operation Steering operation hydraulic hydraulic Rotor Rotor Rotor width Rotor width mm mm 2330 2330 Outer rotor diameter Outer rotor diameter mm mm 1225 1225 Rotor speed Rotor speed rpm rpm 110 � 160 110 � 160 Rotor oscillation angle Rotor oscillation angle � � � � 5 5 Max. working depth Max. working depth mm mm 500 500 Number of teeth Number of teeth 208 208 Height of teeth Height of teeth 200 200 Filling capacities Filling capacities Engine oil Engine oil l l approx. 38 approx. 38 Coolant Coolant l l approx. 50 approx. 50 Fuel Fuel l l approx. 750 approx. 750 Hydraulic oil Hydraulic oil l l approx. 280 approx. 280 Additional engine data Additional engine data Combustion principle Combustion principle 4-stroke diesel 4-stroke diesel Low idle speed Low idle speed rpm rpm 650 � 50 650 � 50 High idle speed High idle speed rpm rpm 2100 � 50 2100 � 50 Specific fuel consumption Specific fuel consumption g g 221 221 Valve clearance intake Valve clearance intake mm mm 0.25 0.25 Valve clearance exhaust Valve clearance exhaust mm mm 0.3 0.3 Injection valves opening pressure Injection valves opening pressure bar bar MSV 280 - 288 MSV 280 - 288 Starter power Starter power kW kW 6.6 6.6 Travel pump Travel pump Bosch-Rexroth Bosch-Rexroth Type Type A4 VG 56 EP A4 VG 56 EP System System Axial piston Axial piston Max. displacement Max. displacement cm3 cm 3 56 56 Max. flow capacity Max. flow capacity l l 117.6 117.6 High pressure limitation High pressure limitation bar bar 450 � 15 450 � 15 Pressure override Pressure override bar bar 410 � 15 410 � 15 Charge pressure, high idle Charge pressure, high idle bar bar 32 � 2 32 � 2 Control start, electrical Control start, electrical mA mA 200 200 Control end, electrical Control end, electrical mA mA 600 600 Travel motor, front Travel motor, front Manufacturer Manufacturer Bosch-Rexroth Bosch-Rexroth Type Type A6VE 107 EP2 A6VE 107 EP2 Quantity Quantity 2 2 System System Axial piston � bent axle Axial piston � bent axle Displacement (stage 1) Displacement (stage 1) cm3 cm 3 107 107 Displacement (stage 2) Displacement (stage 2) cm3 cm 3 0 0 Perm. leak oil rate Perm. leak oil rate l l 2 2 Control start, electrical Control start, electrical mA mA 200 200 Control end, electrical Control end, electrical mA mA 600 600 Travel motor, rear Travel motor, rear Manufacturer Manufacturer Bosch-Rexroth Bosch-Rexroth Type Type A6VE 107 EP2 A6VE 107 EP2 Quantity Quantity 1 1 System System Axial piston � bent axle Axial piston � bent axle Max. displacement (stage 1) Max. displacement (stage 1) cm3 cm 3 107 107 Min. displacement (stage 2) Min. displacement (stage 2) cm3 cm 3 0 0 Perm. leak oil rate Perm. leak oil rate l l 2 2 Flushing rate Flushing rate l l 10 10 Control start, electrical Control start, electrical mA mA 200 200 Control end, electrical Control end, electrical mA mA 400 400 Wheel drive Wheel drive Manufacturer Manufacturer Bosch-Rexroth Bosch-Rexroth Type Type GFT 50 T3 GFT 50 T3 Reduction ratio Reduction ratio 84.2 84.2 Rotor pumps Rotor pumps Bosch-Rexroth Bosch-Rexroth Type front Type front A4 VG 180 EP A4 VG 180 EP Type rear Type rear A4 VG 180 EP A4 VG 180 EP System System Axial piston Axial piston Max. displacement Max. displacement cm3 cm 3 180 180 Max. flow capacity Max. flow capacity l l 378 378 High pressure limitation High pressure limitation bar bar 470 � 15 470 � 15 Pressure override Pressure override bar bar 420 � 15 420 � 15 Charge pressure, high idle Charge pressure, high idle bar bar 21 � 1 21 � 1 Control start, electrical Control start, electrical mA mA 200 200 Control end, electrical Control end, electrical mA mA 600 600 Rotor drive gear Rotor drive gear Manufacturer Manufacturer Bosch-Rexroth Bosch-Rexroth Type Type GFT 50 L2 GFT 50 L2 Transmission ratio Transmission ratio 22 22 Rotor motor Rotor motor Manufacturer Manufacturer Bosch-Rexroth Bosch-Rexroth Type Type A2FE 107 A2FE 107 Hydraulic pump for water spray system Hydraulic pump for water spray system Type Type HYZ HYZ System System Gear pump Gear pump Displacement Displacement cm3 cm 3 16 16 Hydraulic pump for water spray system Hydraulic pump for water spray system Type Type A10VO45DFR1 A10VO45DFR1 System System Axial piston unit Axial piston unit Flow control valve Flow control valve bar bar set to 20 bar set to 20 bar Pressure regulator Pressure regulator bar bar set to 210 bar set to 210 bar Pump for intercooler Pump for intercooler Type Type HYZ HYZ System System Gear pump Gear pump Displacement Displacement cm3 cm 3 19 19 High pressure limitation High pressure limitation bar bar 200 � 10 200 � 10 Steering Steering Type Type HY HY System System Gear pump Gear pump Displacement Displacement cm3 cm 3 22.5 22.5 Max. steering pressure Max. steering pressure bar bar 190 � 10 190 � 10 Steering valve Steering valve Danfoss Danfoss Type Type OSPL 630 LS OSPL 630 LS System System Rotary valve Rotary valve Working valve Working valve Type Type SP-2675-10 SP-2675-10 Pressure limitation steering, gate, cross-slope Pressure limitation steering, gate, cross-slope bar bar 160 � 10 160 � 10 Pressure limitation rotor up Pressure limitation rotor up bar bar 200 � 10 200 � 10 Priority valve Priority valve Type Type OLS80 OLS80 Proportional valve, water injection Proportional valve, water injection Type Type YC-551-32 YC-551-32 High pressure limitation High pressure limitation bar bar 200 � 10 200 � 10 Max. water injection quantity Max. water injection quantity l l 500 500 Flow control valve, intercooler Flow control valve, intercooler Type Type HY HY Rear axle Rear axle Type Type 305 305 Differential Differential Fixed value lock Fixed value lock Degree of locking Degree of locking % % 45 45 Reduction ratio differential Reduction ratio differential 54.8 54.8 working pump working pump Type Type HYZ HYZ System System Gear pump Gear pump Max. displacement Max. displacement cm3 cm 3 8 8 Other details Other details Charge circuit filter Charge circuit filter micron micron 12 12 Return flow filter Return flow filter micron micron 80 80 The following noise and vibration data acc. to - EC Machine Regulation edition 2006 - the noise regulation 2000 - Vibration Protection Regulation 2002 were determined during conditions typical for this type of equipment and by application of harmonized standards. During operation these values may vary because of the existing operating conditions. Noise value Noise value Sound pressure level on the place of the operator: L pA Guaranteed sound power level: L WA Wear your personal noise protection means (ear defenders) before starting operation. Wear your personal noise protection means (ear defenders) before starting operation. Vibration value Vibration value Vibration of the entire body (driver�s seat) The weighted effective acceleration value determined according to ISO 7096 is � 2 Hand-arm vibration values The weighted effective acceleration value determined according to ISO 5349 is � 2 4 Maintenance 4 Maintenance 4.1 General notes on maintenance 4.1 General notes on maintenance When performing maintenance work always comply with the appropriate safety regulations. When performing maintenance work always comply with the appropriate safety regulations. Thorough maintenance of the machine guarantees far longer safe functioning of the machine and prolongs the lifetime of important components. The effort needed for this work is only little compared with the problems that may arise when not observing t... l Always clean machine and engine thoroughly before starting maintenance work. l Always clean machine and engine thoroughly before starting maintenance work. l For maintenance work stand the machine on level ground. l Always remove the main battery switch for all maintenance work. l Perform maintenance work only with the motor switched off. l Relieve hydraulic pressures before working on hydraulic lines. l Before working on electric parts of the machine disconnect the battery and cover it with insulation material. The terms right l When working in the area of the articulated joint attach the articulation lock (transport lock). l When working in the area of the articulated joint attach the articulation lock (transport lock). l During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuels environmentally. l Catch and dispose of biodegradable oils separately. After completing maintenance work reinstall all plates, covers etc. that have been removed, close opened service doors. Frequent causes of faults Frequent causes of faults l Operating errors l Operating errors l Incorrect, insufficient maintenance If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should contact the service departments at our branch offices or dealers. Notes on the fuel system Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel. l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine. l Keep fuel free of contaminants and water, since this will damage the injection elements of the engine. l When choosing the storage place for fuel make sure that spilled fuel will not harm the environment. l Do not let the hose stir up the slurry at the bottom of the drum. l Do not draw off fuel from near the bottom of the drum. l Fuel residues in the drum are not suitable for the engine. Notes on the performance of the engine Notes on the performance of the engine On diesel engines both combustion air and fuel injection quantities are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine. If your engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer. Notes on the cooling system Notes on the cooling system Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing. Coolant is prepared by adding an ethylene-glycol based anti-freeze agent with corrosion inhibiting properties to the cooling water. Mixing with cooling system protection agent is necessary in all climatic zones. It prevents corrosion, lowers the freezing point and raises the boiling point of the coolant. Notes on the hydraulic system Notes on the hydraulic system During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog nozzles a... l If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks. l If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks. l Seal external leaks immediately. If necessary inform the responsible customer service. l Do not store drums with hydraulic oil outdoors, or at least under a cover. Water can be drawn in through the bunghole when the weather changes. l We recommend to use the BOMAG filling and filtering unit with fine filter to fill the system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system. l Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt. l Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in. 4.2 Fuels and lubricants 4.2 Fuels and lubricants Engine oil Engine oil Quality For use in DEUTZ engines the lubrication oils are classified in DEUTZ Lubrication Oil Quality Classes (DQC). Use only oils complying with DQC III-05, DQC III-10 or DQC IV-05 or DQC IV-10 respectively. The list of approved lubrication oils is also available in the Internet under the following address: www.deutz.com www.deutz.com de de >>SERVICE >> Betriebsstoffe und Additive >> Deutz Quality Class >> DQC Freigabeliste >>SERVICE >> Betriebsstoffe und Additive >> Deutz Quality Class >> DQC Freigabeliste en en >>SERVICE >> Operating Liquids and Additives >> DeutzQualityClass >> DQC Release List >>SERVICE >> Operating Liquids and Additives >> DeutzQualityClass >> DQC Release List Consult your local service station if in doubt. l Use winter grade engine oil for winter operation! l Use winter grade engine oil for winter operation! Viscosity Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class) . Too high viscosity can cause starting difficulties, too low �viscosity can jeopardize the lubrication effect and result in a high lubrication oil consumption. Fig. 16 Optimal operating conditions can be achieved by using the oil viscosity chart (Fig. 16) At ambient temperatures below -40 �C the lubrication oil must be pre-heated (e.g. by parking the machine indoors). The viscosity is classified acc. to SAE. Multi-purpose oils should generally be used. Oil change intervals The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operati... DQC III, DQC IV DQC III, DQC IV 500 operating hours When using fuels with a sulphur content of more than 0,5% to 1% or under permanent ambient temperatures below -10�C and when using biodegradable diesel fuel the oil change intervals must be halved. When using fuels with a sulphur content of more than 0,5% to 1% or under permanent ambient temperatures below -10�C and when using biodegradable diesel fuel the oil change intervals must be halved. Fuels Fuels You should only use commercially available brand diesel fuel with a sulphur content of less than 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals. The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled. Quality The following fuel specifications are permitted: l EN 590 l EN 590 l DIN 51628 l ASTM D975 Grade-No. 1-D and 2-D. l JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication properties acc. to EN 590 Winter fuel For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. Diesel fuels suitable for temperatures down to -44 �C are available for arctic climates. At very low temperatures disturbing paraffin separation can ... The admixture of petroleum and the addition of "flow enhancing additives" (fuel additives) is not permitted. Coolant Coolant For fluid cooled engines the cooling fluid must be prepared by admixing a cooling system protection agent to the fresh water and should be checked within the specified maintenance intervals. This prevents damage caused by corrosion, cavitation, freezing and overheating. Fresh water quality The correct quality of water is highly important when preparing coolant. Clear and clean water within the boundaries of the following analysis values should generally be used. Fresh water analysis values Fresh water analysis values pH-value at 20 �C pH-value at 20 �C 6.5 - 8.5 6.5 - 8.5 Chloride ion content (mg Chloride ion content (mg max. 100 max. 100 Sulphate ion content (mg Sulphate ion content (mg max. 100 max. 100 Water hardness (ion content of calcium and magnesium ) (mmol Water hardness (ion content of calcium and magnesium ) (mmol max. 3.56 max. 3.56 Conversion to other units: - German degree (�dH)] - German degree (�dH)] max. 20 max. 20 - English degree (�eH)] - English degree (�eH)] max. 25 max. 25 - French degree (�fH)] - French degree (�fH)] max. 36.5 max. 36.5 corresponds with a content of CaCO3 (mg corresponds with a content of CaCO 3 max. 356 max. 356 Information concerning the water quality can be obtained from the waterworks. If the fresh water analysis values are unknown, these must be determined with the help of a water analysis. If the values of the analysis deviate, the water must be treated accordingly. l pH-value too low Adding of caustic lye of soda or caustic potash solution. l pH-value too low Adding of caustic lye of soda or caustic potash solution. l Water hardness too high: Mix with soft, distilled or fully demineralized water l Chlorides and l Total hardness or carbonate hardness too low: Mixing with hardened water (harder water is in most cases available in the form of drinking water). Another analysis must be made after the fresh water has been prepared. Another analysis must be made after the fresh water has been prepared. Cooling system protection agent As a protection against frost, corrosion and boiling point anti-freeze agents must be used under any climatic conditions. Coolant for fluid cooled engines is prepared by adding an ethylene-glycol based anti-freeze agent with corrosion inhibiting properties to the cooling water. We therefore highly recommend our BOMAG cooling system protection agent. If our cooling system protection agent is not available for any important reasons, you may, in exceptional cases, use products that have been approved by the engine manufacturer. The list of approved cooling system protection agents is also available in the Internet under the following address: www.deutz.com www.deutz.com de de >>SERVICE >> Betriebsstoffe und Additive >> K�hlsystemschutz >> K�hlsystemschutz Technisches Rundschreiben >>SERVICE >> Betriebsstoffe und Additive >> K�hlsystemschutz >> K�hlsystemschutz Technisches Rundschreiben en en >>SERVICE >> Operating Liquids and Additives >> Cooling System Conditioner >> Flyer Cooling System Conditioner Technical Circular >>SERVICE >> Operating Liquids and Additives >> Cooling System Conditioner >> Flyer Cooling System Conditioner Technical Circular Products of the same product group (see Deutz Technical Circular Cooling System Protection Agents) can be mixed with each other. The BOMAG cooling system protection agent corresponds with product group A. Do not mix different coolants and additives of any other kind. Do not mix different coolants and additives of any other kind. Before changing the product you must clean the entire cooling system. Consult your local service station if in doubt. To ensure proper corrosion protection you must use the cooling system protection agent all year around, whereby the following concentration must not be fallen short of or exceeded. Mixing ratio Mixing ratio Cooling system protection agent Cooling system protection agent Fresh water Fresh water Cold protection down to Cold protection down to min. 35% min. 35% 65% 65% -22 �C -22 �C 40% 40% 60% 60% -28 �C -28 �C 45% 45% 55% 55% -35 �C -35 �C max. 50% max. 50% 50% 50% -41 �C -41 �C A proportion of more than 50% of cooling system protection agent causes a drop in cooling power. A proportion of more than 50% of cooling system protection agent causes a drop in cooling power. The use of corrosion protection oils as cooling system protection agents is not permitted. When working at temperature below -41 �C you should consult our local service representative. When working at temperature below -41 �C you should consult our local service representative. Coolant must be disposed of environmentally. Coolant must be disposed of environmentally. Mineral oil based hydraulic oil Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic Viskosit�t von 46 mm 2 2 Bio-degradable hydraulic oil Bio-degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil. The biologically quickly degradable hydraulic oil Panolin HLP Synth.46 meets all demands of a mineral oil based hydraulic oil according to DIN 51524. In hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up. When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details. Check the filter more frequently after this change. Check the filter more frequently after this change. Perform regular oil analyses for content of water and mineral oil. Replace the hydraulic oil filter element every 500 operating hours. Gear oil Gear oil For travel gears and rear axle gears use only multi- purpose gear oils of API-GL5-class, SAE 90. This is a hypoid lubricant of highest quality class for extremely loaded transmissions. The additives in this oil ensure low wear lubrication under all operating conditions. Milling gear oil Milling gear oil For the gearboxes use only a synthetic gear oil type CLP HC acc. to DIN 51 502; DIN 51 517-3; ISO-L- CKC Kinematic viscosity of 220 mm 2 2 Lubrication grease Lubrication grease For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2), acc. to DIN 51502 KP 2G. Thermal oil Thermal oil Only use heat transfer oil Shell Thermia B 39720. Compressor service unit Compressor service unit Use only acid-free pneumatic oil STASTO HP 32. 4.3 Table of fuels and lubricants Assembly Assembly Fuel or lubricant Fuel or lubricant Quantity Quantity Summer Summer Winter Winter Attention Attention Attention Observe the level marks Engine Engine - Engine oil - Engine oil Specification see "Fuels and lubricants - engine oil" Specification see "Fuels and lubricants - engine oil" approx. 38 litres approx. 38 litres SAE 10W-40 (-20 �C to +40 �C) SAE 10W-40 (-20 �C to +40 �C) (BOMAG PN 009 920 06; 20 l) SAE 15W-40 (-15 �C to +40 �C) SAE 15W-40 (-15 �C to +40 �C) SAE 5W-40 (-30 �C to +40 �C) SAE 5W-40 (-30 �C to +40 �C) SAE 5W-30 (-30 �C to +30 �C) SAE 5W-30 (-30 �C to +30 �C) - Fuel - Fuel Diesel Diesel Winter diesel fuel Winter diesel fuel approx. 750 litres approx. 750 litres - Coolant - Coolant Mixture of water and anti-freeze agent Mixture of water and anti-freeze agent Specification see "Fuels and lubricants - coolant" approx. 50 litres approx. 50 litres Hydraulic system Hydraulic system Hydraulic oil (ISO), HLP 46 Hydraulic oil (ISO), HLP 46 (BOMAG PN 009 930 09; 20 l) or ester based biodegradable hydraulic oil approx. 280 litres approx. 280 litres Travel gear Travel gear Gear oil SAE 80W-140, API GL-5 Gear oil SAE 80W-140, API GL-5 (BOMAG PN 009 925 07; 20 l) Front axle: approx. 4 l each Front axle: approx. 4 l each Rear axle: approx. 2.35 l each Rear axle Rear axle - Reduction gear - Reduction gear Gear oil SAE 80W-140, API GL-5 Gear oil SAE 80W-140, API GL-5 (BOMAG PN 009 925 07; 20 l) approx. 2.7 litres approx. 2.7 litres - Differential gear - Differential gear Gear oil SAE 80W-140, API GL-5 Gear oil SAE 80W-140, API GL-5 (BOMAG PN 009 925 07; 20 l) approx. 13.4 litres approx. 13.4 litres Milling drive Milling drive RENOLIN UNISYN CLP 220 RENOLIN UNISYN CLP 220 4 l each 4 l each Assembly Assembly Fuel or lubricant Fuel or lubricant Quantity Quantity Summer Summer Winter Winter Attention Attention Attention Observe the level marks Articulated joint Articulated joint Rear axle Rotor hood bracket Engine hood Attachment plate adjustment spindles High pressure grease (lithium saponified) High pressure grease (lithium saponified) as required as required Air conditioning system Air conditioning system Refrigerant R134a Refrigerant R134a approx. 2400 g approx. 2400 g Exciter shaft housing, attachment plate Exciter shaft housing, attachment plate SAE 75W-90, API GL-5 SAE 75W-90, API GL-5 (BOMAG PN 009 925 05; 20 l) approx. 2.7 l each approx. 2.7 l each Binder metering system Binder metering system - Service unit, pneumatics - Service unit, pneumatics STASTO HP 32 STASTO HP 32 as required as required - Reaction water pump - Reaction water pump Engine oil 10W Engine oil 10W as required as required - Compressor - Compressor Engine oil 10W Engine oil 10W approx. 0.04 litres approx. 0.04 litres - Thermal oil - Thermal oil Shell Thermia B 39720 Shell Thermia B 39720 approx. 52 litres approx. 52 litres 4.4 Running-in instructions The following service work must be performed when taking new machines into operation. The following service work must be performed when taking new machines into operation. Up to approx. 250 operating hours check the engine oil level twice every day. Up to approx. 250 operating hours check the engine oil level twice every day. Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours. After a running time of 15 minutes retighten the V- belts for generator and air conditioning compressor Optional equipment Maintenance after 50 operating hours l Change engine oil and oil filter cartridge. l Change engine oil and oil filter cartridge. l Change all fuel filters. l Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts. l Retighten all bolted connections on the machine. Maintenance after 250 operating hours l Change the oil in the front drive gears. l Change the oil in the front drive gears. l Change the oil in the planetary drives of the rear axle l Change the oil in the rear axle reduction gear l Change the oil in the rear axle. Maintenance after 500 operating hours l Change the oil in the front drive gears. l Change the oil in the front drive gears. l Change the oil in the planetary drives of the rear axle Special intervals l Switch the air conditioning on every month for about 10 minutes. l Switch the air conditioning on every month for about 10 minutes. 4.5 Maintenance table No. No. Maintenance work Maintenance work Comment Comment every 10 operating hours, daily every 10 operating hours, daily every 50 oper. hours every 50 oper. hours every 250 oper. hours every 250 oper. hours every 500 oper. hours every 500 oper. hours every 1000 oper. hours every 1000 oper. hours every 2000 oper. hours every 2000 oper. hours every 4000 oper. hours every 4000 oper. hours every 6000 oper. hours every 6000 oper. hours as required as required 5.6 5.6 Check the engine oil level Check the engine oil level Dipstick mark Dipstick mark X X 5.7 5.7 Check the fuel level Check the fuel level Instrument cluster Instrument cluster X X 5.8 5.8 Check the hydraulic oil level Check the hydraulic oil level Inspection glass Inspection glass X X 5.9 5.9 Check the coolant level Check the coolant level Instrument cluster Instrument cluster X X 5.10 5.10 Check the condition of the cutters Check the condition of the cutters X X 5.11 5.11 Check front and rear tire pressures Check front and rear tire pressures X X 5.12 5.12 Visual inspection for leakages and damage, clean the machine Visual inspection for leakages and damage, clean the machine X X 5.13 5.13 Clean the lateral hood boxes Clean the lateral hood boxes X X 5.14 5.14 Clean the dirt scrapers on the hydraulic cylinders for the rotor hood Clean the dirt scrapers on the hydraulic cylinders for the rotor hood X X 5.15 5.15 Clean the intercooler Clean the intercooler X X 5.16 5.16 Check the reaction water level Check the reaction water level only with binder metering system only with binder metering system X X 5.17 5.17 Check the oil level for the reaction water pump Check the oil level for the reaction water pump only with binder metering system only with binder metering system X X 5.18 5.18 Check the oil level in compressor and service unit Check the oil level in compressor and service unit only with binder metering system only with binder metering system X X 5.19 5.19 Check the thermal oil level Check the thermal oil level only with binder metering system only with binder metering system X X 5.20 5.20 Check the contamination of the hydraulic oil filters Check the contamination of the hydraulic oil filters only with binder metering system only with binder metering system X X 5.21 5.21 Check the binder pump for leaks Check the binder pump for leaks only with binder metering system only with binder metering system X X 5.22 5.22 Check the spraying section for leaks Check the spraying section for leaks only with binder metering system only with binder metering system X X 5.23 5.23 Lubricating the machine Lubricating the machine X X 5.24 5.24 Clean the radiator (water Clean the radiator (water X X 5.25 5.25 Check, clean the additional fuel filter water separator Check, clean the additional fuel filter water separator only with binder metering system only with binder metering system X X 5.26 5.26 Service the air conditioning Service the air conditioning X X 5.27 5.27 Check the oil level in the front right Check the oil level in the front right X X 5.28 5.28 Check the oil level in the rear axle reduction gear Check the oil level in the rear axle reduction gear X X 5.29 5.29 Clean the ventilation valve on the rear axle reduction gear Clean the ventilation valve on the rear axle reduction gear X X 5.30 5.30 Check the oil level in the rear axle Check the oil level in the rear axle X X 5.31 5.31 Clean the rear axle ventilation valve Clean the rear axle ventilation valve X X 5.32 5.32 Check the oil level in the rear planetary gear Check the oil level in the rear planetary gear X X 5.33 5.33 Change engine oil and oil filter Change engine oil and oil filter oil change after 50 and 500 operating hours, then every 500 operating hours min. 1x per year min. 1x per year see foot note X X 5.34 5.34 Check and clean the water separator Check and clean the water separator when the "water in fuel" warning light lights up when the "water in fuel" warning light lights up X X 5.35 5.35 Service the generator V-belt Service the generator V-belt X X 5.36 5.36 Check the V-belt for the air conditioning compressor Check the V-belt for the air conditioning compressor X X 5.37 5.37 Service the battery, check the battery main switch Service the battery, check the battery main switch pole grease pole grease X X 5.38 5.38 Check the engine mounts Check the engine mounts X X 5.39 5.39 Drain the fuel tank sludge Drain the fuel tank sludge X X 5.40 5.40 Oil change in rotor gearbox, check rotor water level Oil change in rotor gearbox, check rotor water level X X 5.41 5.41 Check, adjust the valve clearance Check, adjust the valve clearance Intake: 0.25 mm Exhaust: 0.30 mm Intake: 0.25 mm Exhaust: 0.30 mm X X 5.42 5.42 Change the fuel filter Change the fuel filter X X 5.43 5.43 Replacing the fuel pre-filter cartridge, bleed the fuel system Replacing the fuel pre-filter cartridge, bleed the fuel system X X 5.44 5.44 Check the anti-freeze concentration and the condition of the coolant Check the anti-freeze concentration and the condition of the coolant X X 5.45 5.45 Intercooler, drain lubricating oil Intercooler, drain lubricating oil min. 1x per year min. 1x per year X X 5.46 5.46 Check fastening of engine Check fastening of engine X X 5.47 5.47 Checking the crankcase pressure Checking the crankcase pressure X X 5.48 5.48 Oil change in front travel gear Oil change in front travel gear Running-in instructions: oil change after 250, 500 and 1000 operating hours, then every 1000 operating hours see foot note see foot note X X 5.49 5.49 Oil change in rear planetary gear Oil change in rear planetary gear see foot note see foot note X X 5.50 5.50 Change the oil in the rear axle reduction gear Change the oil in the rear axle reduction gear oil change after 250 and 1000 operating hours, then every 1000 operating hours see foot note see foot note X X 5.51 5.51 Change the oil in the rear axle*** Change the oil in the rear axle*** see foot note see foot note X X 5.52 5.52 Oil change in attachment plate exciter housing Oil change in attachment plate exciter housing X X 5.53 5.53 Change the additional fuel filter Change the additional fuel filter only with binder metering system only with binder metering system X X 5.54 5.54 Changing the thermal oil Changing the thermal oil only with binder metering system only with binder metering system X X 5.55 5.55 Compressor oil change Compressor oil change only with binder metering system only with binder metering system X X 5.56 5.56 Change hydraulic oil and breather filter Change hydraulic oil and breather filter Also after repairs in the hydraulic system. at least every 2 years at least every 2 years see foot note X X 5.57 5.57 Change the hydraulic oil fine filter**** Change the hydraulic oil fine filter**** see foot note see foot note X X 5.58 5.58 Changing the coolant Changing the coolant min. every 2 years min. every 2 years X X 5.59 5.59 Retighten the screws on the articulated joint Retighten the screws on the articulated joint X X 5.60 5.60 Check the fire extinguisher Check the fire extinguisher only by authorized and qualified personnel only by authorized and qualified personnel X X 5.61 5.61 Change the injection valve Change the injection valve only by authorized service personnel only by authorized service personnel X X 5.62 5.62 Replace the crankcase ventilation valve Replace the crankcase ventilation valve X X 5.63 5.63 Replace the coolant pump Replace the coolant pump only by authorized service personnel only by authorized service personnel X X 5.64 5.64 Replace the pressure retaining valve on the injection pump Replace the pressure retaining valve on the injection pump only by authorized service personnel only by authorized service personnel X X 5.65 5.65 Change the dry air filter cartridge Change the dry air filter cartridge at least every year at least every year X X 5.66 5.66 Replacing the cutting teeth Replacing the cutting teeth X X 5.67 5.67 Lubricate the bearings on the cabin lift cylinder Lubricate the bearings on the cabin lift cylinder X X 5.68 5.68 Water sprinkler system, maintenance in the event of frost Water sprinkler system, maintenance in the event of frost X X 5.69 5.69 Change the fresh air filter in the cabin Change the fresh air filter in the cabin X X 5.70 5.70 Replenish the windscreen washer tank Replenish the windscreen washer tank X X 5.71 5.71 Change the tires Change the tires X X 5.72 5.72 Lubricate the attachment plate adjustment spindles Lubricate the attachment plate adjustment spindles X X 5.73 5.73 Clean the bitumen filter Clean the bitumen filter only with binder metering system only with binder metering system X X 5.74 5.74 Reaction water tank, maintenance in the event of frost Reaction water tank, maintenance in the event of frost only with binder metering system only with binder metering system X X 5.75 5.75 Tighten all bolted connections Tighten all bolted connections X X 5.76 5.76 Conservation Conservation X X 5 E-Plan wiring diagrams 5 E-Plan wiring diagrams 5.1 Understanding wiring diagrams Electric circuit diagrams Electric circuit diagrams Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do not contain any information on the type of wiring, their purpose is solely the clarification of control logics. Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do not contain any information on the type of wiring, their purpose is solely the clarification of control logics. The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system. This plan provides the following information: l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc. l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses, switches, consumers, relays, etc. l The sequence in which current flows through the individual elements in the electric circuit. l Connections between the examined electric circuit and other circuits in the vehicle wiring system. l Pin assignment of plug-and-socket connections. Structure of a wiring diagram Structure of a wiring diagram l Cover sheet, see section "Cover sheet" l Cover sheet, see section "Cover sheet" l Table of contents, see section "Table of contents" l Structuring symbol overview, see section "Structuring symbol overview" The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification! The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local identification! l Sheets with illustration of function, see section"Sheets with illustration of function" l Sheets with illustration of function, see section"Sheets with illustration of function" l List of fuels and lubricants, see "List of fuels and lubricants" l Terminal strip overview, see section "Terminal strip overview" l Plug overview, see section "Plug overview" l Pin overview, see section "Pin overview" Cover sheet The cover sheet, see example (Fig. 17) Fig. 17 Example: Cover sheet Table of contents The table of contents, see example (Fig. 18) Fig. 18 Example: Table of contents Overview of structural symbols The structural identification overview represents the structure of the machine with respect to equipment, functions and installation locations. The structural identification overview represents the structure of the machine with respect to equipment, functions and installation locations. Structuring symbols are mainly abbreviations for machine parts Fig. 19 Example: MPH122-2 Fig. 20 Example: MPH122-2 Sheets with representations of functions l The main reading direction is sheet by sheet, from top to bottom and from left to right. l The main reading direction is sheet by sheet, from top to bottom and from left to right. l All sheets are successively numbered. l BOMAG used the resolved type of representation. In this case parts and components with different functions, which belong to the same components (e.g. relay coil and relay contact), can be represented on different sheets. Cross-references, which ref... (Fig. 21) Fig. 21 Example: Sheet with functions Current paths Current paths (Fig. 21) l Current paths are successively numbered from 0 to 9. l Current paths are successively numbered from 0 to 9. Potential cross references Potential cross references (Fig. 21) l Potential cross references serve the purpose of tracking signals, which are transmitted from one representation of a function to another. Potential cross-references may additionally have structuring symbols assigned to them. l Potential cross references serve the purpose of tracking signals, which are transmitted from one representation of a function to another. Potential cross-references may additionally have structuring symbols assigned to them. Example: Potential 15_54 +SEAT Example: Potential 15_54 +SEAT +SEAT Relay cross references Relay cross references (Fig. 21) l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally atta... l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is additionally atta... Example: The relay cross-reference ( Example: -K61 List of component The list of components, see example (Fig. 22) Fig. 22 Example: List of components An electric component is a part, assembly or device in an electrical installation. l Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN - EN 61346 T1-T2. A component identification (BMK), e.g.: �S04� always identifies the same component. In this context the ... l Components are marked with a combination of letters and numbers. The identification with letters follows the standard DIN - EN 61346 T1-T2. A component identification (BMK), e.g.: �S04� always identifies the same component. In this context the ... l The component identifications are alphabetically sorted in the list of components. Each component has the corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which installation location it is assigned t... Component identifications are used in both the electrical and the hydraulic documentation and are identical. Component identifications are used in both the electrical and the hydraulic documentation and are identical. Overview of terminal strips The overview of terminal strips, see axample (Fig. 23) Fig. 23 Example: Terminal strip overview X1 Overview of plugs The overview of plugs, see example (Fig. 24) The following information is listed for each plug: l Contact numbering l Contact numbering l Structuring symbols l Function text l Use in wiring diagram. Fig. 24 Example: Plug overview X0 Overview of pins The overview of pins, see example (Fig. 25) Fig. 25 Example: Overview of pins, control A66 5.2 Circuit symbols in the circuit diagram Circuit symbols Circuit symbols Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a simplified representation of complete systems, from which, however, the function can be clearly identified. This standardization is in compliance ... Fig. 26 Example: Circuit symbol 1 Current source 1 Current source 2 Conductor 3 Switch 4 Ground 5 Filament lamp 6 Filament lamp with two luminous elements 7 Voltmeter 8 Amperemeter 9 Resistance 10 Fuse 11 Terminal strip 12 Plug Different symbols are used to simplify the differentiation of terminal strips 11 (Fig. 26) Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable connection and mating plug. Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable connection and mating plug. Representation of electric devices Electronic devices and components are increasingly used in the construction equipment industry. Controls with software, control elements (e.g. joysticks and man Black-Box representation Black-Box representation (Fig. 27) The Black-Box representation shows the device as a Box with the connections required for the machine function. Connections which are not needed do not need to be represented. The Black-Box representation is mainly used when no differentiated information (e.g. signals on pins) is available. Fig. 27 Example: Central lubrication system Identification of externally supplied documentation (Fig. 28) In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the projecting of machines. These systems may be composed of various components and wirings. For easier differentiation of BOMAG designati... Fig. 28 Example: Identification of externally supplied documentation PLC representation PLC representation (Fig. 29) The PLC-Box representation of connecting pins uses a table with associated connecting plugs, which are used in connection with the machine functions. The table symbols can be arranged in a line, if necessary. Connections which are not needed do not n... Fig. 29 PLC representation The PLC-Box representation is mainly used for controls with BOMAG software, or for electronic devices which were specified accordingly, and where information on the assignment of signals is available. Identification of similar, adjacent switching symbols In wiring diagrams you will frequently find the situation that symbols of the same type appear in a line or are arranged just next to each other. In such cases it is common practice to reduce the identification on the subsequent symbol to the criteri... Example: -X0 36 and -X0 37 (Fig. 29) In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right plug symbol. 5.3 Identification of switch blocks in the wiring diagram Switches of modular design Switches of modular design l For normally open contacts the contact symbols "_3 l For normally open contacts the contact symbols "_3 l For normally closed contacts the contact symbols "_1 In combination with the contact block numbering described above each individual connection is clearly defined. Fig. 30 Example: The contact block marked with the "circle" is referred to as "43" The contact block marked with "X" is referred to as "23" The contact block marked with "Z" is referred to as "13" The contact block marked with "Y" is referred to as "53" 6 Electrics 6 Electrics 6.1 Designation of components in the wiring diagram The designation of components in the wiring diagram groups several electrical parts of the machine in one group. The components can be identified by the following table. The designation of components in the wiring diagram groups several electrical parts of the machine in one group. The components can be identified by the following table. Component designation Component designation Meaning Meaning A A Interval switch, indicator relay, modules, electronic component Interval switch, indicator relay, modules, electronic component B B Pressure, pressure differential, temperature switches and sensors, transducers Pressure, pressure differential, temperature switches and sensors, transducers C C Capacitor Capacitor E E Headlights, heater, air conditioning condenser Headlights, heater, air conditioning condenser F F Fuses Fuses G G Battery, generator Battery, generator H H Control lights, warning buzzer, warning light Control lights, warning buzzer, warning light K K Relays Relays M M Starter, pumps, motors Starter, pumps, motors P P Operating hour meter, general gauges Operating hour meter, general gauges R R Transducers, resistors Transducers, resistors S S Switches, momentary contact switches Switches, momentary contact switches V V Diode Diode X X Terminal Terminal Y Y Solenoid valves Solenoid valves 6.2 Terminal designations in wiring diagram l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ... l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ... l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a terminal designation. In Germany the designation of the individual connection terminals is determined by the standard DIN 72552. The following ... Terminal designation Terminal designation Meaning Meaning 15 15 Switch plus (after battery) : Output of ignition switch Switch plus (after battery) : Output of ignition switch 15a 15a Output from dropping resistor to ignition coil and starter Output from dropping resistor to ignition coil and starter 17 17 Preheating starter switch, preheating Preheating starter switch, preheating 19 19 Preheating starter switch, starting Preheating starter switch, starting 30 30 Battery plus direct Battery plus direct 30a 30a Battery changeover relay 12V Battery changeover relay 12V 31 31 Battery minus direct or ground Battery minus direct or ground 31a 31a Battery changeover relay 12V Battery changeover relay 12V 31b 31b Return line to battery minus or ground via switch or relay (switched minus) Return line to battery minus or ground via switch or relay (switched minus) 31c 31c Battery changeover relay 12V Battery changeover relay 12V 49 49 Input flasher relay Input flasher relay 49a 49a Output flasher relay Output flasher relay 49b 49b Flasher relay output 2nd flasher circuit Flasher relay output 2nd flasher circuit 49c 49c Flasher relay output 3rd flasher circuit Flasher relay output 3rd flasher circuit 50 50 Starter, starter control Starter, starter control 50a 50a Battery changeover relay, output for starter control Battery changeover relay, output for starter control 53 53 Wiper motor input (+) Wiper motor input (+) 53a 53a Wiper motor (+) end limit shut down Wiper motor (+) end limit shut down 53b 53b Wiper shunt winding Wiper shunt winding 56 56 Head light Head light 56a 56a Head light, travel light and travel light control Head light, travel light and travel light control 56b 56b Head lights, dimmed head light Head lights, dimmed head light 56d 56d Head lights, flash light Head lights, flash light 57 57 Parking light for motor cycles (abroad also for cars and trucks) Parking light for motor cycles (abroad also for cars and trucks) 57a 57a Parking light Parking light 57L 57L Parking light left Parking light left 57R 57R Parking light right Parking light right 58 58 Side lights, tail light, number plate light, dashboard light Side lights, tail light, number plate light, dashboard light 58b 58b Tail light changeover for single axle trailers Tail light changeover for single axle trailers 58c 58c Trailer plug for single core wired and trailer fused tail light Trailer plug for single core wired and trailer fused tail light 58d 58d Adjustable dashboard light, tail light and side light Adjustable dashboard light, tail light and side light 58L 58L Side light, left Side light, left 58R 58R Side light, right Side light, right 61 61 Generator control Generator control 75 75 Radio, cigarette lighter Radio, cigarette lighter 76 76 Loudspeaker Loudspeaker 87 87 Relay contact on breaker and two-way contact, input Relay contact on breaker and two-way contact, input 87a 87a Relay contact on breaker and two-way contact, output 1 (breaker side) Relay contact on breaker and two-way contact, output 1 (breaker side) 87b 87b Relay contact on breaker and two-way contact, output 2 Relay contact on breaker and two-way contact, output 2 87c 87c Relay contact on breaker and two-way contact, output 3 Relay contact on breaker and two-way contact, output 3 87z 87z Relay contact on breaker and two-way contact, input 1 Relay contact on breaker and two-way contact, input 1 87y 87y Relay contact on breaker and two-way contact, input 2 Relay contact on breaker and two-way contact, input 2 87x 87x Relay contact on breaker and two-way contact, input 3 Relay contact on breaker and two-way contact, input 3 88 88 Relay contact for maker Relay contact for maker 88a 88a Relay contact on maker and two-way contact, (maker side) output 1 Relay contact on maker and two-way contact, (maker side) output 1 88b 88b Relay contact on maker and two-way contact, (maker side) output 2 Relay contact on maker and two-way contact, (maker side) output 2 88c 88c Relay contact on maker and two-way contact, (maker side) output 3 Relay contact on maker and two-way contact, (maker side) output 3 88z 88z Relay contact on maker, input 1 Relay contact on maker, input 1 88y 88y Relay contact on maker, input 2 Relay contact on maker, input 2 88x 88x Relay contact on maker, input 3 Relay contact on maker, input 3 B+ B+ Battery positive Battery positive B- B- Battery minus Battery minus D+ D+ Dynamo Plus Dynamo Plus D- D- Dynamo Minus Dynamo Minus DF DF Dynamo field (generator excitation current) Dynamo field (generator excitation current) DF1 DF1 Dynamo field 1 (generator excitation current) Dynamo field 1 (generator excitation current) DF2 DF2 Dynamo field 2 (generator excitation current) Dynamo field 2 (generator excitation current) 6.4 Battery service, checking the main battery switch 6.3 Batteries Battery � accumulator Battery � accumulator Fig. 1 In vehicles batteries are used to start the engine. The ability to start the engine depends on the charge condition of the batteries. Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging electric current. The basic element of a lead accumulator is the cell. It contains the plate blocks consisting of positive and negative plates. These plates are separated from each other by separators. All positive plates are arranged parallel to the plus pole, the negative plates parallel to the minus pole of the cells. Fig. 2 All cells are filled with a conductive fluid, the electrolyte. For a 12 Volt battery 6 cells are connected in series. Capacity is a synonym for the amount of current taken up and discharged by a battery over a specified period of time. Battery maintenance Battery maintenance Maintenance free batteries are gaining more and more significance, this freedom from maintenance, however, is only limited to the fact that no water needs to be added. Maintenance free batteries are gaining more and more significance, this freedom from maintenance, however, is only limited to the fact that no water needs to be added. If the battery is not charged and discharged over a longer period of time, the battery will slowly discharge by itself. The accumulator may only be discharged down to a final discharging voltage of 10.5 Volt, as otherwise there is a risk of sulphation, i.e. the generated lead sulphate forms increasingly coarser crystals, which will finally not react at all or only ver... In the worst case the accumulator can only be disposed of after such an exhaustive discharge. The following therefore applies for longer downtimes: l Remove the battery and store it in a cool, dry and frost protected room. l Remove the battery and store it in a cool, dry and frost protected room. l Check the open circuit voltage on the battery at regular intervals (at least once every month). l Recharge immediately if the open circuit voltage has dropped to 12.25 Volt (no rapid charging). The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge. The open circuit voltage of batteries occurs approx. 10 h after the last charging or approx. 1 h after the last discharge. Battery test in general Battery test in general l Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area? l Is the battery leaking? Can traces of impact, shock or compression be found in the leaking area? l Check for e.g. incorrect fastening, foreign bodies on the battery mounting surface and similar. 6.4 Battery service, checking the main battery switch Batteries with screw plugs Checking the electrolyte level Checking the electrolyte level Fig. 3 1 Upper filling level mark 1 Upper filling level mark 2 Lower filling level mark l If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells. l If the electrolyte level only reaches up to the lower filling level mark (2), fill distilled water into the corresponding cells. Checking the electrolyte density Fig. 4 The cells are filled with diluted sulphuric acid as electrolyte (approx. 25 Vol% sulphuric acid in distilled water), also referred to as accumulator acid, which has a density of 1.285 kg 3 3 With a lead cell the acid density is therefore a measure for the charge condition. This characteristic is used to determine the charge condition of a lead battery. The so-called electrolyte tester (densimeter) is used for this purpose. Fig. 5 Checking the electrolyte density: 1) correct 2) poor 3) poor (Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte. (Hold the pipe of the electrolyte tester vertically, without taking it out of the electrolyte. Do not draw too much electrolyte into the pipe. Make sure that the float is not obstructed in its movement and hold the electrolyte tester at eye level. The electrolyte tester must be read at the highest electrolyte level. l If the electrolyte temperature deviates from the electrolyte tester calibration temperature, the indicated value for the specific electrolyte weight must be corrected acc. to the formula l If the electrolyte temperature deviates from the electrolyte tester calibration temperature, the indicated value for the specific electrolyte weight must be corrected acc. to the formula (reference) Reference The specific weight varies slightly with temperature. To be exact, the specific weight drops by 0.0007 per 1 �C temperature increase (by 0.0004 per 1 �F) and increases by 0,0007 per 1 �C temperature reduction (by 0,0004 per 1 �F) . If e.g. a temp... l Specific weight at 20 �C = measuring value + 0,0007 � (electrolyte temperature: 20 �C) l Specific weight at 20 �C = measuring value + 0,0007 � (electrolyte temperature: 20 �C) l Specific weight at 68 �F = measuring value + 0,0004 � (electrolyte temperature: 68 �F) Acid density at 27 �C in kg 3 l 1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged. l 1.25 -1.28, open-circuit voltage approx. 12.7 Volt. Battery is charged. l 1.20 -1.24, open circuit voltage approx.12.4 to 12.5 Volt, is 50% discharged. Charging is necessary. l 1.19 and less, open circuit voltage less than 12.3 Volt. Battery is insufficiently charged. The battery needs to be recharged immediately. l If there is a deviation of the specific weight of more than 0.05 between any of the cells, the battery needs to be replaced. l If the current consumption during charging is not 1 6.4 Battery service, checking the main battery switch Testing batteries without screw plugs On closed batteries the acid density cannot be measured, we therefore recommend testing with the following mobile tester: Fig. 6 Battery and generator tester The battery and generator tester comes with an 8-line LC display with background illumination and is able to print out test results via an (optional) integrated thermal printer. Before testing clean the poles and ensure good connection between clamps and poles. Before testing clean the poles and ensure good connection between clamps and poles. The test program calculates the text messages "good" or "replace" on the basis of the charge condition (derived from the battery voltage) and the currently available starting power of the battery. A battery with 45% starting power may thus be rated g... The starting power can exceed 100%. 6.4 Battery service, checking the main battery switch 6.4 Battery service, checking the main battery switch Danger of cauterisation ! Danger of explosion! Danger of cauterisation ! Danger of explosion! Danger of cauterisation ! Danger of explosion! When working on the battery do not use open fire, do not smoke! The battery contains acid. Wear protective clothing! Do not let acid come in contact with skin or clothes! Do not lay any tools on the battery! For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases. If a battery is defective you should always replace both batteries to avoid damage caused by differing battery conditions If a battery is defective you should always replace both batteries to avoid damage caused by differing battery conditions Dispose of the old batteries environmentally. Dispose of the old batteries environmentally. Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self- discharge, which may, in not checked occasionally, even cause damage to the battery as a result ... Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked. Each battery suffers under self- discharge, which may, in not checked occasionally, even cause damage to the battery as a result ... The following therefore applies for the service life: l Switch off all consumers (e.g. ignition, light, inside light, radio). l Switch off all consumers (e.g. ignition, light, inside light, radio). l Check open-circuit voltage of the battery at regular intervals. At least once per month. Reference values: 12.6 V = fully charged; 12.3 V = 50% discharged. l Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging. l Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform quick charging. The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or one hour after the last discharge. l After each charging process allow the battery to rest for one hour before taking it into service. l After each charging process allow the battery to rest for one hour before taking it into service. l For resting periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit voltage measurements. Fig. 7 l Open the maintenance door to the battery compartment l Open the maintenance door to the battery compartment (Fig. 7) Fig. 8 l Pull the carrier plate with batteries (2) l Pull the carrier plate with batteries (2) (Fig. 8) l Turn the tommy screw (1) anti-clockwise. l Press the locking button and turn the tommy screw back clockwise. l Release the locking button and turn the tommy screw anti-clockwise, until the lock is released. Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty! Exhausted batteries (batteries with formation of sulphate on the plates are not covered under warranty! Fig. 9 l Clean battery poles and terminal clamps l Clean battery poles and terminal clamps (Fig. 9) l Retighten the pole clamps. l Check the fastening of the battery. l On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water. Checking the main battery switch Checking the main battery switch Fig. 10 Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency. Pull out the main battery switch at the earliest 40 seconds after switching off the ignition, except in cases of emergency. l Turn the main battery switch l Turn the main battery switch (Fig. 10) 6.5 Starting with jump wires 6.5 Starting with jump wires When using external starting aid two external batteries are required, one for each on-board battery. When using external starting aid two external batteries are required, one for each on-board battery. When using external starting aid two external batteries are required, one for each on-board battery. Fig. 11 l Open the maintenance door to the battery compartment l Open the maintenance door to the battery compartment (Fig. 11) Fig. 12 A wrong connection will cause severe damage in the electric system. A wrong connection will cause severe damage in the electric system. l When starting with external batteries connect the positive poles l When starting with external batteries connect the positive poles (Fig. 12) l Start as described under "Starting the engine". l Start as described under "Starting the engine". The ignition switch is designed with a re-start lock. For a new starting attempt the ignition key must first be turned back to position "0". The ignition switch is designed with a re-start lock. For a new starting attempt the ignition key must first be turned back to position "0". l Once the engine is running switch on a powerful consumer (working light, etc.). l Once the engine is running switch on a powerful consumer (working light, etc.). If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components. If no powerful consumer is switched on voltage peaks may occur when separating the connecting cables between the batteries, which could damage electrical components. l After starting disconnect the negative poles (ground cable) first and the positive poles after. l After starting disconnect the negative poles (ground cable) first and the positive poles after. l Switch off the consumer. Run the engine warm for a short while. Run the engine warm for a short while. 6.6 Magnetic sensor in return flow filter blocks, B19 Magnetic sensor Magnetic sensor The magnetic sensor is in the return flow filter block. The sensor switches when it has picked up metal chips. The magnetic sensor is in the return flow filter block. The sensor switches when it has picked up metal chips. Fig. 1 Monitoring by ESX-control Monitoring by ESX-control The signal is evaluated by the ESX-control and displayed 10 seconds later in the display module The signal is evaluated by the ESX-control and displayed 10 seconds later in the display module (Fig. 2) The warning buzzer sounds. Fig. 2 Display module in central electrics Warning light for magnetic sensor, B19 The switch contact connects the monitoring module (A81, terminal X1:223) to ground. The magnetic sensor warning lamp d (Fig. 3) Fig. 3 Monitoring module 6.7 Pressure switch in return flow filter block, B25 Pressure switch Pressure switch Pressure switch 1 Pressure switch 1 (Fig. 1) �0,5 Fig. 1 Monitoring by ESX-control Monitoring by ESX-control The signal is evaluated by the ESX-control and displayed 10 seconds later in the display module (P18) The signal is evaluated by the ESX-control and displayed 10 seconds later in the display module (P18) (Fig. 2) The warning buzzer sounds. After 2 minutes the code "573" is displayed, the engine is shut down. Fig. 2 Display module in central electrics (P18) Warning lamp for return flow filter block. The switch contact connects the monitoring module (A81, terminal X1:217) to ground. The warning light for the return flow filter block i (Fig. 3) Fig. 3 Monitoring module (A81) 6.8 Differential pressure switches for hydraulic oil filter, B21, B22 and B42 Pressure differential switch Pressure differential switch The differential pressure switches switch to reference ground at a pressure differential of The differential pressure switches switch to reference ground at a pressure differential of D D Fig. 1 Monitoring by ESX-control Monitoring by ESX-control The signals are evaluated by the ESX-control and displayed 10 seconds later in the display module The signals are evaluated by the ESX-control and displayed 10 seconds later in the display module (Fig. 2) The warning buzzer sounds. After 2 minutes the code "573" is displayed, the engine is shut down. Fig. 2 Display module in central electrics (P18) Warning light for differential pressure switch, B21 Warning light for differential pressure switch, B21 The switch contact connects the monitoring module (A81, terminal X1:210) to ground. The warning lamp for differential pressure switch I l (Fig. 3) Warning lamp for differential pressure switch, B22 Warning lamp for differential pressure switch, B22 The switch contact connects the monitoring module (A81, terminal X1:219) to ground. The warning lamp for differential pressure switch II k (Fig. 3) Warning light for differential pressure switch, B42 Warning light for differential pressure switch, B42 The switch contact connects the monitoring module (A81, terminal X1:218) to ground. The warning lamp for differential pressure switch III j (Fig. 3) Fig. 3 Monitoring module (A81) 6.9 Hydraulic oil temperature Temperature sensor, R04 Temperature sensor, R04 Temperature sensor 2 (Fig. 4) Fig. 4 Hydraulic oil tank Temperature display Temperature display The display o (Fig. 5) Fig. 5 Monitoring module (A81) 291 OHM ^= 40�C 291 OHM ^= 40�C 36 OHM ^= 120�C If no temperature sensor is connected or the cable is broken, the temperature gauge will go out. Monitoring by ESX-control Temperature switch, B20 The temperature switch 1 (Fig. 4) �3�C �3�C Monitoring by ESX-control Monitoring by ESX-control The signal is evaluated by the ESX-control and displayed 10 seconds later in the display module (P18) The signal is evaluated by the ESX-control and displayed 10 seconds later in the display module (P18) (Fig. 6) The warning buzzer sounds. After 2 minutes the code "575" is displayed, the engine is shut down. Fig. 6 Display module in central electrics (P18) Hydraulic oil temperature warning light Hydraulic oil temperature warning light The switch contact connects the monitoring module (A81, terminal X1:216) to ground. The hydraulic oil temperature warning lamp h (Fig. 5) 6.10 Filling level switch hydraulic oil, B23 Filling level switch Filling level switch Fig. 1 Hydraulic oil tank Observe the installation direction 1 Observe the installation direction 1 (Fig. 2) Fig. 2 Note on assembly: Assemble with Omnifit FD20. Note on assembly: Assemble with Omnifit FD20. Tightening torque: 1 - 2 revolutions after hand-tight. Monitoring by ESX-control Monitoring by ESX-control The signal is evaluated by the ESX-control and displayed 10 seconds later in the display module (P18) The signal is evaluated by the ESX-control and displayed 10 seconds later in the display module (P18) (Fig. 3) Code "579" appears after 20 seconds, the engine is shut down and the warning buzzer sounds. Fig. 3 Display module in central electrics (P18) Hydraulic oil level warning light Hydraulic oil level warning light The switch contact connects the monitoring module (A81, terminal X1:243) to ground. The hydraulic oil level warning lamp g (Fig. 4) Fig. 4 Monitoring module (A81) 6.11 Charge pressure switch rotor pumps, B04 and B125 Charge pressure switch Charge pressure switch Fig. 1 1 Charge pressure switch B04 on rotor pump 2 1 Charge pressure switch B04 on rotor pump 2 2 Charge pressure switch B125 on rotor pump 1 Monitoring by ESX-control Monitoring by ESX-control The pressure switch opens at a pressure of 10 The pressure switch opens at a pressure of 10 �1 The signals are evaluated by the ESX-control and displayed 10 seconds later in the display module (Fig. 3) The warning buzzer sounds. After 2 minutes the code "321" is displayed, the engine is shut down. Fig. 2 Display module in central electrics (P18) Charge pressure switch warning lamp, B04 Charge pressure switch warning lamp, B04 The switch contact switches the monitoring board (A15, terminal X1:232) to floating state. The warning lamp charge pressure switch rotor I a (Fig. 3) Charge pressure switch warning lamp, B125 Charge pressure switch warning lamp, B125 The switch contact switches the monitoring board (A15, terminal X1:231) to floating state. The warning lamp charge pressure switch rotor II b (Fig. 3) Fig. 3 Monitoring module (A15) 6.12 Pressure transducer for travel control, B112 Fig. 1 l Measuring range, 0 - 600 bar l Measuring range, 0 - 600 bar l Output range 4-20 mA The MPH is equipped with a travel pressure control. With this control the travel speed is regulated according to the travel system pressure. This means, that the travel speed will be reduced when the pressure in the travel system exceeds 360 bar. The analog transducer is evaluated by the E-Box (A66, travel control). Fig. 2 The pressure transducer with integrated pressure shock reducer (Fig. 2) The installed pressure shock reducer in general is a nozzle in the passage between measuring medium and pressure sensitive element of the pressure transducer. This nozzle has an opening of 0.3 mm. Contaminated medium may cause blockage of the nozzle. However, with upright assembly of the measuring transducer this risk of blockage is minimized, because fluid only passes through the nozzles when filling the dead space behind the nozzle. 6.13 Rotary speed sensors, B107, B108 and B109 All travel motors are equipped with a speed sensor. With the anti-spin control (ASR) and the speed all rotary speeds of the motors must be measured All travel motors are equipped with a speed sensor. With the anti-spin control (ASR) and the speed all rotary speeds of the motors must be measured Fig. 1 The Hall effect speed sensor serves the contact-free detection of very low rotary speeds. Two Hall effect semi-conductor elements inside the sensor measure any changes in the magnetic flux caused be a ferromagnetic gearing on the sensor. The integrat... Switching distance: 0.3 to 1 mm 6.14 Level sensor in diesel tank (R03) Fig. 1 The fluid of the level to be measured carries a float, which lowers or rises with the fluid level. Contact springs mounted on the float thereby slide along two resistor wires arranged parallel to the movement of the float and generate a resistance va... Fuel level gauge The display I (Fig. 2) Fig. 2 Monitoring module (A15) 0 OHM ^= Tank full 0 OHM ^= Tank full 81 OHM ^= Tank empty If no level switch is connected or the cable is broken, the fuel level gauge will go out. Cab electrics Fig. 1 1 S126 Rotary switch, rear working light and rotor Fig. 2 1 S126 Rotary switch, rear working light and rotor 1 S126 Rotary switch, rear working light and rotor 1 S126 Rotary switch, rear working light and rotor 1 S126 2 S53 Rotary switch, working light middle 2 S53 3 S11 Rotary switch, front working light 3 S11 4 S55 Travel lever left 4 S55 5 A81 Instrument cluster engine 5 A81 6 P04 Speedometer 6 P04 7 S01 Emergency stop push button 7 S01 8 S155 Speed regulator 8 S155 9 S54 Rotary switch for travel ranges 9 S54 10 S03 Push button for warning horn 10 S03 11 S04 Rotary switch for parking brake 11 S04 12 S129 Rotary switch for vibration of attachment plate 12 S129 Optional equipment 13 S130 Rotary switch attachment plate up 13 S130 14 XS 24 V sockets 14 XS 15 XS 12 V sockets 15 XS 16 P29 Water flow meter* 16 P29 17 A15 Instrument cluster for machine function 17 A15 18 S55 Travel lever right 18 S55 19 S148 Rotary switch for automatic power limit control 19 S148 20 S127 Engine speed potentiometer 20 S127 21 S118 Warning light and diagnostic push button for engine control 21 S118 22 S59 Rotary switch for rotor speed 22 S59 23 S05 Rotary switch for water injection* 23 S05 24 S151 Rotary controller for water flow rate* 24 S151 25 S00 Ignition switch 25 S00 26 Fuses 27 S39 Lever to lift 27 S39 28 S60 Lever for tailgate 28 S60 29 S62 Steering lever for rear frame 29 S62 30 S63 Lever for cross-slope of rear frame 30 S63 31 Lever, swivelling of driver�s seat 32 Lever to slide the driver's seat Fig. 3 42) S21 43) S20 44) S186 45) S38 46) S45 Fig. 4 48) B29 49) S44 6.16 Fuses Fig. 5 No. 1 = Fuse box, cabin No. 1 = Fuse box, cabin (1) 7.5A (1) 7.5A (F42) Cabin light (2) 15A (F31) Cabin ventilator (3) 15A (F28) Wiper (4) 15A (F27) wiper (5) 15A (F41) Flashing beacon (6) 15A (F40) cabin heater Fig. 6 No. 2 = Fuses No. 2 = Fuses l Fold down central electrics flap. l Fold down central electrics flap. Fig. 7 Fire hazard! Fire hazard! Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. (X1:1) 30A (X1:1) 30A (F05) sockets (X1:2) 30A (F13) Ignition switch (X1:3) 30A (F34) Air conditioning (X1:4) 25A (F93) Engine control (potential 30) (X1:5) 30A (F67) power input, control (potential 30) (X1:6) 10A (F84) Processor control (X1:7) 30A (F06) water injection module (X1:8) 15A (F106) Sensor back-up alarm, engine speed, power limit control (X1:9) 10A (F66) front head lights (X1:10) 10A (F108) Middle head lights (X1:11) 20A (F22) Rear head lights, rotor (X1:12) 15A (F40) Heating (X1:13) 20A (F107) Rotor, gate, steering, cross-slope (service functions) (X1:14) 10A (F 14) Emergency stop EDC, engine control "15" (X1:15) 15A (F24) Displays (X1:16) 15A (F26) Tooth change, turning of rotor, brake, limp home function, speed range selection (X1:17) Spare 1 (X1:18) Spare 2 Machine related electrics 1 1 1 2 3 4 Wiring loom, central electrics - engine 5 Wiring loom, engine 1 Wiring loom, central electrics - sockets and voltage converter 1 Wiring loom, central electrics - sockets and voltage converter 1 Wiring loom, central electrics - sockets and voltage converter 1 Wiring loom, central electrics - sockets and voltage converter 2 Wiring of electric junction box 3 Wiring loom, electric junction box - seat console 4 Wiring loom, electric junction box - warning buzzer and ignition switch 5 Wiring of operating console 1 Wiring loom, central electrics - valves in rear frame 1 Wiring loom, central electrics - valves in rear frame 1 Wiring loom, central electrics - valves in rear frame 1 Wiring loom, central electrics - valves in rear frame 2 3 Wiring loom, proximity switches steering system 4 Wiring loom, central electrics - rear frame 1 1 1 1 2 Ground cable, front frame - rear frame 3 Ground cable 4 5 Wiring loom, central electrics - front frame 1 Wiring loom, central electrics - main fuse 1 Wiring loom, central electrics - main fuse 1 Wiring loom, central electrics - main fuse 1 Wiring loom, central electrics - main fuse 2 Wiring loom, generator - starter 3 Wiring loom, battery G01 (-) - battery G03 (+) 4 Wiring loom, main battery fuse - battery G01 (+) 5 Wiring loom, main battery switch - battery G03 (-) 6 Ground cable, engine - frame 7 Ground cable, frame - main battery switch 8 Wiring loom, battery G01 - starter 9 Ground cable, starter - engine Fig. 8 External socket External socket Fig. 9 S172 Emergency Stop switch, left hand side 1 S172 (Fig. 9) Fig. 10 S173 Emergency Stop switch, right hand side 2 S173 (Fig. 10) Fig. 11 S30 Main battery switch S30 Proximity switch, rear wheel steering Fig. 12 under hydraulic oil tank Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Proximity switch, rear wheel steering Proximity switch, rear wheel steering B46 B46 24 Volt 24 Volt Proximity switch on rotor coupling left Fig. 13 Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Proximity switch, rotor in top position Proximity switch, rotor in top position B45 B45 24 Volt 24 Volt Proximity switch, hood in top position Fig. 14 Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Proximity switch, hood in top position Proximity switch, hood in top position B76 B76 24 Volt 24 Volt Proximity switch, cross slope Fig. 15 on live ring of articulated joint Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Proximity switch, cross slope Proximity switch, cross slope B48 B48 24 Volt 24 Volt Sensor for water pump Fig. 16 Front frame in front of radiator Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Water pump sensor, lack ofwater in suction line from water tank Water pump sensor, lack ofwater in suction line from water tank B33 B33 24 Volt 24 Volt Optional sensor for water flow rate Fig. 17 Transducer for water flow rate Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Transducer, water flow rate sensor Transducer, water flow rate sensor B119, Bl. 009 B119, Bl. 009 BUS BUS 6.18 Electronic control units Control units Control units Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which are mainly installed in places where something needs to be controlled or regulated. Control units are used in almost any electronic sector i... Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which are mainly installed in places where something needs to be controlled or regulated. Control units are used in almost any electronic sector i... Control units generally work according to the IPO- principle. IPO stands for Input-Processing-Output. Sensors are available for input. Sensors determine a physical characteristic like e.g. rotary speed, pressure, temperature, etc. This value is compa... Fig. 1 Electronic control (ESX) In current vehicles control units are linked via various system buses (CAN, LIN, MOST, Flexray). The units exchange information about operating states and other relevant data in vehicle across the system. Furthermore, the on-board diagnostic or the d... Signals Analog signals Analog signals Process states are continuous (analog) when they can be mapped by means of a real number, e.g. temperature = 65.5 �C. The sensor converts a continuous process status into an analog signal. If the control unit needs the numerical value of the analog ... Binary signals Binary signals Process states are bivalent (binary) if they have only 2 possible states of truth, such as e.g. button pressed CAN-bus, Controller Area Network created by Bosch at the end of the eighties for automobile applications. created by Bosch at the end of the eighties for automobile applications. Development objectives: Real-time critical, robust and low price communication of control units, such as transmission and engine control, but also less time critical applications in the field of convenience electronics, such as air conditioning. Fig. 2 Why CAN? l Networking of control units for the realization of complex functions. l Networking of control units for the realization of complex functions. l Networking of control units for the realization of complex functions. l Reduction of the extend of wiring and plug connections. l Better diagnostic possibilities (central diagnostics socket). Characteristics of CAN It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required. It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are required. CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always occur simultaneously in both lines, the software is thus able to filter out interfering signals more easily. Wire (+) = cable colour blue Wire (-) = cable colour yellow Measuring on the CAN Measuring on the CAN Signals transmitted through the bus line can generally not be measured with simple measuring instruments. Testing is therefore quite complicated for the user. Correct connection of lines can only be checked by means of a continuity test. BOMAG displa... 6.19 Checking the voltage supply for the control unit Power supply for a control unit, general Power supply for a control unit, general All electronic switching and control units require an electric power supply to be able to work. If the plus or minus supply is faulty, the control unit will work incorrectly or fail. The following describes the electric power supply for the ESX-control. The following describes the electric power supply for the ESX-control. (Fig. 3) shows a simplified representation of how the control unit (ESX, 68 pole) is connected. The complete representation can be found in the wiring diagram of the machine. (Fig. 3) The procedure can also be used for other controls. Pin assignment and voltage supply may be different, but the procedures for line testing are generally the same. Fig. 3 Circuitry example 1 1 Engine block ESX ESX Control unit F00 F00 Main fuse Fx,Fxx Fx,Fxx Fuses potential 30 Fxxx Fxxx Fuses potential 15 G G Generator G01 G01 Battery GND GND Housing earth H08 H08 Charge control light S00 S00 Ignition switch S01 S01 Emergency stop switch Pin 28 Pin 28 Voltage supply for control Pin 54 Pin 54 if the signal (12 Pin 55 Pin 55 Ground supply for control Pin 56 to 60 Pin 56 to 60 Voltage supply for outputs GND GND Housing earth Fault in current supply, general Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides of control units are in most cases connected to the vehicle mains supply via several cables, so that several parallel current branches ex... Fig. 4 Circuitry example The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply voltage. The following faults may occur: l Line interruption in a plus supply line l Line interruption in a plus supply line l high voltage drop in a plus supply line l line interruption on the minus side Measuring principle for line testing When a line conducts an electric current, a voltage drop will occur in the line (U V V l the available amperage (I) and l the available amperage (I) and l the electric resistance (R line In order to have reliable comparison possibilities at hand one should always work with the same amperage. Identical marginal conditions are therefore used in all of the following examples: 12 Volt � vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network. 12 V 24 V Test steps Test steps 1. Switch off the ignition. 2. Unplug the control unit from wiring loom. 3. If available connect the Pinbox (Fig. 5) 4. Check with multimeter. If a setpoint is not reached, proceed step by step to identify the weak spot. Repair as necessary. Repeat the measurement. The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition first and then pull off or plug on the plug. The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition first and then pull off or plug on the plug. Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint. Fig. 5 Pinbox for 68 pole ESX control General measuring setup to check a supply line (plus side) Fig. 6 Measuring arrangement 12 Volt 1 1 Supply line, plus side 2 2 Plug contact in wiring loom plug on control or Pinbox (Fig. 5) E E Lamp, 12V P P Multimeter G01 G01 Battery as voltage source, 12V U U V Voltage drop caused by the lamp current Setpoint The voltage drop U V Setpoint � General measuring setup to check a return line (minus side) Fig. 7 Measuring arrangement 12 Volt 1 1 Return line, minus side 2 2 Plug contact in wiring loom plug on control or Pinbox (Fig. 5) E E Lamp, 12V P P Multimeter G01 G01 Battery as voltage source, 12V U U V Voltage drop caused by the lamp current Setpoint The voltage drop U V Setpoint � Connection example to check the plus line between battery and plug pin 28 Fig. 8 X X Wiring loom plug disconnected from control unit or Pinbox (Fig. 5) P P Multimeter S00 S00 Ignition switched on. Setpoint : E is bright. U V S00 S00 Ignition switched off. Setpoint : E is dark. U V Connection example to check the minus line between battery and plug pin 55 Fig. 9 P P Multimeter X X Wiring loom plug disconnected from control unit or Pinbox (Fig. 5) E E Setpoint : E is bright. U V Test protocol for ESX E lamp 12V E lamp 12V E lamp 24V G01, battery P multimeter, measuring range: DC Plug pin Plug pin Note Note Setpoints Setpoints 28 28 Ignition ON Ignition ON E between plug pin 28 and battery minus P between battery plus and plug pin 28 E is bright, U V 28 28 Ignition OFF Ignition OFF E between plug pin 28 and battery plus P between battery minus and plug pin 28 E is dark, U V 54 54 Ignition OFF, emergency stop not operated Ignition OFF, emergency stop not operated E between plug pin 54 and battery minus P between battery plus and plug pin 54 E is bright, U V 54 54 Ignition OFF, emergency stop operated Ignition OFF, emergency stop operated E between plug pin 54 and battery minus P between battery plus and plug pin 54 E is dark, U V 55 55 Ignition OFF Ignition OFF E between plug pin 55 and battery minus P between battery plus and plug pin 55 E is bright, U V 56, 57, 58, 59, 60 56, 57, 58, 59, 60 Ignition OFF Ignition OFF E between plug pin 56, 57, 58, 59, 60 and battery minus P between battery plus and plug pin 56, 57, 58, 59, 60 E is bright, U V If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram. If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring diagram. Example 1: In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop is too high. There are two possible reasons. Either all contacts are corroded, or the supply line between battery and fuse Fxx has poor contact. Example 2: Only one measuring value exceeds the setpoint. In this case the fault must be located between the last branch and the corresponding plug pin. 6.20 Diagnostics concept Introduction Introduction A correct and reliable diagnose is a general prerequisite for the detection of faults in system. For this to count as a rule several points must be fulfilled. One of these points is the ability of the engine to run a systematic trouble shooting proce... Fault description and questioning of the customer Fault description and questioning of the customer After the customer has explained his complaint(s) the engineer has to ask further questions to track down the cause of the fault. If the complaint is additionally related to electric Fig. 10 (1) Fault memorized in error log (1) Fault memorized in error log Clear cause? Clear cause? l If the fault message leaves no doubt, repair work may be started immediately. l If the fault message leaves no doubt, repair work may be started immediately. (2) No fault memorized in the error log at the time of initial questioning (2) No fault memorized in the error log at the time of initial questioning Even if the fault is in the electric In order to examine the electric Consideration, if the error log has not recorded a fault Consideration, if the error log has not recorded a fault l What could be the cause of the complaint? l What could be the cause of the complaint? l Which measuring possibilities are available? Localizing faults Line or component? Line or component? Fig. 11 l In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the... l In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense to check the component and the... l Checking the voltage supply for the control unit l Checking the sensor lines l Checking the actor lines Sequence after the fault is found Fig. 12 6.21 Override function, ESX-control In case of severe malfunctions or failure of the ESX- control Pin X0:2 changes to floating state. In case of severe malfunctions or failure of the ESX- control Pin X0:2 changes to floating state. The coil of relay K90 is no longer excited, current flows from potential (F26) through contacts K90:30 f (Fig. 13) Control chamber short-circuit valve and brake open Control chamber short-circuit valve and brake open Current flows from fuse (F26) through contacts K77:7 Brake valve and control chamber short-circuit valve will open. Forward travel Forward travel When the travel lever is shifted forward current flows from potential (F106) through the contacts S55:03 The machine travels forward with low speed (limp- home function). Reverse travel Reverse travel When the travel lever is shifted backwards current flows from potential (F106) through the contacts S55:05 The machine travels reverse with low speed (limp- home function). Fig. 13 Monitoring module (A15) 7 Electronic control 7 Electronic control 7.1 Training 8 Engine electrics 8 Engine electrics 8.1 Engine control unit Pulling off the plug connectors of the control unit while the control unit is working (i.e. with the power supply to terminal 15switched on) is not permitted. Correct procedure: Switch off the electric power supply (normally with the ignition key), w... Pulling off the plug connectors of the control unit while the control unit is working (i.e. with the power supply to terminal 15switched on) is not permitted. Correct procedure: Switch off the electric power supply (normally with the ignition key), w... Pulling off the plug connectors of the control unit while the control unit is working (i.e. with the power supply to terminal 15switched on) is not permitted. Correct procedure: Switch off the electric power supply (normally with the ignition key), w... Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged. The engine control unit is the central component of the EMR3-system. It has the function of ensuring optimal performance of the engine with the following goals The engine control unit is the central component of the EMR3-system. It has the function of ensuring optimal performance of the engine with the following goals l excellent exhaust gas characteristics, l excellent exhaust gas characteristics, l low fuel consumption, l smooth running of engine, l long lifetime of engine, l efficient servicing under all operating conditions. For this purpose the engine control unit uses the recorded measuring values and the parameters stored in its data memory to run a number of calculations, which form the basis or all the available functions. The most im... l exact control of the injection process (among others the number, start and duration of injections), l exact control of the injection process (among others the number, start and duration of injections), l idle speed regulation, l regulation of exhaust gas recirculation, l optimization of smooth running (by means of injection quantity correction), l engine monitoring, l system diagnose. Fig. 14 The EMR3-E (TCD 2015) (Fig. 14) l socket D2.1 to connect the vehicle wiring loom, l socket D2.1 to connect the vehicle wiring loom, l socket D2.2 to connect the engine wiring loom for sensors and actuators, l socket D2.3 to connect the engine wiring loom for fuel metering unit and injection valves. Main relay Main relay When shutting down the engine, the ignition switch isolates the electronic system from terminal 15. Meter readings are saved in the non-volatile memory. After approx. 10 seconds the internal main relay switches off and disconnects the control unit fr... When shutting down the engine, the ignition switch isolates the electronic system from terminal 15. Meter readings are saved in the non-volatile memory. After approx. 10 seconds the internal main relay switches off and disconnects the control unit fr... batt Replacing the control unit Replacing the control unit It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void. It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void. It is not permitted to interchange control units from one manufacturing series or against another engine number. In this case the warranty will become null and void. Each control unit is clearly designated to the engine, in accordance with the respective application. In case of a replacement the control unit therefore needs to be completed with the engine specific data set. When ordering a new control unit you mu... The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue. The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue. 8.2 Pin assignment 8.3 System faults indicated by flashing code Engine protection function of the electric engine controller EMR3 Engine protection function of the electric engine controller EMR3 Depending on the design of the monitoring function the EMR3in certain fault situations is able to protect the engine against damages by simply monitoring the compliance with important limit values during operation and by checking the correct function... Depending on the design of the monitoring function the EMR3in certain fault situations is able to protect the engine against damages by simply monitoring the compliance with important limit values during operation and by checking the correct function... Depending on the engine configuration the flashing fault lamp can have the following meaning: l Shut-down request for the operator l Shut-down request for the operator l Attention: Loss of warranty if disregarded! l Automatic engine shut-down after a short pre-warning time, possibly in connection with a restarting prevention. l Forced engine operation at low idle speed to cool the engine, possible in connection with automatic shut-down. l Start prevention. Indication of system fault Indication of system fault The diagnostic button provides the possibility to read out existing faults in form of flashing codes. The diagnostics button and the fault lamp are located on the operatorsstandofthemachine.' Fig. 15 1 Diagnostics button, S118 1 Diagnostics button, S118 2 Fault lamp, H04 3 EMR3 control unit If the fault log of the EMR3 engine control unit holds at least one active system fault, an uniformly flashing (in case of severe system faults) or a permanent light (in case of minor system faults) will automatically inform about this condition. In ... Fig. 16 The following steps are required to read out the flashing codes for saved system faults: l Hold the diagnostics button depressed (1 to 3 seconds), until the flashing light or the permanent light of the fault lamp goes out. l Hold the diagnostics button depressed (1 to 3 seconds), until the flashing light or the permanent light of the fault lamp goes out. l After approx. 2 s watch the flashing code or the first or the next active fault. l Wait until the fault lamp shows the original flashing or permanent light again after about 5 seconds. Example: 1x short flashing, Example: 1 2 8 1-2-8 (Fig. 16) All active and passive system faults can be invoked by repetitive execution of these steps. If this read-out process is continued after the last fault, the output will be restarted with the first fault. The light will go out after the fault has been rectified. With some faults it is necessary to switch off the ignition, then wait for 30 seconds before switching the ignition back on. The light will go out after the fault has been rectified. With some faults it is necessary to switch off the ignition, then wait for 30 seconds before switching the ignition back on. Deleting the fault log The EMR3 engine control unit has two fault logs.Each system fault is simultaneously saved in both logs. However, fault log 2 is only transmitted after switching off the voltage via terminal 15 and the associated afterrunning. Earlier switching off ma... The EMR3 engine control unit has two fault logs.Each system fault is simultaneously saved in both logs. However, fault log 2 is only transmitted after switching off the voltage via terminal 15 and the associated afterrunning. Earlier switching off ma... The diagnostics button enables you to delete passive faults from the first fault log. The second fault log can only be cleared with SERDIA. The following describes the steps for clearing fault log 1: l Ignition OFF, press and hold the diagnostics button. l Ignition OFF, press and hold the diagnostics button. l Switch the ignition on. l Only release the diagnostics button after approx. 10 seconds. l All passive faults in fault log 1 will be deleted. l The deleting process is confirmed by three short flashing pulses. Flashing code Flashing code Flashing code Function Function Fault Fault Short (0.4s) Short (0.4s) Long (0.8s) Long (0.8s) Short 0.4s Short 0.4s 1 1 2 2 3 3 Output to coolant temperature indicator lamp Output to coolant temperature indicator lamp Signal faulty, control unit overheating Signal faulty, control unit overheating 1 1 2 2 6 6 Manual throttle control Manual throttle control Signal faulty Signal faulty 1 1 2 2 8 8 Intake air temperature sensor Intake air temperature sensor Signal faulty Signal faulty 1 1 3 3 3 3 Gear oil temperature sensor Gear oil temperature sensor Signal faulty Signal faulty 1 1 3 3 4 4 Rail pressure monitoring Rail pressure monitoring Signal implausible, pressure Signal implausible, pressure 1 1 3 3 5 5 Output to lubrication oil pressure warning lamp Output to lubrication oil pressure warning lamp Signal faulty, control unit overheating Signal faulty, control unit overheating Output to valve of fuel metering unit Output to valve of fuel metering unit Signal faulty, control unit overheating Signal faulty, control unit overheating 1 1 3 3 6 6 Air filter monitoring Air filter monitoring Air pressure after filter too low Air pressure after filter too low 1 1 3 3 7 7 Output to actuators Output to actuators Short-circuit to battery Short-circuit to battery 1 1 3 3 8 8 Output to actuators Output to actuators Short-circuit against ground Short-circuit against ground 1 1 4 4 2 2 Output to engine operation lamp Output to engine operation lamp Signal faulty, control unit overheating Signal faulty, control unit overheating 1 1 4 4 3 3 Multiple stage switch 1 Multiple stage switch 1 Signal faulty Signal faulty 1 1 4 4 4 4 Lubrication oil temperature sensor Lubrication oil temperature sensor Signal faulty Signal faulty Monitoring of lubrication oil temperature Monitoring of lubrication oil temperature Temperature outside nominal range Temperature outside nominal range 1 1 4 4 5 5 Monitoring of override switch Monitoring of override switch Signal implausible Signal implausible 1 1 4 4 6 6 Rail pressure limiting valve Rail pressure limiting valve Valve open Valve open 1 1 4 4 7 7 Rail pressure sensor Rail pressure sensor Signal implausible, pressure deviation beyond permissible range Signal implausible, pressure deviation beyond permissible range 2 2 1 1 2 2 Monitoring of camshaft Monitoring of camshaft No camshaft signal, no crankshaft signal No camshaft signal, no crankshaft signal 2 2 1 1 3 3 Monitoring of camshaft Monitoring of camshaft Discrepancy between camshaft and crankshaft signals Discrepancy between camshaft and crankshaft signals 2 2 1 1 4 4 Motor protection Motor protection Status of overspeed Status of overspeed 2 2 1 1 6 6 Fuel low pressure sensor Fuel low pressure sensor Signal faulty Signal faulty Fuel low pressure monitoring Fuel low pressure monitoring Fuel low pressure outside nominal range Fuel low pressure outside nominal range 2 2 1 1 9 9 Output to actuator for exhaust damper engine brake Output to actuator for exhaust damper engine brake Signal faulty, control unit overheating Signal faulty, control unit overheating 2 2 2 2 2 2 Throttle pedal input 1 (PWM) Throttle pedal input 1 (PWM) PWM signal faulty PWM signal faulty 2 2 2 2 3 3 Charge air pressure sensor Charge air pressure sensor Signal faulty Signal faulty Charge air pressure monitoring Charge air pressure monitoring Charge air pressure outside nominal range Charge air pressure outside nominal range 2 2 2 2 4 4 Oil pressure sensor Oil pressure sensor Signal faulty Signal faulty 2 2 2 2 5 5 Coolant temperature sensor Coolant temperature sensor Signal faulty Signal faulty 2 2 2 2 6 6 Input throttle pedal 1 (analog) Input throttle pedal 1 (analog) Signal faulty Signal faulty 2 2 2 2 7 7 Fuel temperature sensor Fuel temperature sensor Signal faulty Signal faulty 2 2 2 2 8 8 Water level sensor in fuel filter Water level sensor in fuel filter Signal faulty Signal faulty Fuel filter water level monitoring Fuel filter water level monitoring Max. water level exceeded Max. water level exceeded 2 2 3 3 1 1 Monitoring of lubrication oil pressure Monitoring of lubrication oil pressure Pressure outside the nominal range Pressure outside the nominal range 2 2 3 3 2 2 Monitoring of coolant temperature Monitoring of coolant temperature Temperature above nominal range Temperature above nominal range 2 2 3 3 3 3 Monitoring of intake air temperature Monitoring of intake air temperature Temperature above nominal range Temperature above nominal range 2 2 3 3 5 5 Monitoring of coolant level Monitoring of coolant level Level below nominal range Level below nominal range 2 2 3 3 7 7 Monitoring of fuel temperature Monitoring of fuel temperature Temperature outside nominal range Temperature outside nominal range 2 2 3 3 8 8 Output to fan actuator 1 Output to fan actuator 1 Signal faulty, control unit overheating Signal faulty, control unit overheating Monitoring of fan speed Monitoring of fan speed Speed outside nominal range Speed outside nominal range 2 2 4 4 1 1 Monitoring of combustion Monitoring of combustion Misfiring detected in one or several cylinders Misfiring detected in one or several cylinders 2 2 6 6 1 1 Monitoring of output to actuators Monitoring of output to actuators Relay does not open or is delayed, short circuit to ground Relay does not open or is delayed, short circuit to ground 2 2 6 6 3 3 Output to cold starting aid Output to cold starting aid Signal faulty, relay defective, jammed or incorrectly connected, short circuit Signal faulty, relay defective, jammed or incorrectly connected, short circuit 2 2 7 7 1 1 CAN-Bus CAN-Bus Time-Out for one or several sent messages, bus inactive Time-Out for one or several sent messages, bus inactive 2 2 8 8 2 2 Sensor supply voltage 1 Sensor supply voltage 1 Voltage outside nominal range Voltage outside nominal range 2 2 9 9 2 2 Atmospheric pressure sensor Atmospheric pressure sensor Signal faulty Signal faulty 3 3 1 1 4 4 Hydraulic oil temperature sensor Hydraulic oil temperature sensor Signal faulty Signal faulty Hydraulic oil temperature monitoring Hydraulic oil temperature monitoring Temperature outside nominal range Temperature outside nominal range 3 3 1 1 8 8 Battery monitoring Battery monitoring Voltage outside nominal range Voltage outside nominal range 3 3 2 2 8 8 Output to cold starting aid control lamp Output to cold starting aid control lamp Signal faulty, control unit overheating Signal faulty, control unit overheating 4 4 1 1 4 4 Output to external exhaust gas recirculation actuator Output to external exhaust gas recirculation actuator Signal faulty Signal faulty 4 4 1 1 5 5 Output to external exhaust gas recirculation actuator Output to external exhaust gas recirculation actuator Signal faulty, control unit overheating Signal faulty, control unit overheating 4 4 1 1 6 6 Output to external exhaust gas recirculation actuator Output to external exhaust gas recirculation actuator Signal faulty Signal faulty 4 4 1 1 7 7 Lubrication oil wear time meter Lubrication oil wear time meter Critical time reached Critical time reached 5 5 1 1 2 2 Output to start relay Output to start relay Signal faulty, control unit overheating Signal faulty, control unit overheating 5 5 1 1 3 3 Output to fault lamp Output to fault lamp Signal faulty, control unit overheating Signal faulty, control unit overheating 5 5 1 1 4 4 Monitoring of terminal 15 Monitoring of terminal 15 No signal detected No signal detected 5 5 1 1 5 5 Monitoring of terminal 50 Monitoring of terminal 50 Permanent signal detected Permanent signal detected 5 5 2 2 1 1 Speed measurement Speed measurement Travel speed implausible Travel speed implausible 5 5 2 2 8 8 Output to internal engine brake Output to internal engine brake Signal faulty Signal faulty 8.5 Diagnose with SERDIA SERDIA SERDIA With the diagnostics tool SERDIA and a hardware interface one can read out With the diagnostics tool SERDIA and a hardware interface one can read out Fig. 1 Service-Software TCD 2012 The SERDIA software is first choice for any diagnostics task. SERDIA is a software program from Deutz which can be used in connection with a laptop computer to perform more detailed fault analyses, especially reading out of the error log. This displays information on l Location of fault (e.g. �coolant temperature sensor�) l Location of fault (e.g. �coolant temperature sensor�) l Nature of fault (e.g. �fallen short of bottom limit value�, �sporadic fault�) l Environmental data l Number of fault locations and frequency of fault l Fault status (active � fault present l Fault messages for non-present Function test The control outputs can be activated with the engine shut down. Assignment of inputs Display of the current input and output assignment of the EMR-control. Representation of measuring values Fig. 2 There is a vast variety of measuring values available for selection which can even be used if no EMR-fault is present (start behaviour, engine sawing, lack of power). Representation of fault log Fig. 3 When looking for the cause of a fault in the EMR3-system examining the fault log of the engine control unit usually provides useful information. 8.6 Diagnose with CAN-bus The CAN-bus is used to transfer standard messages of the SAE J 1939. The CAN-bus is used to transfer standard messages of the SAE J 1939. The display is a compact, robust and integratable modules which enables the user to invoke engine data and to display these in the following formats: l Analog display l Analog display l Digital data l Multi data (a combination of analog and digital data) l Alarm messages currently present The different diagnostic screens enable detailed examination of the engine data flow Fig. 1 Display for EMR control (Fig. 1) 8.7 Diagnostics interface Fig. 1 Control unit Fig. 2 Diagnostic link A A Battery plus (+) B Battery minus (-) F CAN2 low G CAN1 low H CAN1 high K K-Line M CAN2 high Fig. 3 Diagnostics interface SERDIA connection Fig. 4 The KWP-protocol with encrypted dataflow is used via the K-line. For this purpose the PC or laptop (Fig. 4) Operation of SERDIA is described in a separate operation manual. CAN-bus display connection Operation of the display is described in a separate operation manual. Fig. 5 Display for EMR control (Fig. 5) BOMAG part-no.: 057 189 94 Fig. 6 The display is connected to the diagnostic interface by means of a special cable. Wiring loom for display (Fig. 6) BOMAG part-no.: 079 900 19 EMR3 List of fault codes 8.9 Sensors Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged. Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged. Sensors and actuators must not be connected to external power sources for the purpose of testing, but must only be operated on the EMR3. Otherwise components may be permanently damaged. Sensors must under no circumstances be repaired, but must be replaced if they are defective. Fig. 1 1 Oil pressure sensor 1 Oil pressure sensor 2 Fuel temperature sensor 3 Sensor for charge air temperature and charge air pressure 4 Engine control unit 5 Coolant temperature sensor 6 Oil level sensor, option 7 Central plug 8 Rotary speed sensor for crankshaft 9 Rotary speed sensor for camshaft 10 Wiring loom connecting cable Fig. 2 Fig. 3 8.10 Oil pressure sensor Pressure sensor, B88 Pressure sensor, B88 Fig. 1 Fig. 2 Oil pressure sensor Oil pressure monitoring EMR fault code EMR fault code Fig. 3 The operator is warned if l the oil pressure falls short of the warning limit and l the oil pressure falls short of the warning limit and l the power is reduced by the EMR after a pre-warning time, or l the oil pressure falls short of the shut-down limit and the engine is shut down after a pre-warning time. permanent light permanent light A fault message is present, the engine can be started and the refuse compactor is still operable with limitations. the control light flashes after 2 seconds Severe fault, the engine cannot be started. Monitoring by ESX-control Monitoring by ESX-control The signal is evaluated by the ESX-control (Pin X0:52) and displayed 5 seconds later in the display module (P18) The signal is evaluated by the ESX-control (Pin X0:52) and displayed 5 seconds later in the display module (P18) (Fig. 4) The warning buzzer sounds. Fig. 4 Display module in central electrics (P18) Engine oil pressure warning lamp Engine oil pressure warning lamp If there is no oil pressure, the EMR-control (PIN XD2.1.20, ground switching) switches, whereby the coil of relay (K60) is excited. The switch contact of relay (K60) supplies the monitoring module (A81, terminal X1:230) with ground potential. The eng... a (Fig. 5) Fig. 5 Monitoring module (A81) Disassembling the pressure sensor Removing and installing the pressure sensor Ensure absolute cleanliness when working in the lubrication oil system. Ensure absolute cleanliness when working in the lubrication oil system. Thoroughly clean the area around the affected component. Dry off wet locations with compressed air. Immediately close all connections and openings with new and clean plugs Only remove plugs Catch engine oil and dispose of environmentally. Catch engine oil and dispose of environmentally. Disassembling the pressure sensor Disassembling the pressure sensor Fig. 6 l Unlock and pull out the cable plug l Unlock and pull out the cable plug (Fig. 6) l Unscrew the oil pressure sensor with a socket spanner. l Check the component visually. Installing the pressure sensor Installing the pressure sensor Fig. 7 l Insert the oil pressure sensor with a new seal ring and tighten. l Insert the oil pressure sensor with a new seal ring and tighten. Tightening torque: 20 Nm Tightening torque: 20 Nm Fig. 8 l Plug in the cable plug. l Plug in the cable plug. Delete the fault entry in the fault log of the engine control unit. Delete the fault entry in the fault log of the engine control unit. Fuel temperature sensor Temperature senor, B126 Temperature senor, B126 Fig. 1 l Temperature correction for injection quantity l Temperature correction for injection quantity Fig. 2 Charge air temperature - charge air pressure sensor Charge air temperature - charge air pressure sensor, B133 Charge air temperature - charge air pressure sensor, B133 Fig. 1 Fig. 2 This sensor unites two functions in one housing. The one function measures the charge air pressure in the and adapts the injection quantity in dependence on the measured pressure. On the other hand the EMR now detects the temperature of the passing a... With a faulty pressure sensor the engine continues to run with charge pressure simulation. With a faulty pressure sensor the engine continues to run with charge pressure simulation. With a defective temperature sensor the engine also carries on running. Charge air temperature monitoring The operator is warned if l the temperature exceeds the warning limit and l the temperature exceeds the warning limit and l the power is reduced by the EMR 3 after a pre- warning time, or l the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time. Warning light engine overheating Monitoring by ESX-control The signal is evaluated by the ESX-control (Pin X0:18) and displayed 30 seconds later in the display module The signal is evaluated by the ESX-control (Pin X0:18) and displayed 30 seconds later in the display module (Fig. 3) The warning buzzer sounds. Fig. 3 Display module in central electrics (P18) Warning light engine overheating Warning light engine overheating If the coolant temperature is exceeded the EMR-control (PIN XD2.1.56, ground switching) switches, whereby the coil of relay (K15) is excited. The switch contact of relay (K15) supplies the monitoring module (A81, terminal X1:224) with ground potentia... c (Fig. 4) Fig. 4 Monitoring module (A81) Disassembling and assembling the sensor Disassembling the sensor Disassembling the sensor Fig. 5 l Unlock and pull out the cable plug l Unlock and pull out the cable plug (Fig. 5) l Unscrew the screw. l Remove the pressure l Check the component visually. Installing the sensor Installing the sensor Fig. 6 l Assemble a new O-ring l Assemble a new O-ring (Fig. 6) l Slightly cover the O-ring with grease. Fig. 7 l Carefully insert the pressure l Carefully insert the pressure (Fig. 7) l Plug on the cable plug and engage the lock. l Tighten the screw (1). Delete the fault entry in the fault log of the engine control unit. Delete the fault entry in the fault log of the engine control unit. 8.13 EMR coolant temperature sensor Temperature sensor, B113 Temperature sensor, B113 Fig. 1 Fig. 2 The coolant temperature has an effect on the injection quantity. Coolant temperature monitoring EMR fault code EMR fault code Fig. 3 The operator is warned if l the temperature exceeds the warning limit and l the temperature exceeds the warning limit and l the power is reduced by the EMR after a pre-warning time, or l the temperature exceeds the shut-down limit and the engine is shut down after a pre-warning time. permanent light permanent light A fault message is present, the engine can be started and the refuse compactor is still operable with limitations. the control light flashes after 2 seconds Severe fault, the engine cannot be started. Monitoring by ESX-control Monitoring by ESX-control The signal is evaluated by the ESX-control (Pin X0:18) and displayed 30 seconds later in the display module (P18) The signal is evaluated by the ESX-control (Pin X0:18) and displayed 30 seconds later in the display module (P18) (Fig. 4) The warning buzzer sounds. Fig. 4 Display module in central electrics (P18) Warning light engine overheating Warning light engine overheating If the coolant temperature is exceeded the EMR-control (PIN XD2.1.39, ground switching) switches, whereby the coil of relay (K146) is excited. The switch contact of relay (K146) supplies the monitoring module (A81, terminal X1:229) with ground potent... b (Fig. 5) Fig. 5 Monitoring module (A81) Disassembling the temperature sensor Removing and installing the temperature sensor Catch running out fluids in a suitable vessel and dispose of environmentally. Catch running out fluids in a suitable vessel and dispose of environmentally. Follow the corresponding documentation in the operating instructions to drain and fill the cooling system. Follow the corresponding documentation in the operating instructions to drain and fill the cooling system. Disassembling the temperature sensor Disassembling the temperature sensor Fig. 6 l Unlock and pull out the cable plug l Unlock and pull out the cable plug (Fig. 6) Fig. 7 l Unscrew the coolant temperature sensor l Unscrew the coolant temperature sensor (Fig. 7) l Check the component visually. Installing the temperature sensor Installing the temperature sensor Fig. 8 l Tighten the coolant temperature sensor l Tighten the coolant temperature sensor (Fig. 8) Make sure that the seal rings are present . Make sure that the seal rings are present . Tightening torque: 22 �2 Fig. 9 l Push on the cable plug l Push on the cable plug (Fig. 9) Delete the fault entry in the fault log of the engine control unit. Delete the fault entry in the fault log of the engine control unit. Rotary speed sensor for camshaft Rotary speed sensor, B114 Rotary speed sensor, B114 Fig. 1 l Inductive sensor l Inductive sensor l Determination of TDC l Limp-home function in case of crankshaft sensor failure 8.15 Sensor, water in fuel Which damage results from water in diesel fuel? Which damage results from water in diesel fuel? The diesel fuel is "diluted" and its lubricating properties are reduced, i.e. the injection pump or the high pressure pump in Common-Rail engines can seize. Furthermore, metal parts will corrode after longer exposure to water. Sensor, B124 Sensor, B124 Fig. 2 1 Water separator sensor (B124) 1 Water separator sensor (B124) Warning light water in fuel Warning light water in fuel If there is water in the fuel filter the EMR-control (PIN XD2.1.38, ground switching) switches, whereby the coil of relay (K104) is excited. The switch contact of relay (K104) connects the monitoring board (A15, terminal X1:301) to ground potential. ... d (Fig. 3) Fig. 3 Monitoring module (A15) EMR fault code EMR fault code Fig. 4 The fault lamp (H04) is permanently on. The fault lamp (H04) is permanently on. Permanent light Permanent light A fault message is present, the engine can be started and the MPH is still operable with limitations. 8.16 Air filter vacuum switch Vacuum switch, B03 Vacuum switch, B03 The signal is not monitored by the engine control unit. The signal is not monitored by the engine control unit. The signal is not monitored by the engine control unit. The signal is monitored by the ESX-control. Fig. 5 Monitoring by ESX-control Monitoring by ESX-control The signal is evaluated by the ESX-control (Pin X0:11) and displayed 2 minutes later in the display module (P18) The signal is evaluated by the ESX-control (Pin X0:11) and displayed 2 minutes later in the display module (P18) (Fig. 6) Fig. 6 Display module in central electrics (P18) Air filter warning light The vacuum switches operate at a vacuum of > 50 mbar. The switch contacts connect the monitoring module (A81, terminal X1:221) to ground. The air filter warning lamp e (Fig. 7) Fig. 7 Monitoring module (A81) 8.17 Coolant temperature sensor Temperature sensor, B53 Temperature sensor, B53 The temperature sensor is not monitored by the engine control unit. The temperature sensor is not monitored by the engine control unit. The temperature sensor is installed inside the engine. The analog sensor is a variable resistance to reference ground. Fig. 8 Diesel engine Temperature gauge, P14 This gauge shows the temperature of the coolant. Fig. 9 Coolant temperature display (n) 480 OHM ^= 40�C 480 OHM ^= 40�C 36 OHM ^= 120�C If no temperature sensor is connected or the cable is broken, the temperature gauge will go out. 8.18 Float switch, coolant tank Float switch, B55 Float switch, B55 The signal is not monitored by the engine control unit. The signal is not monitored by the engine control unit. The signal is not monitored by the engine control unit. The signal is monitored by the ESX-control. Fig. 1 Monitoring by ESX-control Monitoring by ESX-control The signal is evaluated in the ESX-control (Pin X0:19). The signal is evaluated in the ESX-control (Pin X0:19). After 10 seconds the display module (P18) (Fig. 2) The warning buzzer sounds. After 20 minutes the code "525" is displayed, the engine is shut down. Fig. 2 Display module in central electrics (P18) Coolant level warning lamp Coolant level warning lamp The float switch switches if the coolant level is too low. The switch contact connects the monitoring module (A81, terminal X1:222) to ground. The coolant level warning lamp f (Fig. 3) Fig. 3 Monitoring module (A81) 8.19 Charge control light, engine RPM-meter The generator is not monitored by the engine control unit. The generator is not monitored by the engine control unit. The generator is not monitored by the engine control unit. Fig. 1 Generator 1 Terminal W 1 Terminal W 2 Terminal D+ 3 Terminal B+ Charge control light Charge control light If the battery is not being charged, a ground signal is applied to D+ terminal 2 (Fig. 1) k, yellow (Fig. 2) RPM-meter RPM-meter The engine revolution counter shows the engine speed in revolutions per minute. Terminal "W" on the generator delivers a pulsating direct voltage, which is utilized to determine the rotary speed of the engine. Engine speed display, n (Fig. 2) Operating hour meter Operating hour meter The operating hour meter counts the operating hours while the engine is running. If the battery is being charged, a charging voltage is applied to D+ terminal 2 (Fig. 1) Operating hour meter, m (Fig. 2) Fig. 2 Monitoring module (A15) 8.20 Generator General General The generator should be of light weight, have a high rate of efficiency and supply all consumers in the vehicle with electric current at a steady voltage already at idling speed. Terminal designations l B61, L = charge control l B61, L = charge control l B+, B = battery plus, also with the designation "30" l B- = battery minus, also with the designation "31" l D+ = dynamo plus corresponds with terminal "61" and "L" l D- = dynamo minus (this designation is only found on D.C. generators or A.C. generators with regulator removed) l DF = dynamo field (this designation is only found on D.C. generators or A.C. generators with regulator removed). Note: The designation DF is also found on older alternators with externally arranged regulator on the connection of the exciting coil t... l DF1 = dynamo field 1 l DF2 = dynamo field 2 l IG = "15" ignition switch Three-phase generator The AC-generator first of all produces AC-voltage The AC-generator first of all produces AC-voltage Why does AC-current need to be rectified? There are a few components for which can either be operated with alternating current or direct current, because they work independently from the current flow direction. This includes : l Incandescent lamps l Incandescent lamps l Fluorescent lamps l Glow lamps l Electric heating elements. There are also a few components that could be operated either with alternating current, direct current or three-phase current, if the components were designed accordingly. This includes : l Electric motors l Electric motors l Relays. Finally, a variety of important components solely require direct current. These will under no circumstances work with alternating or three-phase current. This includes : l Accumulators l Accumulators l Control units l All electronics l Communication equipment. Design and function Design and function Fig. 3 1 Fan 1 Fan 2 Holding plate 3 Stator core 4 Stator winding 5 Brush 6 Brush holder 7 Rectifier 8 Bearing cover 9 Rotor winding 10 Rotor 11 V-belt pulley Fig. 4 Rotor with claw poles In the generator the armature windings are located inside the stationary stator (Fig. 5) (Fig. 4) Fig. 5 Stator The three stator windings (Fig. 5) Fig. 6 3-phase current The wiring diagram (Fig. 6) The diodes D1, D2, D3 are also referred to as minus diodes, because they have B- as common connection (minus plate). The other diodes are the plus diodes. The rectifier diodes have the effect that the negative half-wave is suppressed and only the positive section of the wave is allowed to pass, resulting in a pulsating D.C. voltage. Charge control light The charge control light has two duties: l Indication of the correct generator function l Indication of the correct generator function l External excitation of the generator during the starting phase Fig. 7 plus controlled charging regulator (Fig. 7) shows the current flow with the ignition switched on, engine stopped. (Fig. 7) Fig. 8 plus controlled charging regulator (Fig. 8) shows the current flow with the ignition switched on, engine running. (Fig. 8) 1 Battery 1 Battery 2 Charge controller 3 Ignition switch 4 Charge control light 5 Rectifier 6 Rotor 7 Sliprings 8 Auxiliary rectifier Normally the charge control light lights with the engine stopped and the ignition switched on and goes out at low engine speed, but at the latest after a single, short-term increase in engine speed from idle speed, because there is no longer a voltag... Any other behaviour would indicate a defect on the generator (rectifier, carbon brushes, regulator) or a defect on the lamp, presumed the on-board battery is not discharged. A far more important function of the lamp is the transition and provision of field current. At standstill there is no magnetic field in the de-energized generator. Since this is necessary for the generation of electric current, the rotor must be supp... The current flows from the ignition switch via the charge control light through the generator winding against ground (terminal 31) and is limited to approx. 300 mA by the light bulb (4 W) (without the lamp the current flow would be 2 to 5 A). While t... With used, older generators a weak permanent magnetic field may have developed over the lifetime, which does even exist when no voltage is applied. This type of machines can even start without charge control light and produce current during operation... Charge controller The charge controller has the following functions l To regulate the voltage generated by the generator l To regulate the voltage generated by the generator l To protect against overloads caused by too high output current l Protection against reverse current If the output voltage or the output current of the generator exceeds the determined maximum values, the field current and thus the electric power is reduced. Electronic charge regulator Electronic charge regulator Fig. 9 In AC-generators the electrically generated exciter field of the generator rotor is influenced by an attached electronic charge regulator. Together with the holder for the carbon brushes this regulator forms a unit, which transfers the field current ... Fig. 10 plus controlled regulator Fig. 11 minus controlled regulator Checking the generator First one must check whether the generator is actually defective. First one must check whether the generator is actually defective. l This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt. l This can be easily found out by checking whether the charge control light in the dashboard lights up. If the light does not go out, even at higher speeds, there must be a defect on the generator, the regulator, the wiring or the V-belt. l When the engine is at rest, the charge control light must light up. If not, the lamp may probably be defective. Defects on generator or wiring are obviously also possible. The following points allow to contain faults in the voltage supply within certain limits. l Cable connections on the generator OK? l Cable connections on the generator OK? l V-belt OK? l Generator ground (engine ground) OK? l Pre-excitation from vehicle electronics OK? Only if all criteria mentioned above are OK, the fault must be in the generator itself. In this case it must be replaced or the following trouble shooting procedure must be performed. Checking the pre-exciter circuit, D+ generator The most common reason for a 3-phase alternator not charging is a too low pre-excitation current. The pre- excitation current through connection D+ depends on the connected consumer (resistance), e.g. charge control light or relay of a MD+ engine con... The pre-excitation current should be approx. 250 mA at 12 Volt. This corresponds with a 3 Watt light bulb or an equivalent combination of light bulb + resistance or an LED + resistance. The total resistance of the disconnected dead supply line D+ max. should not exceed 48 Ohm. In case of faults like l charge control light stays on l charge control light stays on l no voltage increase, e.g. from 12 V to 14 V one should check that the correct resistance is assured. Fig. 12 Connections on the three-phase alternator (exemplary design) If the charge control light or LED stays on when the engine is running, you should proceed as follows: l Temporarily bridge connections D+ and B+ on the three-phase alternator l Temporarily bridge connections D+ and B+ on the three-phase alternator (Fig. 12) If this measure does not clear the fault, the alternator must be defective. Measuring the charge current Measuring the charge current l All plug-and-socket connectors must be free of corrosion and intermittent contact. l All plug-and-socket connectors must be free of corrosion and intermittent contact. l The generator ground connection must be OK. l During the measurement switch on as many consumers as possible. 1 Attach the clip-on ammeter around the B+ line. 1 Attach the clip-on ammeter around the B+ line. 2 Gradually increase the engine speed. 3 The generator current must be at least as high as the total current of all switched on consumers. Checking the rotor The rotor coils can only be measured in disassembled state. The rotor coils can only be measured in disassembled state. Fig. 13 l Measure the resistance between the sliprings. l Measure the resistance between the sliprings. l If the resistance does not comply with the factory specification, replace the rotor. l Use the resistance range of the continuity tester to check the continuity between slipring and core. l Replace the rotor if no infinite value is indicated. Factory specification for resistance: 2.8 to 5 OHM. Factory specification for resistance: 2.8 to 5 OHM. Checking the stator The stator coils can only be measured in disassembled state. The stator coils can only be measured in disassembled state. Fig. 14 l Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding. l Use the resistance range of the continuity tester to measure the resistance between the individual lines of the stator winding. l If the measuring value does not comply with the factory specification, replace the stator. l Use the resistance range of the continuity tester to check the continuity between the individual stator windings and the core. l Replace the stator if no infinite value is indicated. Factory specification for resistance: Less than 1 OHM. Factory specification for resistance: Less than 1 OHM. Checking the bearings Fig. 15 l Check whether the bearing rotates without obstruction. l Check whether the bearing rotates without obstruction. l Replace the bearing if it does not rotate properly. Checking the regulator voltage with the generator tester The battery and generator tester comes with an 8-line LC display with background illumination and is able to print out test results via an (optional) thermal printer. Fig. 16 The generator test assesses the regulator voltage and the ripple factor of the generator voltage. l All plug-and-socket connectors must be free of corrosion and intermittent contact. l All plug-and-socket connectors must be free of corrosion and intermittent contact. l The generator ground connection must be OK. l The battery should be in good condition � the idle voltage of the battery should be at least 12.6 Volt. l If possible switch off all consumers. l Perform the measurement at raised engine speed. Checking the regulator voltage with the multimeter Fig. 17 l All plug-and-socket connectors must be free of corrosion and intermittent contact. l All plug-and-socket connectors must be free of corrosion and intermittent contact. l The generator ground connection must be OK. l The battery should be in good condition � the idle voltage of the battery should be at least 12.6 Volt. l If possible switch off all consumers. l Perform the measurement at raised engine speed. l The voltage (B+) should adjust itself at 13 to 14 Volt. Checking the regulator in disassembled state On a Bosch generator The Delco-Remy generator When testing the regulator one should be aware that there are 2 different types of regulators: When testing the regulator one should be aware that there are 2 different types of regulators: l If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon ... l If the carbon brush is not connected to ground the regulator is a so-called minus controlled regulator. The exciter winding is positioned between D+ and DF, the regulator therefore regulates the exciter winding on the ground side. The other carbon ... D+ (vehicle wiring system) D- (ground contact, mostly located on one of the fastening screws) DF (Dynamo Field) Fig. 18 l If the carbon brush is connected to ground the regulator is a so-called plus controlled regulator. The exciter winding is positioned between DF and D-, the regulator therefore regulates the exciter winding on the plus side. The other carbon brush i... l If the carbon brush is connected to ground the regulator is a so-called plus controlled regulator. The exciter winding is positioned between DF and D-, the regulator therefore regulates the exciter winding on the plus side. The other carbon brush i... The basic function of a disassembled regulator can be easily tested with a 12V lamp and an adjustable D.C. power supply unit (0V ... 20V). Fig. 19 E.g minus controlled regulator One connects the regulator (Fig. 19) With this test the major difficulty is the problem to remove the regulator an identify terminals D+, DF and D-. Fig. 20 Fig. 21 The illustrations (Fig. 20) (Fig. 21) Replacing carbon brushes l On a l On a Bosch generator 5 mm l For replacing the carbon brushes in the Delco- Remy generator 8.21 Replacing the voltage regulator Disassembling the regulator Disassembling the regulator Fig. 1 l Unscrew the hexagon nut M5 from terminal W l Unscrew the hexagon nut M5 from terminal W (Fig. 1) l Remove hexagon nut, washer and flat-pin plug. Fig. 2 l Unscrew the fastening nuts M5 from the protective cover l Unscrew the fastening nuts M5 from the protective cover (Fig. 2) Fig. 3 l Lift off the plastic protective cover using a screwdriver l Lift off the plastic protective cover using a screwdriver (Fig. 3) l Remove the protective cover. Fig. 4 l Slacken the screws M3 (A) l Slacken the screws M3 (A) (Fig. 4) l Loosen the screws M5 (B). l Remove the screws, lift off the voltage regulator. Assembling the voltage regulator Assembling the voltage regulator Fig. 1 Check the correct alignment of the gasket before placing it on the brush holder Check the correct alignment of the gasket before placing it on the brush holder (Fig. 1) Fig. 2 The gasket must be pushed fully against the brush holder The gasket must be pushed fully against the brush holder (Fig. 2) Fig. 3 l Attach the voltage regulator l Attach the voltage regulator (Fig. 3) The gasket must be inserted into the rectifier plate. The gasket must be inserted into the rectifier plate. l Tighten the screw M3 (A).- Tightening torque 0.7- 1.0 Nm. l Tighten the screw M3 (A).- Tightening torque 0.7- 1.0 Nm. l Tighten the screw M5 (B).- Tightening torque 3.5- 4.5 Nm. Fig. 4 l Attach the protective cover and fasten it with washers and hexagon nuts 1 l Attach the protective cover and fasten it with washers and hexagon nuts 1 (Fig. 4) l Attach flat-pin plug, washer and hexagon nut to terminal (W) and tighten.- Tightening torque 2.7-3.8 Nm. 8.22 Electric starter General General Combustion engines need to be started by means of a special device, because they are not able to start by themselves. Considerable resistances caused by compression and friction must thereby be overcome. The starter converts the electric energy stored in the battery into mechanical energy. The starter can only generate its power when a battery with appropriate capacity is available. Duties of the starter: l to accelerate the combustion engine to start speed with lowest possible current consumption. l to accelerate the combustion engine to start speed with lowest possible current consumption. l establish the gear connection between starter and combustion engine. l to maintain this connection. l to switch on the starter current. After starting the engine: l to return the starter pinion to initial position. l to return the starter pinion to initial position. l to switch off the starter current. Directly acting electric starter This shows the design of this starter. It consists of a starter motor and a magnetic switch. This shows the design of this starter. It consists of a starter motor and a magnetic switch. Fig. 5 1 Magnetic switch 1 Magnetic switch 2 Armature 3 Actuating lever 4 Freewheeling clutch 5 Resetting spring 6 Brush 7 Exciting winding 8 Armature 9 Collector Ignition switch in position "START" Ignition switch in position "START" Fig. 6 Magnetic switch open With the ignition switch (5) in "START" position current flows from the battery (10) through the holding winding (2) and the pick-up winding (3). The armature (1) is magnetically picked up and forces the pinion (8) with the actuating lever (6) to engage with the ring gear (7). 1 Armature 1 Armature 2 Holding winding 3 Pick-up winding 4 Magnetic switch 5 Ignition switch 6 Actuating lever 7 Ring gear 8 Pinion 9 Freewheeling clutch 10 (Battery Pinion meshes with the ring gear Pinion meshes with the ring gear Fig. 7 Magnetic switch closed When the pinion (3) meshes with the flywheel mounted ring gear (4) and the magnetic switch (2) is closed, a strong current flows from the battery (7) directly into the exciting winding (6) and the armature winding, but not into the pick-up winding. This causes the armature (5) to rotate with high speed and drives the pinion, which in turn drives the ring gear (4) with a speed of 200 to 300 rpm 1 Pick-up winding 1 Pick-up winding 2 Magnetic switch 3 Pinion 4 Ring gear 5 Armature 6 Exciting winding 7 Battery Engine running Engine running Fig. 8 Once the engine is running and drives the pinion (1) via the ring gear (2), the freewheeling clutch (3) will open and prevent the armature (4) from being driven by the engine. 1 Pinion 1 Pinion 2 (Ring gear 3 Freewheeling clutch 4 Armature Ignition switch released Ignition switch released Fig. 9 When releasing the ignition switch (6) it will return from position "START" to "ON" and interrupt the starter current circuit. Current will now flow from the battery (9) through the contact plate in the pick-up winding (3) and the holding winding (2)... This opens the current circuit on the contact plate and the pinion (7) is pulled back from the ring gear (8) and stops. 1 Armature 1 Armature 2 Holding winding 3 Pick-up winding 4 Resetting spring 5 Magnetic switch 6 Ignition switch 7 Pinion 8 Ring gear 9 Battery Magnetic switch Fig. 10 Direct acting electric motor Fig. 11 Geared motor Armature (4), contact plate (3) and armature guide (6) form a closed unit. When the ignition switch is turned to "START", the armature is picked up and causes the pinion of the clutch to disengage. This causes the pinion and the ring gear to mesh, while the contact plate establishes a connection between the contacts, which enable the main current to flow into the armature. Once the ignition switch is opened, the resetting spring (5) will pull t... 1 Holding winding 1 Holding winding 2 Pick-up winding 3 Contact plate 4 Armature 5 Resetting spring 6 Armature guide Freewheeling clutch Fig. 12 Freewheeling clutch The freewheeling clutch is designed in such a way, that the flow of force is automatically interrupted if the pinion (5) of the clutch rotates faster than the freewheeling ring (1) at higher engine speeds. This makes sure that the armature will only drive the ring gear, but can never be driven by the engine. 1 Freewheeling ring 1 Freewheeling ring 2 Roller 3 Roller spring 4 Splined shaft 5 Pinion 6 Pinion Trouble shooting "Starter" The most frequent fault is definitely a fully discharged battery. The most frequent fault is definitely a fully discharged battery. The most frequent fault is definitely a fully discharged battery. If the starter rotates too slowly, either the brushes are partly worn off, or parts of the exciter or armature winding is shorted. In some cases oxidized electric contacts or a soiled ground connection causing extremely high voltage losses in the overal If the starter rotates too slowly If the starter only emits a clicking sound,- either the magnetic switch is defect If the starter only emits a clicking sound Frequently a jammed return mechanism is the reason for a starter failure. Occasionally worn contacts are found on the magnetic return switch Defects on the actual starter motor including pinion and carbon brushes are very rare. With a trouble shooting chart the faults in the starter system can be narrowed down. The starter system can only work when many conditions are fulfilled at the same time. l Immobilizer deactivated? l Immobilizer deactivated? l Ignition switch OK? l Travel lever in correct position? l Emergency stop not actuated? l Battery sufficiently charged? l Battery poles OK? l Main battery fuse OK? l Main battery switch closed? l Main starter cable (terminal 30) OK? l Starter control cable (terminal 50) OK, voltage drop? l Ground cable OK? l Switching of magnetic switches OK? The sequence of these tests is generally of no significance. It mainly depends on: l the experience of the specialist l the experience of the specialist l the failure probability of the component to be tested and the testing effort for the respective part. Only if all criteria mentioned above are OK, the fault must be in the starter itself. In this case it can be repaired or replaced. Testing and measuring the starter Function control with the starter removed Function control with the starter removed Fasten the starter to make sure that it will not come loose during the test. Fasten the starter to make sure that it will not come loose during the test. Fig. 13 l Connect a jumper lead between start terminal (1) and battery plus (2). l Connect a jumper lead between start terminal (1) and battery plus (2). l Connect a jumper cable instantaneously between starter housing and battery minus (3). If the motor does not start, the starter is defective. Repair or replace the starter. If the motor does not start, the starter is defective. Repair or replace the starter. Checking the magnetic switch Checking the magnetic switch Fig. 14 l Connect a jumper lead between start terminal (1) and battery plus (2). l Connect a jumper lead between start terminal (1) and battery plus (2). l Connect a jumper cable instantaneously between starter housing and battery minus (3). If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter. If the pinion does not disengage, the magnetic switch is defective. Repair or replace the starter. Continuity test for the magnetic switch Continuity test for the magnetic switch Fig. 15 l Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed. l Use a continuity tester to check for continuity between terminal (1) and terminal (29 while holding the pin depressed. l Replace the magnetic switch if no continuity is detected. 9 Engine 9 Engine 9.9 Check, adjust the valve clearance 9.1 Diesel engine The MPH 122-2 is driven by a V6 cylinder Deutz diesel engine series TCD 2015. The MPH 122-2 is driven by a V6 cylinder Deutz diesel engine series TCD 2015. These engines are V-type engines with water cooling, whereby the cylinder banks are arranged to each other under a 90� angle. The engines are designed in four-valve technology with turbo charging and intercooler. They are extremely compact and are fitted with a solenoid valve controlled electronic injection system (MVS). Emission limit values acc. to EPA The engines are designed with exhaust gas recirculation. The engines are characterized by the following positive features: l compact design l compact design l low noise level l almost vibration free operation l low fuel consumption l low exhaust emission EPA l high power density l excellent access to all service locations. l high reliability l low running costs, l long lifetime Fig. 1 Deutz diesel engine TCD 2015 9.9 Check, adjust the valve clearance 9.2 Engine description TCD 2015 V 6 cylinder Fig. 1 Deutz diesel engine TCD 2015 V06 right hand side 1 Crankcase ventilation 1 Crankcase ventilation 2 Connection to coolant heat exchanger 3 Pre-heating plug 4 Connection from intercooler 5 Connection to intercooler 6 Connection from coolant heat exchanger 7 Lubrication oil filter cartridge 8 Coolant pump 9 Connection from separate lubrication oil tank 10 Connection to separate lubrication oil tank 11 Vibration damper 12 Generator 13 Engine type plate (company plate) 14 Exhaust manifold 15 Connection to EMR3 system 16 Connection to MVS system 17 Connection from air filter 18 Cylinder head cover 19 Connection to exhaust silencer 20 Exhaust turbo charger 21 Charge air suction line 22 Transport device Fig. 2 Deutz diesel engine TCD 2015 V06 left hand side 23. Auxiliary drive 24. Engine suspension 25. Transmission connection (SAE) 26. Flywheel 27. free auxiliary drive 28. Crankcase ventilation line 29. Lubrication oil cooler 30. Injection pump (plug-type pump) 31. Injection line 9.9 Check, adjust the valve clearance 9.3 Lubrication oil circuit TCD 2015 Fig. 1 Lubrication oil schematic 1 Lubrication oil sump 1 Lubrication oil sump 2 Lubrication oil suction pipe 3 Lubrication oil pump 4 Pressure relief valve 5 Lubrication oil cooler 6 Lubrication oil filter 7 Main oil galleries 8 Crankshaft bearings 9 Conrod bearings 10 Camshaft bearings 11 Oil flow to individual injection pumps 12 Injection pump with injection valve 13 Camshaft lubrication 14 Line to spray nozzle 15 Spray nozzle with pressure retaining valve for piston cooling 16 Plunger with rocker arm pulse lubrication 17 Push rod, oil supply to rocker arm lubrication 18 Rocker arm 19 Oil return bore in cylinder head leading to crankcase 20 Oil pressure sensor 21 Oil line to exhaust turbo charger 22 Exhaust turbo charger 23 Oil line to crankshaft and camshaft, compressor 24 Compressor (optional) 25 Hydraulic pump (optional) 26 Pressure retaining valve (adjustable) 27 Return flow from compressor 28 Return flow from exhaust turbo charger 9.9 Check, adjust the valve clearance 9.4 Coolant circuit TCD 2015 Fig. 1 Coolant diagram 1 Coolant pump 1 Coolant pump 2 Lubrication oil cooler 3 Coolant channel 4 Cooling of cylinder liner 5 Compressor (optional) 6 Transmission oil cooler (optional) 7 Additional cooler (optional) 8 Temperature sensor 9 Thermostat 10 Compensation tank 11 Filler socket 12 Heat exchanger 13 Cabin heater (optional) 9.9 Check, adjust the valve clearance 9.5 Fuel circuit TCD 2015 Fig. 1 Fuel diagram 1 Fuel tank 1 Fuel tank 2 min. distance 500 mm 3 Fuel supply line from tank 4 Manual priming pump for bleeding 5 Fuel pre-filter (example) 6 Fuel priming pump 7 Fuel twin filter 8 Fuel supply line to injection pumps 9 Injection pump 10 Injection line 11 Injection valves 12 Fuel supply line to injection pumps 13 Fuel return line from injection pumps 14 Pressure retaining valve 15 Fuel return line to fuel tank Fuel pre-filter Fuel pre-filter Fig. 2 Fuel pre-filter 1 Filter bracket 1 Filter bracket 2 Filter cartridge 3 Water collecting bowl 4 Electric connection 5 Drain plug 6 Manual fuel pump 7 Bleeding screw 8 Sealing face A Electric water level sensor Fuel filter system Fig. 3 Fuel pre-filter 1 Fuel pressure filter, min. 3�m 1 Fuel pressure filter, min. 3�m 2 Bleeding screws 3 Fuel pre-filter 4 additional hand pump 9.9 Check, adjust the valve clearance 9.6 Injection system (MVS) TCD 2015 The solenoid valve system (MVS) is a new fully electronically controlled diesel injection system without mechanical link to the operator (no governor rod). In contrast to conventional injection systems the MVS enables an absolutely unrestricted contr... The solenoid valve system (MVS) is a new fully electronically controlled diesel injection system without mechanical link to the operator (no governor rod). In contrast to conventional injection systems the MVS enables an absolutely unrestricted contr... The MVS consists of a pump with solenoid valve and injection nozzle for each individual cylinder. The solenoid valve closes the fuel bypass in the plunger chamber, thus causing an increase in injection pressure and finally triggers the injection when the nozzle opening pressure is reached. If injection is to be ended, the valve will open the bypa... The solenoid valves are triggered by the electronic control unit in dependence on the operatig parameters. The system is capable of providing a wide range of limp-home functions, should any of the sensors fail. This ensures a reliable and safe comple... Fig. 1 MVS - Injection system TCD 2015 Fig. 2 Electrics of TCD 2015 1 Oil pressure sensor 1 Oil pressure sensor 2 Fuel temperature sensor 3 Sensor for charge air temperature and charge air pressure 4 Engine control unit 5 Coolant temperature sensor 6 Oil level sensor 7 Central plug 8 Rotary speed sensor for crankshaft 9 Rotary speed sensor for camshaft 10 Power supply 11 Multi-function display 12 Outputs (configurable) 13 Inputs (configurable) (PWM 14 Travel pedal 15 Manual throttle (optional) 16 Changeover function 17 Key switch Start 18 Diagnostics push button 19 Fault lamp with flashing code 20 Diagnostics interface Injection pump with solenoid valve Fig. 3 Pump Fig. 4 Injection pump and nozzle 9.9 Check, adjust the valve clearance 9.7 Exhaust gas recirculation TCD 2015 In order to be able to meet the exhaust gas standards EC and stage In order to be able to meet the exhaust gas standards EC and stage On 6 and 8 cylinder engines TCD 2015 the exhaust gas recirculation has been realized internally through the exhaust valves. For this purpose the camshaft has been manufactured with an additional cam for short-term opening of the exhaust valve Fig. 1 Exhaust valve control TCD 2015 9.9 Check, adjust the valve clearance 9.8 Wastegate - charge pressure controller on TCD-engines The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbocharger The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbocharger The Wastegate (exhaust gas bypass valve) is used to control the charge pressure The charge pressure control takes place by means of a charge pressure triggered pressure valve in connection with the exhaust gas bypass valve. Depending on this bypass valve hot exhaust gases flow past the exhaust gas turbine into the exhaust withou... The bypass valve is normally closed Fig. 1 Exhaust gas turbocharger with Wastegate Wastegate active, charge pressure control, i.e. bypass valve open Fig. 1 Exhaust gas turbocharger with Wastegate Wastegate on TCD 2013 Fig. 2 Exhaust gas turbocharger with Wastegate 9.9 Check, adjust the valve clearance 9.9 Check, adjust the valve clearance We recommend to have this work carried out by trained personnel or our after sales service. We recommend to have this work carried out by trained personnel or our after sales service. We recommend to have this work carried out by trained personnel or our after sales service. Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine oil temperature must be less than 80 �C. Fig. 3 l Remove all valve covers l Remove all valve covers (Fig. 3) Fig. 4 Adjustment diagram Adjustment diagram (Fig. 4) Valves Valves Cylinder Cylinder overlapping overlapping A1 A1 B3 B3 A3 A3 B2 B2 A2 A2 B1 B1 adjustment adjustment B2 B2 A2 A2 B1 B1 A1 A1 B3 B3 A3 A3 l Turn the crankshaft until the valves are overlapping. l Turn the crankshaft until the valves are overlapping. This engine is equipped with an internal exhaust recirculation system. During the intake cycle the exhaust valve opens for a short moment. This engine is equipped with an internal exhaust recirculation system. During the intake cycle the exhaust valve opens for a short moment. This must not be mistaken as overlapping of valves! Fig. 5 Check the valve clearance Check the valve clearance l Intake valves 0,25 mm l Intake valves 0,25 mm l Exhaust valves 0,30 mm l A feeler gauge of appropriate thickness (1) must fit with little resistance between rocker arm (2) (Fig. 5) l If the gap is too narrow or too wide for the feeler gauge, the valve must be adjusted. Adjusting the valve clearance Adjusting the valve clearance l Loosen counter nut (4) l Loosen counter nut (4) (Fig. 5) l Adjust the setscrew (5) with a screwdriver, until the feeler gauge can be inserted and pulled out with little resistance after retightening the counter nut. l Repeat the adjustment procedure on each cylinder. Fig. 6 l Assemble all cylinder nead covers with new gaskets l Assemble all cylinder nead covers with new gaskets (Fig. 6) After a short test run check the engine for leaks. After a short test run check the engine for leaks. 9.10 Checking the engine oil level 9.10 Checking the engine oil level The machine must be in horizontal position. The machine must be in horizontal position. The machine must be in horizontal position. If the engine is warm, shut it down and check the oil level after five minutes. With a cold engine the oil level can be checked immediately. For quality of oil refer to the table of fuels and lubricants. Fig. 7 l Pull out the dipstick l Pull out the dipstick (Fig. 7) l Reinsert the oil dipstick until it bottoms and pull it out again. l The oil level must always be between the "MIN"- and "MAX"-marks, fill up oil if necessary. 9.11 Changing engine oil and oil filter cartridge 9.11 Changing engine oil and oil filter cartridge Danger of scalding! Danger of scalding! Danger of scalding! When draining off hot oil. By hot oil when unscrewing the engine oil filter. Drain the oil only when the engine is warm. Drain the oil only when the engine is warm. For quality and quantity of oil refer to the "table of fuels and lubricants". Catch running out oil and dispose of environmentally together with the oil filter cartridge. Catch running out oil and dispose of environmentally together with the oil filter cartridge. Fig. 8 l Unscrew the cap from the oil drain socket l Unscrew the cap from the oil drain socket (Fig. 8) l Drain off and catch the engine oil. l Screw the cap back on after the oil has run out. Fig. 9 l Loosen and unscrew the engine oil filter cartridge l Loosen and unscrew the engine oil filter cartridge (Fig. 9) l Wipe the sealing face clean. l Cover the rubber seal of the new engine oil filter slightly with clean oil. l Spin the new engine oil filter cartridge on and tighten it hand tight. Fig. 10 l Fill in new engine oil l Fill in new engine oil (Fig. 10) l Screw the cap back on again. l Screw the cap back on again. l Perform a short test run and check the oil level on the dipstick, correct the oil level as necessary. 9.12 Check the coolant level 9.12 Check the coolant level Danger of scalding! Danger of scalding! Danger of scalding! Open the cap on the coolant compensation tank only when the engine is cold. If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. If, during the daily inspection the coolant level is found to have dropped, check all lines, hoses and engine for leaks. Do not use radiator sealant to seal leaks. For coolant refer to the "table of fuels and lubricants". Fig. 11 A too low coolant level is indicated by the coolant level warning light (f) A too low coolant level is indicated by the coolant level warning light (f) (Fig. 11) l Open the upper left hand maintenance door. l Open the upper left hand maintenance door. Fig. 12 l Unscrew the filler cap l Unscrew the filler cap (Fig. 12) l Screw the cover back on again. 9.13 Checking the condition of the coolant 9.13 Checking the condition of the coolant In case of lubrication oil entering into the cooling system or a suspicious turbidity caused by corrosion residues or other suspended matter, the coolant must be drained off and the complete cooling system needs to be cleaned. Lubrication oil can dam... In case of lubrication oil entering into the cooling system or a suspicious turbidity caused by corrosion residues or other suspended matter, the coolant must be drained off and the complete cooling system needs to be cleaned. Lubrication oil can dam... In case of lubrication oil entering into the cooling system or a suspicious turbidity caused by corrosion residues or other suspended matter, the coolant must be drained off and the complete cooling system needs to be cleaned. Lubrication oil can dam... Environmental damage! Environmental damage! Do not let engine coolant and cleansing fluid seep into the ground, but dispose of environmentally. Cooling system soiled by corrosion residues or other suspended matter (no contamination by lubrication oil) Cooling system soiled by corrosion residues or other suspended matter (no contamination by lubrication oil) l Drain all coolant off, see section �changing coolant�. l Drain all coolant off, see section �changing coolant�. l Fill in clean water l Start the engine and flush the cooling system out for a short while l Drain all water off l Fill the cooling system with coolant. For coolant quantity refer to the table of fuels, lubricants and filling capacities. Soiled cooling system with proportions of lubrication oil (oil film on coolant) Soiled cooling system with proportions of lubrication oil (oil film on coolant) l Drain all coolant off, see section �changing coolant�. l Drain all coolant off, see section �changing coolant�. l Prepare a cleaning mixture of clean water and cleansing agent P3 Standard or P3T 5124. Mixing ratio: 50 grams cleansing agent for 1 litre of water. Stir the cleansing mixture well. Stir the cleansing mixture well. Fig. 13 l Remove thermostat cover 2 l Remove thermostat cover 2 (Fig. 13) l Reassemble the thermostat cover. l Fill the cooling system with cleansing mixture. l Start the engine and run it until a water temperature of approx. 90 �C is reached. l Maintain this temperature for about 5 minutes. l Shut the engine down and let the water cool down to a temperature of approx. 50 �C. l Drain all cleansing mixture off. l Fill the cooling system 2x after each other with clear water and flush for about 5 minutes with the engine running. l Drain all water off. l Reinstall the thermostat (Fig. 13) l Fill the cooling system with coolant. For coolant quantity refer to the table of fuels, lubricants and filling capacities. 9.14 Checking 9.14 Checking Danger of scalding! Danger of scalding! Danger of scalding! Change the coolant only when the engine is cold. Do not start the engine after draining off the coolant. Do not start the engine after draining off the coolant. When changing the coolant without any signs of contamination, cleaning of the cooling system is not necessary. Catch coolant and dispose of environmentally. Catch coolant and dispose of environmentally. Fig. 14 l Unscrew the radiator cap l Unscrew the radiator cap (Fig. 14) Fig. 15 l Unscrew the plug from the drain cock l Unscrew the plug from the drain cock (Fig. 15) l Guide the drain hose into a vessel of appropriate size. l Open the drain cock and let the coolant run out. l Once all coolant has run out close the drain cock, remove the drain hose and screw the plug back on. l Fill coolant in through the opening in the compensation tank (Fig. 14) For coolant quantity refer to the table of fuels, lubricants and filling capacities. l Close the compensation tank. For bleeding start the engine and run it warm. l Close the compensation tank. For bleeding start the engine and run it warm. l Check the coolant level, top up if necessary. Fig. 16 l The coolant level must reach the edge of the filler neck, top up if necessary l The coolant level must reach the edge of the filler neck, top up if necessary (Fig. 16) 9.15 Check, clean the water separator 9.15 Check, clean the water separator Fire hazard! Fire hazard! Fire hazard! When working on the fuel system do not use open fire, do not smoke. Catch running out fuel and dispose of environmentally. Catch running out fuel and dispose of environmentally. The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should check the filter bowl initially every day, later as required, for s... The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should check the filter bowl initially every day, later as required, for s... If a too high quantity is drained off, the filter needs to be bled, see section "Replacing the fuel pre-cleaner cartridge". Fig. 17 If the warning light for water in the fuel (d) If the warning light for water in the fuel (d) (Fig. 17) l Open the right hand service door. l Open the right hand service door. Fig. 18 l Slacken the drain plug l Slacken the drain plug (Fig. 18) l Turn the plug tightly back in. Check for leaks, if necessary use a new seal ring. Once the water separator is empty the warning light for water in fuel must go out. Once the water separator is empty the warning light for water in fuel must go out. 9.16 Changing the fuel filter 9.16 Changing the fuel filter Fire hazard! Fire hazard! Fire hazard! When working on the fuel system do not use open fire, do not smoke, do not spill any fuel. Health hazard! Health hazard! Do not inhale any fuel fumes. Ensure strict cleanliness! Thoroughly clean the area around the fuel filters. Ensure strict cleanliness! Thoroughly clean the area around the fuel filters. After work on the fuel system bleed the system, perform a test run and check for leaks. Additional bleeding of the fuel system by a 5 minute test run in idle speed or low load is mandatory. Catch running out fuel and dispose of environmentally together with the fuel filters. Catch running out fuel and dispose of environmentally together with the fuel filters. l Open the right hand engine compartment cover. l Open the right hand engine compartment cover. Fig. 19 l Loosen and unscrew the fuel filter cartridge l Loosen and unscrew the fuel filter cartridge (Fig. 19) l Clean the sealing face on the filter carrier from any dirt. l Clean the sealing face on the filter carrier from any dirt. The filter cartridge must never be filled beforehand. The filter cartridge must never be filled beforehand. l Slightly oil the rubber seal on the new filter cartridge. l Slightly oil the rubber seal on the new filter cartridge. l Screw the new filter with seal ring on by hand, until the seal contacts, then tighten for half a turn. l Screw the new filter with seal ring on by hand, until the seal contacts, then tighten for half a turn. l Always bleed the fuel system after changing the fuel pre-filter cartridge (see next chapter). l Check for leaks after a short test run. l Check for leaks after a short test run. 9.17 Replacing the fuel pre-filter cartridge, bleed the fuel system 9.17 Replacing the fuel pre-filter cartridge, bleed the fuel system Fire hazard! Fire hazard! Fire hazard! When working on the fuel system do not use open fire, do not smoke and do not spill any fuel. Health hazard! Health hazard! Do not inhale any fuel fumes. Ensure strict cleanliness! Thoroughly clean the area around the fuel filters. Ensure strict cleanliness! Thoroughly clean the area around the fuel filters. After work on the fuel system bleed the system, perform a test run and check for leaks. Additional bleeding of the fuel system by a 5 minute test run in idle speed or low load is mandatory. Catch running out fuel and dispose of environmentally. Catch running out fuel and dispose of environmentally. Change the fuel pre-filter cartridge Change the fuel pre-filter cartridge Fig. 20 l (1) Shut down the engine l (1) Shut down the engine (Fig. 20) l (2) Pull the cable off the water separator. Loosen the bleeding screw and drain off fuel from the bleeding screw. l (3) Loosen and unscrew the fuel pre-filter cartridge using an appropriate filter wrench. l (4) Unscrew the water separator from the filter cartridge. l (5) Apply a thin coat of oil to the rubber seal of the water separator. l (6) Turn the water separator on by hand, until the seal contacts, then tighten hand-tight. l (7) Apply a thin coat of oil to the rubber seal of the filter element. l (8) Turn the filter cartridge on by hand, until the seal contacts, then tighten hand-tight. Plug the cable of the water sensor back on. Bleed the fuel system Bleed the fuel system Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible. Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible. Therefore bleed the fuel system after changing the fuel pre-filter or working on the fuel system. Fig. 21 l Slacken the bleeding screw (1) l Slacken the bleeding screw (1) (Fig. 21) l Operate the fuel hand pump (2) manually, until fuel flows out of the loosened bleeding screw without air bubbles. l Operate the fuel hand pump (2) manually, until fuel flows out of the loosened bleeding screw without air bubbles. l Then tighten the bleeding screw while pumping. l Slacken the bleeding screws on the fuel pre-filters for 2 to 3 turns. l Operate the fuel hand pump (2) manually, until fuel flows out of the loosened bleeding screws without air bubbles. l Then tighten the bleeding screws while pumping. l Start the engine and run it 5 minutes with idle speed. 9.18 Cleaning, changing the dry air filter cartridge 9.18 Cleaning, changing the dry air filter cartridge Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element. Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element. Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element. Fig. 22 Maintenance of the dry air filter is due when air filter control light (e) (Fig. 22) Once the air filter warning light lights up, work may be continued until the end of the day. Once the air filter warning light lights up, work may be continued until the end of the day. Do not clean the safety cartridge, but replace immediately. Do not clean the safety cartridge, but replace immediately. Fig. 23 l Unscrew wing nut (1) l Unscrew wing nut (1) (Fig. 23) Fig. 24 l Unscrew hexagon nut (1) l Unscrew hexagon nut (1) (Fig. 24) l The safety cartridge remains in the housing. l The safety cartridge remains in the housing. Cleaning the main filter element Cleaning the main filter element If necessary, the main filter element may be cleaned up to five times. It must be renewed at the latest after a maximum utilization period of two years. If necessary, the main filter element may be cleaned up to five times. It must be renewed at the latest after a maximum utilization period of two years. The number of cleaning intervals of the main filter element can be marked on the safety element with a ball pen or a felt pen. Cleaning does not make sense if the main filter cartridge is covered with a sooty deposit. Use a new filter cartridge. Incorrectly handled filter cartridges may become ineffective because of damage (e.g. cracks) and cause damage to the engine. Replace the safety cartridge if the main filter element is defective! Additional cleaning intervals between two filter services signalized by the fault monitoring board are not necessary. Fig. 25 l Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar) l Blow the filter cartridge out from inside to outside with dry compressed air (max. 5 bar) (Fig. 25) Fig. 26 l Examine the filter cartridge with a torch for cracks and holes in the paper bellows l Examine the filter cartridge with a torch for cracks and holes in the paper bellows (Fig. 26) Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element. Do not continue to run the machine with a damaged main filter element. If in doubt use a new main filter element. Cleaning the dust bowl Cleaning the dust bowl Fig. 27 l Remove the insert l Remove the insert (Fig. 27) l Wipe the filter housing out with a cloth. Do not clean with compressed air. l Reinsert the element. Changing the safety filter element Changing the safety filter element The safety filter element must not be cleaned and should not be used again after it has been removed. The safety filter element must not be cleaned and should not be used again after it has been removed. Break the seal only to replace the safety filter element. The safety filter element must be replaced, if the main filter element is defective, after five times cleaning of the main filter element, at the latest after 2 years, if the air filter warning light in the instrument cluster comes on again after the main filter element has been serviced. Fig. 28 l Unscrew hexagon nut 1 l Unscrew hexagon nut 1 (Fig. 28) l Insert a new safety cartridge and fasten it with a new fastening nut. l Insert a new safety cartridge and fasten it with a new fastening nut. l Insert the element into the filter housing. l Insert a new main filter cartridge and fasten it with a new fastening nut. l Screw the cover on. 9.19 Servicing the generator V-belt 9.19 Servicing the generator V-belt Danger of injury! Danger of injury! Danger of injury! Work on the V-belt drive must only be performed with the engine shut down. Check the V-belt Check the V-belt Fig. 29 l Inspect the entire circumference of the V-belt l Inspect the entire circumference of the V-belt (Fig. 29) Check the V-belt tension Check the V-belt tension A belt tension meter is required to check the V-belt tension. A belt tension meter is required to check the V-belt tension. Fig. 30 l Lover the indicator arm (1) l Lover the indicator arm (1) (Fig. 30) l Rest the guide (3) on the V-belt (2) between two belt pulleys. The stop should abut against the side. l Evenly press the button (4) under a right angle to the V-belt (2), until the spring engages audibly and noticeably. l Lift the meter carefully without changing the position of the indicator arm (1). l Read the measuring value at the intersecting point (arrow), scale (5) and indicator arm (1). Retighten the V-belt Retighten the V-belt Fig. 31 l Loosen screws (2) l Loosen screws (2) (Fig. 31) l Tighten the screw (1) clockwise, until the required belt tension is reached. l Retighten screws (2). Changing the V-belt Changing the V-belt l Loosen screws (2) l Loosen screws (2) (Fig. 31) l Loosen screw (1). l Remove the belt and install a new one. l Tighten the screw (1) clockwise, until the required belt tension is reached. l Retighten screws (2). Retighten new V-belts after a running time of 15 minutes. Retighten new V-belts after a running time of 15 minutes. 9.20 Check the engine mounts 9.20 Check the engine mounts l Check all fastening screws on the engine mounts for tight fit, tighten if necessary. l Check all fastening screws on the engine mounts for tight fit, tighten if necessary. l Check all fastening screws on the engine mounts for tight fit, tighten if necessary. 9.21 Check the fastening of engine 9.21 Check the fastening of engine Fig. 32 l Check charge air line l Check charge air line (Fig. 32) l Check exhaust pipe and lubrication oil line to and from the exhaust turbo charger for tight fit and leaks. l Check connecting sockets for tight fit. l Check combustion air pipe and connecting sockets for leak tightness and tight fit . l Check combustion air pipe and connecting sockets for leak tightness and tight fit . 9.22 Cleaning the intercooler 9.22 Cleaning the intercooler Fig. 33 l Open the cleaning flaps l Open the cleaning flaps (Fig. 33) Fig. 34 l Remove dried on dirt with a suitable brush l Remove dried on dirt with a suitable brush (Fig. 34) Fig. 35 l Blow the cooling air channels out with compressed air l Blow the cooling air channels out with compressed air (Fig. 35) l In case of oily contamination spray the parts with cold cleansing agent and spray it off with a water jet after s sufficient soaking time. l In case of oily contamination spray the parts with cold cleansing agent and spray it off with a water jet after s sufficient soaking time. l If steam cleaning equipment is available, this should preferably be used. l If steam cleaning equipment is available, this should preferably be used. l After wet cleaning run the engine warm to evaporate all water residues and to avoid corrosion. l After wet cleaning run the engine warm to evaporate all water residues and to avoid corrosion. l Close the engine cover. l Close the engine cover. Fig. 36 If the charge air temperature warning light (c) If the charge air temperature warning light (c) (Fig. 36) 9.23 Intercooler, draining off oil 9.23 Intercooler, draining off oil Do this work at least once every year. Do this work at least once every year. Do this work at least once every year. Environmental damage Environmental damage Catch running out fluid, do not let it seep into the ground and dispose off environmentally. l Open the left hand engine compartment door. l Open the left hand engine compartment door. Fig. 37 l Unscrew the drain plug l Unscrew the drain plug (Fig. 37) 9.24 Checking the crankcase pressure 9.24 Checking the crankcase pressure Excessive pressure in the crankcase can cause lubrication oil leaks on all seals. Excessive pressure in the crankcase can cause lubrication oil leaks on all seals. Excessive pressure in the crankcase can cause lubrication oil leaks on all seals. This may be caused by a not correctly functioning crankcase ventilation. Moreover, too high crankcase pressure can also cause damage to the exhaust turbocharger and the complete engine. l Pull out the oil dipstick . l Pull out the oil dipstick . Fig. 38 l Connect the U-pipe pressure gauge (1) l Connect the U-pipe pressure gauge (1) (Fig. 32) l Make sure that the connection is tightly sealed! l Fill half of the U-pipe pressure gauge with water. l Fasten the U-pipe pressure gauge at a quiet location (e.g. on the wall). l Run the engine up to operating temperature. l Run the engine at high idle or under full load. l Read the pressure on the fine measurement or U- pipe pressure gauge. Nominal value Nominal value high idle speed: high idle speed: max. 20 mm water column max. 20 mm water column full load: full load: max. 50 mm water column max. 50 mm water column If the pressure exceeds the permissible crankcase pressure you should perform troubleshooting and rectify the fault. If the pressure exceeds the permissible crankcase pressure you should perform troubleshooting and rectify the fault. 9.25 Replacing the crankcase ventilation valve 9.25 Replacing the crankcase ventilation valve Fig. 39 l Replace the crankcase ventilation valve l Replace the crankcase ventilation valve (Fig. 39) 9.26 General trouble shooting chart TCD 2015 Faults Faults Causes Causes Action Action Engine does not start or starts poorly Engine does not start or starts poorly Temperature below starting limit Temperature below starting limit Engine oil with wrong SAE viscosity class Engine oil with wrong SAE viscosity class Change the lubrication oil Change the lubrication oil Fuel quality not as specified in the operating instructions Fuel quality not as specified in the operating instructions Change the fuel Change the fuel Air in the fuel system Air in the fuel system Bleed the fuel system Bleed the fuel system Battery defective or not charged Battery defective or not charged Check the battery Check the battery Cable to starter loose or oxidized Cable to starter loose or oxidized Check cable connection Check cable connection Starter defective or pinion does not engage Starter defective or pinion does not engage Check starter Check starter Engine does not start and diagnostic lamp flashing Engine does not start and diagnostic lamp flashing Engine electronics prevent starting Engine electronics prevent starting Check fault by fault code, repair as necessary Check fault by fault code, repair as necessary Engine starts, but runs irregularly or misfires Engine starts, but runs irregularly or misfires Fuel quality not as specified in the operating instructions Fuel quality not as specified in the operating instructions Change the fuel Change the fuel Injection line leaking Injection line leaking Check the injection line Check the injection line Injection valve defective Injection valve defective Check the injection valve Check the injection valve Speed changes are possible and diagnostic lamp lights Speed changes are possible and diagnostic lamp lights Engine electronics detected a system fault and activates a substitute speed Engine electronics detected a system fault and activates a substitute speed Check fault by fault code, repair as necessary Check fault by fault code, repair as necessary Engine overheating. Temperature warning system responds Engine overheating. Temperature warning system responds Oil level too low Oil level too low Fill up lubrication oil Fill up lubrication oil Engine oil level too high Engine oil level too high Check oil level, drain off if necessary Check oil level, drain off if necessary Air filter clogged Air filter clogged Check Check Air filter service switch Air filter service switch Check Check Fan defective Fan defective Check fan Check fan Short circuit of heat in cooling system Short circuit of heat in cooling system Check the cooling system Check the cooling system Resistance in cooling system too high Resistance in cooling system too high Check the cooling system Check the cooling system Insufficient engine power Insufficient engine power Engine oil level too high Engine oil level too high Check the oil level Check the oil level Fuel quality not as specified in the operating instructions Fuel quality not as specified in the operating instructions Change the fuel Change the fuel Air filter clogged Air filter clogged Check Check Air filter service switch Air filter service switch Check Check Charge air pipe leaking Charge air pipe leaking Check the charge air pipe Check the charge air pipe Injection line leaking Injection line leaking Check the injection line Check the injection line Injection valve defective Injection valve defective Check the injection valve Check the injection valve Insufficient engine power and diagnostic lamp lights Insufficient engine power and diagnostic lamp lights Engine electronics reducing the output power Engine electronics reducing the output power Check fault by fault code, repair as necessary Check fault by fault code, repair as necessary Engine does not work with all cylinders Engine does not work with all cylinders Injection line leaking Injection line leaking Check the injection valve Check the injection valve Injection valve defective Injection valve defective Check the injection valve Check the injection valve Engine has to low or no oil pressure Engine has to low or no oil pressure Oil level too low Oil level too low Fill up lubrication oil Fill up lubrication oil Extremely slanted position of engine Extremely slanted position of engine Check engine pillow blocks Check engine pillow blocks Engine oil of wrong SAE class or quality Engine oil of wrong SAE class or quality Change the lubrication oil Change the lubrication oil Engine has excessive oil consumption Engine has excessive oil consumption Engine oil level too high Engine oil level too high Check oil level, drain off if necessary Check oil level, drain off if necessary Extremely slanted position of engine Extremely slanted position of engine Check engine pillow blocks Check engine pillow blocks Blue engine exhaust smoke Blue engine exhaust smoke Engine oil level too high Engine oil level too high Check oil level, drain off if necessary Check oil level, drain off if necessary Extremely slanted position of engine Extremely slanted position of engine Check engine pillow blocks Check engine pillow blocks White engine exhaust smoke White engine exhaust smoke Temperature below starting limit Temperature below starting limit Fuel quality not as specified in the operating instructions Fuel quality not as specified in the operating instructions Change the fuel Change the fuel Injection valve defective Injection valve defective Check the injection valve Check the injection valve Black engine exhaust smoke Black engine exhaust smoke Air filter clogged Air filter clogged Check Check Air filter service switch Air filter service switch Check Check Charge air pipe leaking Charge air pipe leaking Check the charge air pipe Check the charge air pipe Injection valve defective Injection valve defective Check the injection valve Check the injection valve 9.27 Special tools, Deutz engine (TCD 2015) 10 Air conditioning system 10 Air conditioning system 10.1 Physical basics In order to understand the working principle of an air conditioning system one must first become familiar with the physical basics of such a system. In order to understand the working principle of an air conditioning system one must first become familiar with the physical basics of such a system. The four well known physical conditions of water apply also for the refrigerant in the air conditioning system. 1. gaseous (invisible) 2. vaporous 3. liquid 4. solid Fig. 1 If the water in a container is heated up (absorption of heat), the rising steam is visible. If the steam is heated up further, due to the absorption of heat, the visible steam will turn into invisible gas. This process is reversible. When withdrawing... A - heat absorption A - heat absorption B- Heat dissipation Fig. 2 Heat always flows from the warmer to the colder matter. Any matter consists of a mass of moving molecules. The rapidly moving molecules or a warmer matter dissipate part of their energy to the slower moving molecules with less heat. The movement of t... Pressure and boiling point The boiling point is the temperature at which fluid changes to gaseous state. Changing the pressure above a fluid also changes the boiling point. It is a well known fact, that e.g. the lower the pressure applied to water, the lower the boiling point. When looking at water, the following values do apply: l Atmospheric pressure, boiling point 100�C l Atmospheric pressure, boiling point 100�C l Overpressure 0.4 bar, boiling point 126�C l Vacuum -0.6 bar, boiling point 71�C For an optimal exchange of heat, liquid refrigerants must have a low boiling point, so that they can absorb and dissipate heat quickly. Fig. 3 Steam pressure curve Steam pressure curve for refrigerant R134a The steam pressure curve is a means for explaining the operation principle of an air conditioning system. A- liquid B- gaseous The diagram shows the evaporation curve of R134a. The diagram for example shows, that R134a is liquid at 0�C and a pressure of 5 bar, but becomes gaseous at 40�C and 5 bar. For better understanding one must also be aware of the following: 1. A gas heats up when being compressed (e.g. air pump, turbo charger, ...). 2. When relieving gas it will cool down (e.g. white frost forms on the valve when relieving air pressure from a car tire). 3. Condensing gas dissipates a lot of heat energy. 4. If a fluid evaporates it requires a lot of heat, i.e. the fluid thereby cools down the surrounding environment (e.g. alcohol on skin) At absolute pressure 0 bar correspond with an absolute vacuum. The normal ambient pressure (overpressure) corresponds with 1 bar absolute pressure. On the scales of most pressure gauges 0 bar corresponds with an absolute pressure of 1 bar (indicated ... At absolute pressure 0 bar correspond with an absolute vacuum. The normal ambient pressure (overpressure) corresponds with 1 bar absolute pressure. On the scales of most pressure gauges 0 bar corresponds with an absolute pressure of 1 bar (indicated ... Fig. 4 Pressure - Temperature Diagram In the pressure - temperature diagram for the refrigerant the drawn in closed curve shows the cycle of the refrigerant. This cycle permanently continues in direction of the arrow. The characters A, B, C, D stand for: A - compression B- condensation C- relaxation D- evaporation. Excerpt from the wet steam table Excerpt from the wet steam table This table is used for the determination of evaporation and condensation temperature. Saturation temperature Saturation temperature Overpressure (pressure gauge reading Pe in bar) Overpressure (pressure gauge reading Pe in bar) Absolute pressure (pamb = 1 bar P in bar) Absolute pressure (pamb = 1 bar P in bar) -20 -20 0,33 0,33 1,33 1,33 -10 -10 1,01 1,01 2,01 2,01 0 0 1,93 1,93 2,93 2,93 10 10 3,15 3,15 4,15 4,15 20 20 4,72 4,72 5,72 5,72 10.2 Refrigerant R134a General General The evaporation and condensation process is the method commonly used in mobile air conditioning systems. The system in this case works with a substance that boils at low temperature, a substance referred to a refrigerant. The refrigerant used is tetr... Although the refrigerant circuit is a hermetically closed loop, the system loses approx. 100g of refrigerant over the course of 1 year by diffusion through hoses, pipes and seals, even though the system is free of leaks. If too much refrigerant is lo... Physical data of the refrigerant R134a Chemical formula: CH2F-CF3 or CF3-CH2F Chemical designation: Tetrafluoroethane Boiling point at 1 bar: - 26.5 �C Solidification point: -101.6 �C Critical temperature: 100,6 �C Critical pressure: 40.56 bar (absolute) Critical point: Critical point (critical temperature and critical pressure) means that above this point there is no separating interface between liquid and gas. Above its critical point any substance is gaseous. At temperatures below the critical point all refrigera... Characteristics of the refrigerant R134a: Refrigerant R134a is currently available under the following trade marks. H-FKW 134a SUVA 134a KLEA 134a Colour: Refrigerant in form of vapour or liquid is colourless as water. The gas is invisible. Only the bordering layer between gas and liquid is visible. (Fluid level in rising pipe of filling cylinder or bubbles in inspection glass). In the inspection glass... Steam pressure: In an incompletely filled, closed container, vaporous refrigerant will volatilize from the surface in the same quantity that will turn liquid in combination with steam particles. This state of equilibrium occurs under pressure and is frequently refer... Physical properties of R134a: The steam pressure curves of R134a and other refrigerants are partly very similar, making a clear differentiation solely by pressure impossible. With R 134a the compressor is lubricated by special synthetic refrigeration oils, e.g. PAG-oils (polyalky... Behaviour with metals: In pure condition refrigerant R134a is chemically stable and does not attack iron and aluminium. However, contamination of the refrigerant, e.g. with chlorine compounds, leads to aggressiveness against certain metals and plastics. This can cause clog... Critical temperature Up to a gas pressure of 39.5 bar overpressure (this corresponds with a temperature of 101 �C) the refrigerant R134a remains chemically stable, above this temperature the refrigerant decomposes (see combustibility). Water content: In liquid refrigerant water can only be dissolved in very low quantities. In contrast to this refrigerant steam mixes with water steam at any ratio. If the dryer in the liquid container has absorbed approx. 8 gr. of water, the refrigerant circuit tra... Inflammability: Refrigerant is not inflammable. On the contrary, it has fire inhibiting or fire extinguishing properties. Refrigerant is decomposed by flames or glowing surfaces. Ultraviolet light also cracks refrigerant (caused by electric welding). This results in... Filling factor: In a container there must be a steam space above the liquid space. The liquid expands with increasing temperature. The steam filled space becomes smaller. From a certain time on the container will be filled with just liquid. After this only a minor t... Environmental aspects Environmental aspects The contribution of R134a to the greenhouse effect is by factor 10 smaller than the contribution of R12. Since approx. 1992 the air conditioning systems for newly produced construction equipment were successively converted to refrigerant R134a. This refrigerant does not contain any chlorine and is thus harmless for the ozone layer. Until approx. 1992 ai... 10.3 Compressor oil The compressor oil lubricates the movable parts in the compressor, seals e.g. the gap between piston and cylinder inside the compressor to prevent refrigerant loss and prevents other seals in the system from drying up. The compressor oil lubricates the movable parts in the compressor, seals e.g. the gap between piston and cylinder inside the compressor to prevent refrigerant loss and prevents other seals in the system from drying up. Part of the compressor oil dissolves in the refrigerant until saturation is reached, so that a gas mixture of refrigerant, water steam, compressor oil and contrast agent circulates through the system. Compressor oil (the oil quantity should be 10 % of the refrigerant weight) mixes with the refrigerant and circulates permanently through the system. In connection with R134a- air conditioning systems special synthetic compressor oils, e.g. polyalkylene glycol (PAG) oils, are used. This is necessary, because e.g. mineral oil does not mix with R134a. Apart from this, the materials in the R134a air ... Properties of compressor oil The most important properties are high solvency in connection with refrigerants, good lubrication characteristics, that they are free of acids and their low water content. For this purpose only certain oils can be used. PAG-oils suitable for use with... 10.4 Working principle of the air conditioning system All air conditioning systems are based on the same principle. They extract heat from the surrounding environment. Everybody knows the effect: if a sweating body is exposed to wind it will cool down, because heat is extracted. For this purpose a refri... All air conditioning systems are based on the same principle. They extract heat from the surrounding environment. Everybody knows the effect: if a sweating body is exposed to wind it will cool down, because heat is extracted. For this purpose a refri... Fig. 1 Principle sketch of an air conditioning system An engine driven compressor (1) draws in gaseous refrigerant from the evaporator (5) and compresses it. During this process the temperature of the refrigerant increases tremendously. The refrigerant vapour is then pumped to the condenser (2). This condenser is arranged directly in front of the vehicle radiator, so that a sufficient air flow is assured. In the condenser (2) the gas is cooled down and consequently liquefied. In the dryer The expansion valve (4) regulates the flow rate from the dryer 10.5 Monitoring devices Pressure switch Pressure switch The pressure switch (8) is used as monitoring feature for too high and too low pressures. The switching contacts (4 and 5) effect the magnetic clutch of the compressor via a relay (6). If the system pressure increases excessively, e.g. because of a excessively soiled condenser, a failed fan or a defective expansion valve, the high pressure contact (5) will cut off the electric power supply to the magnetic clutch when the set pressu... The low pressure contact (4) interrupts the electric power supply to the magnetic clutch when the set pressure is fallen short of (possible causes: lack of refrigerant, defective expansion valve, too low heat load, defective evaporator fan, ...). Sin... Thermostat Thermostat A frost protection thermostat (3) protects the evaporator against icing. Similar to the pressure switch, the thermostat activates or deactivates the magnetic clutch for the compressor. Depending on the design, the feeler of the temperature control is... With adjustable temperature regulators the switching point can be changed so that the compressor is already shut down at higher temperatures. This enables regulation of the air temperature. Monitoring chain Monitoring chain Fig. 2 Monitoring chain consisting of: l 1 Switch l 1 Switch l 2 Fuse l 3 Thermostat l 4 Low pressure switch contact l 5 High pressure switch contact l 6 Relay l 7 Connection for magnetic clutch l 8 Pressure switch 10.6 Description of components Compressor Compressor Fig. 1 The compressor 1 (Fig. 1) Two service valves are installed next to the compressor. These are used to e.g. evacuate or fill the system. Compressor data Displacement: 155 cm� Weight: 6.9 kg max. rpm: 6000 Sense of rotation: clockwise Refrigerant: R134a Oil quantity (scope of delivery): 207 g Oil: PAG SP-20 (H14-003-404) The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only refrigeration oil PAG SP-20 (H14-003-404). The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only refrigeration oil PAG SP-20 (H14-003-404). When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil The actual quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components. Used compressor oil Used compressor oil The following table shows how much compressor oil Reason of oil loss Reason of oil loss Amount of oil lost Amount of oil lost Loss when emptying Loss when emptying approx. 15 gr approx. 15 gr Defective A Defective A approx. 30 gr approx. 30 gr Hose change Hose change approx. 15 gr approx. 15 gr Replacement of condenser Replacement of condenser approx. 30 gr approx. 30 gr Replacement of evaporator Replacement of evaporator approx. 30 gr approx. 30 gr Replacement of liquid container Replacement of liquid container approx. 30 gr approx. 30 gr Replacement of expansion valve Replacement of expansion valve approx. 15 gr approx. 15 gr Please bear in mind, that the new compressor is delivered with a filling of 207 gr. compressor oil. To avoid excessive oil in the A Please bear in mind, that the new compressor is delivered with a filling of 207 gr. compressor oil. To avoid excessive oil in the A The quantity depends on the amount of oil that may have been lost in connection with the possible replacement of other components. The compressor oil quantity must be 10% of the refrigerant quantity in the complete system. With a refrigerant filling of 1100 gr. the system requires a compressor oil Procedure: Drain and measure the compressor oil from the old compressor. Drain the compressor oil from the new compressor and only fill in the exact quantity that had been drained out of the old compressor. The compressor oil from the new compressor can be used for this purpose. Topping up compressor oil Topping up compressor oil Condenser The two condensers are installed at the top in the cabin. The two condensers are installed at the top in the cabin. Fig. 1 Condenser The fins must be free of dirt and damage. The fins must be free of dirt and damage. When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil. When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil. Dryer Fig. 1 Dryer The fluid container collects the fluid drops and passes these then as a constant flow to the expansion valve. Moisture that has entered during assembly of the refrigerant circuit is absorbed by a dryer in the fluid container. At evaporation temperatures below zero the refrigerant will deposit previously absorbed moisture on the expansion valve, where this water turns into ice and thus adversely affects the controllability of the expansion valve. Moreover, moisture in the ... Inside the refrigerant container the heavy liquid refrigerant collects in the lower part of the container, flows through a rising pipe to the outlet marked "A" and thus ensures bubble free operation of the expansion valve. Since the absorbing capacity of this filter Since the absorbing capacity of this filter The filter The filter This requires emptying the air conditioning system! Installation position: The arrow marks on the filter Filter Pressure relief valve Pressure relief valve Fig. 2 The fluid container is equipped with a safety valve. Response pressure 32 �4 Tightening torque 10 -15 Inspection glass Inspection glass Fig. 3 During operation the refrigerant must flow through the inspection glass without air bubbles. In most cases the presence of air bubbles is a sign for a too low refrigerant level in the system. Apart from this, the refrigerant may not sufficiently cond... However, incorrect evacuation or filling may also be the reason for air entering into the system and since air cannot be condensed, one will not be able to get rid of these bubbles by topping up refrigerant. In this case the air conditioning system n... Air in the system is characterized by high pressures and temperatures. Air in the system is characterized by high pressures and temperatures. On R134a refrigeration systems the inspection glasses are equipped with moisture indicators. In addition to the float, the dryer The refrigerant level should be inside the inspection glass and should only be checked after approx. 5 minutes continuous operation, because the refrigerant must first evenly distribute all over the system. In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage. In case of mechanical damage or corrosion on this pressure container this collector unit must be replaced, to avoid bursting and further damage. Expansion valve Fig. 1 The expansion valve always allows a small amount of the high pressure liquefied refrigerant to flow into the evaporator, which has a much lower pressure. This lower pressure causes these liquid refrigerant to expand and to evaporate to gaseous state.... The thermostatic expansion valve operates with an external pressure compensation. This type of expansion valve works with high accuracy, because it uses pressure and temperature at the evaporator outlet and adjusts and overheating of approx. 7 K. The... In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+ In case of dirt in the refrigerant system you should also check or clean the screen at the expansion valve inlet.+ Evaporator Fig. 1 The evaporator consists mainly of a heat exchanger, with refrigerant flowing through a pipe system with cooling flanges. As with the condenser, correct operation of all fans and cleanliness of the fins must be assured. Air conditioning systems have a circulation air filter mounted in the air flow in front of the evaporator, which should be cleaned or changed by the operator after each third trip, depending on the amount of dirt. A condensation water filter is mounted in the air flow after the evaporator. This filter has the function to collect the water that has condensed from the air in the evaporator block and to discharge this water into the water pan With a defective con... When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil. When replacing a heat exchanger, e.g. evaporator or condenser, any compressor oil lost by exchanging the components, must be replaced with fresh oil. Thermostat Thermostat with fixed setting Thermostat with fixed setting Fig. 1 The feeler of a defroster thermostat to switch off the magnetic clutch in case of icing up or to switch the clutch back on after defrosting, is mounted on the evaporator. With fixed temperature controls the control switches the compressor off at about +1 �C and back on again at about +2.5�C to +5.5 �C. Adjustable thermostat Adjustable thermostat With adjustable temperature regulators the switching point can be changed so that the compressor is already shut down at higher temperatures. This enables regulation of the air temperature. Fig. 2 adjustable temperature controller The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on. The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on. Pressure switch Fig. 1 After a minimum pressure is reached in the low pressure side or a maximum pressure in the high pressure side, the pressure switch will switch of the magnetic clutch of the compressor, thus to avoid destruction of system components by excessive pressu... Working pressure: Low pressure off: 1.5 � 0.5 Low pressure on: 3.5 bar Overpressure off: 25.0 �1.5 Overpressure on: 18.0 �1.5 The pressure switch can be installed in filled condition. The pressure switch can be installed in filled condition. Pipes and hoses Pipes and hoses in air conditioning systems must meet very high requirements with respect to resistance against heat and pressure. The requirements concerning leak tightness and, in case of hoses, against diffusion, i.e. seepage of refrigerant throug... Pipes and hoses in air conditioning systems must meet very high requirements with respect to resistance against heat and pressure. The requirements concerning leak tightness and, in case of hoses, against diffusion, i.e. seepage of refrigerant throug... O-rings are made of a special type of chloroprene rubber (neoprene). Before assembly of the air conditioning system these O-rings must be lubricated with compressor oil Recommended tightening torques for O-ring sealed fittings Thread Thread Thread Spanner width Spanner width Torque Torque 5 5 17 or 19 17 or 19 13,6 - 20,3 Nm 13,6 - 20,3 Nm 3 3 32,5 - 39,3 Nm 32,5 - 39,3 Nm 7 7 27 27 35,3 - 42,0 Nm 35,3 - 42,0 Nm 1 1 1 1 32 32 40,7 - 47,5 Nm 40,7 - 47,5 Nm M30X2 M30X2 36 36 105,0 - 115,0 Nm 105,0 - 115,0 Nm M36X2 M36X2 41 41 165,0 - 175,0 Nm 165,0 - 175,0 Nm Bending radii for air conditioning hoses Hose type Hose type Nominal width Nominal width Bending radius Bending radius GH 134 GH 134 NW8 NW8 min. 50 mm min. 50 mm GH 134 GH 134 NW10 NW10 min. 65 mm min. 65 mm GH 134 GH 134 NW12 NW12 min. 75 mm min. 75 mm GH 134 GH 134 NW16 NW16 min. 100 mm min. 100 mm GH 494 GH 494 NW20 NW20 min. 160 mm min. 160 mm GH 494 GH 494 NW25 NW25 min. 194 mm min. 194 mm GH 494 GH 494 NW32 NW32 min. 225 mm min. 225 mm 10.10 Servicing the air conditioning compressor 10.7 Measuring the compressor oil level The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only compressor oil The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only compressor oil The compressor oil level must be checked after replacing a system component or if a leak in the system is suspected. Use only compressor oil l Run the compressor for 10 minutes at engine idle speed. l Run the compressor for 10 minutes at engine idle speed. l remove the refrigerant from the air conditioning system. Fig. 1 l Turn the compressor, as shown in l Turn the compressor, as shown in (Fig. 1) l Remove the oil plug. The oil level must reach the bottom edge of the bore, top up or drain off oil if necessary. The oil level must reach the bottom edge of the bore, top up or drain off oil if necessary. l Close the oil plug again. l Close the oil plug again. The contact area must be clean and should be free of damage. The contact area must be clean and should be free of damage. Tightening torque 15 to 25 Nm l Refill the air conditioning system. l Refill the air conditioning system. 10.10 Servicing the air conditioning compressor 10.8 Checking the magnetic clutch l Measure the voltage. l Measure the voltage. l Measure the voltage. Nominal value = vehicle voltage Nominal value = vehicle voltage l Check the magnetic coil locking ring for secure fit. l Check the magnetic coil locking ring for secure fit. l Check the current consumption. Fig. 1 at 12 Volt vehicle voltage approx. 3.5 Amp. at 12 Volt vehicle voltage approx. 3.5 Amp. at 24 Volt vehicle voltage approx. 1.75 Amp. Overcurrent indicates a short circuit inside the magnetic coil. No current indicates an interrupted electric circuit. Fig. 2 Measuring the air gap l Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1). l Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1). The gap should be 0.4 to 0.8 mm. The gap should be 0.4 to 0.8 mm. l Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged. l Take off the drive V-belt and rotate the V-belt pulley by hand while the magnetic clutch is disengaged. In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced. In case of excessive flatness faults or deviations the magnetic clutch needs to be replaced. Cross-section of magnetic clutch Cross-section of magnetic clutch Fig. 3 shows a cross-section of the magnetic clutch. If the coil (7) is not supplied with operating voltage, there is no contact between the front plate of the clutch (1) and the V-belt pulley (2). A spring presses the front plate away from the belt ... Fig. 3 Cross-section of magnetic clutch 10.10 Servicing the air conditioning compressor 10.9 Inspection and maintenance work l Visual inspection of the complete system for damage. l Visual inspection of the complete system for damage. l Visual inspection of the complete system for damage. l Check the compressor mounting bracket on the vehicle engine for tight fit and damage. l Check the condition, alignment and tightness of the V-belt. l Check the routing of refrigerant hoses and cables in the area of the vehicle engine and transmission, as well as on the chassis for chafing and rectify any detected faults. Ensure sufficient clearance to hot parts, such as the exhaust; install a pr... l Check the routing of hoses and hoses on the attachment box or in the cabin. l Check all hose and screw fittings for leaks. l Check the fastening of the condenser unit. l Clean the condenser fins, replace the condenser block if damaged fins are found. l Check the fastening of the evaporator unit. l Check the function of evaporator and condenser fans. l Check the electric control panel. If discolorations on conductors are found, these should be replaced and possibly also the corresponding relays. l Switch on the cooling system and check the refrigerant level. l Filter l Measure the temperature on the evaporator: Measure the intake air temperature - Measure the blow out air temperature - The temperature difference should be at least 8-10 K. l Measuring the pressure in the refrigerant circuit l Measuring the pressure in the refrigerant circuit 10.10 Servicing the air conditioning compressor 10.10 Servicing the air conditioning compressor Optional equipment Danger of injury! Danger of injury! Danger of injury! Work on the V-belt must only be performed with the engine shut down. Check the V-belt Check the V-belt Fig. 4 l Inspect the entire circumference of the V-belt l Inspect the entire circumference of the V-belt (Fig. 4) l Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm (0.4 � 0.6 inches) between the V-belt pulleys, retighten if necessary. Retighten the V-belt Retighten the V-belt Fig. 5 l Slacken the bearing screw (2) l Slacken the bearing screw (2) (Fig. 5) l Slightly loosen the hexagon screw (1) on the slot for the compressor bracket. l Loosen the counter nut (3). l Turn down tensioning screw (4) in direction of arrow, until the correct V-belt tension is reached. l Retighten all fastening screws. Changing the V-belt Changing the V-belt l Slacken the bearing screw (2) l Slacken the bearing screw (2) (Fig. 5) l Slightly loosen the hexagon screw (1) on the slot for the compressor bracket. l Loosen the counter nut (3). l Turn tensioning screw (4) in direction of arrow to the stop. l Take off the old V-belt and replace it with a new one. l Turn down tensioning screw (4) in direction of arrow, until the correct V-belt tension is reached. l Retighten all fastening screws. Retighten new V-belts after a running time of 15 minutes. Retighten new V-belts after a running time of 15 minutes. 10.11 Service the air conditioning 10.11 Service the air conditioning Optional equipment Cleaning the condenser Cleaning the condenser A soiled condenser results in a considerable reduction of air conditioning power. A soiled condenser results in a considerable reduction of air conditioning power. Under extremely dusty conditions it may be necessary to clean the condenser several times per day. If, during operation of the air conditioning system, the warning buzzer sounds switch the air conditioning off and clean the condenser. Danger of accident! Danger of accident! Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system. Use access steps and grips to mount and dismount the machine. Fig. 6 l Use the access steps l Use the access steps (Fig. 6) In case of formation of foam have the air conditioning system inspected by the service department of BOMAG. In case of formation of foam have the air conditioning system inspected by the service department of BOMAG. Fig. 7 l Use access steps on cross member and holding grips on the frame of the air conditioning unit l Use access steps on cross member and holding grips on the frame of the air conditioning unit (Fig. 7) Fig. 8 l Clean the condenser fins l Clean the condenser fins (Fig. 8) Fig. 9 l Clean the condenser fins l Clean the condenser fins (Fig. 9) Checking the refrigerant level Checking the refrigerant level l Start the engine. l Start the engine. Fig. 10 l Turn the rotary switch for air conditioning l Turn the rotary switch for air conditioning (Fig. 10) l Open the air outlet nozzles. Fig. 11 l Turn the rotary thermostat switch l Turn the rotary thermostat switch (Fig. 11) The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on. The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on. Fig. 12 l Check whether the white float l Check whether the white float (Fig. 12) The refrigerant level is correct. The refrigerant level is correct. Fig. 13 l If the white float l If the white float (Fig. 13) The refrigerant level is not correct. The refrigerant level is not correct. l Refrigerant must be filled up, if necessary check the air conditioning system for leaks. l Refrigerant must be filled up, if necessary check the air conditioning system for leaks. Checking the moisture level of the drying agent Checking the moisture level of the drying agent Fig. 14 l Check the moisture indication pearl l Check the moisture indication pearl (Fig. 14) orange orange Drying agent o.k. colourless moisture level of drying agent too high. l Inform the service department. Replace drier l Inform the service department. Replace drier Have the drier Have the drier Checking the condition of the drier Checking the condition of the drier According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with t... According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with t... Danger of injury! Danger of injury! In case of mechanical damage or corrosion on this drier Fig. 15 l Check the drier l Check the drier (Fig. 15) 10.12 Drying and evacuation Evacuation of air conditioning systems using R-type refrigerants not only has the purpose of emptying the system of all air before filling in refrigerant, but also to verify the leak tightness over a longer lifetime in the achieved vacuum. However, t... Evacuation of air conditioning systems using R-type refrigerants not only has the purpose of emptying the system of all air before filling in refrigerant, but also to verify the leak tightness over a longer lifetime in the achieved vacuum. However, t... Any water residues in the refrigerant circuit will combine with the refrigerant, which will lead to the previously described consequential damage. Vacuum pumps with a capacity of more than 100 l The refrigerant compressor is not suitable for the purpose of evacuation, because it is not able to achieve a sufficient final vacuum and, apart from this, may be mechanically damaged because of a lack of lubrication when running empty during evacuation It is common practice to evacuate the refrigeration system to a final vacuum of 1 Torr, i.e. 1.33 mbar. Function drying: Under normal ambient pressure (1.013 mbar) evaporates absolute at 100� C. If the pressure is reduced, water will already evaporate, e.g. under a pressure of 10 mbar, at an ambient temperature of almost 7�C, but the water will not evaporate all at o... 10.13 Emptying in case of repair For repair work the air conditioning systems must very often be emptied of all refrigerant. For repair work the air conditioning systems must very often be emptied of all refrigerant. Especially with expensive refrigerants and larger amounts of oil it may be necessary to keep the refrigerant for later use. For later use these refrigerants must be drawn out with suitable equipment and intermediately stored in collecting containers. Contaminated refrigerant must be disposed of environmentally Contaminated refrigerant must be disposed of environmentally Releasing refrigerant into the atmosphere is prohibited (see restrictive injunction concerning CFC, day of enforcement 01. 08. 1991, � 8) For draining refrigeration systems you should not simply use any delivery containers, but only appropriate pressure bottles, which must be specially marked and should comply with the pressure gas directive. For draining refrigeration systems you should not simply use any delivery containers, but only appropriate pressure bottles, which must be specially marked and should comply with the pressure gas directive. When transferring refrigerant you must make sure that the bottle does not contain more than the permitted amount of refrigerant in litres and has sufficient gas space for expansion (filling factor: 0,7). In order to reduce the evacuation period in case of short repairs, you may fill the refrigerant circuit with approx. 0.5 bar nitrogen when opening. This ensures that nitrogen will flow out of the refrigerant circuit while it is open and no air or moi... 10.14 Leak test The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul... The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul... The use of leak detection colouring matter is not permitted, because its chemical composition is unknown and its effect on compressor oil and rubber elements is not predictable. The use of leak detection colouring matter makes any warranty claims nul... Before starting the evacuation process, the refrigerant circuit is filled with nitrogen through a pressure reducer valve (approx. 22 bar). After this all connections in the air conditioning system are checked with the help of a suitable leak detectio... A leak test is required if a pressure drop is noticed. The leak test must be repeated after filling the air conditioning system with refrigerant. Leak test with electronic leak tester Fig. 1 Electronic leak tester Small leaks with only very low amounts of refrigerant escaping can be detected, e.g. with an electronic leak tester. Such equipment is able to detect leaks of less than 5 gr. per year. The leak tester used must be specially designed for the refrigerant composition in the air conditioning system. For example, leak detectors for refrigerant R12 are not suitable for R134a, because the refrigerant R134a is free of chlorine atoms, meani... Leak test with soap bubbles Leak test with soap bubbles Fig. 2 Soap bubble test Points susceptible for leakage are sprayed with a soapy solution. Bubbles indicate the leak. The detection limit for R 134a is 250 g 10.15 Filling instructions Filling instructions Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions. Filling of refrigerant into the dried, vented and oil filed machines takes place under various conditions. In most large series production facilities highly complicated equipment is available for this purpose, whereas individual machines at the place of installation must be filled directly from the refrigerant container. Liquid refrigerant is only used to pre-fill the pressure side of the evacuated refrigeration system (protective filling). After switching the refrigeration system on and watching the inspection glass, gaseous refrigerant can be filled into the system while the engine is running, if the refrigerant level is found to be too low (gas bubbles in the inspection glass). Liquid refrigerant in the suction side of the compressor should generally be avoided during filling and operation of the refrigeration system, since this could damage the compressor.. Liquid refrigerant in the suction side of the compressor should generally be avoided during filling and operation of the refrigeration system, since this could damage the compressor.. When filling the air conditioning system directly from the refrigerant bottle care must be taken not to overfill the system. As an additional control and for statistical purposes, e.g. for refilling, it is important to write down the weight of the fi... With correct operation of the air conditioning the refrigerant container should be about 1 White frost on the suction line is no measure for assessing the filling. White frost on the suction line is no measure for assessing the filling. Fig. 1 1 High pressure - gaseous 1 High pressure - gaseous 1 High pressure - gaseous 2 High pressure - liquid 3 Low pressure - gaseous 4 Compressor 5 Compressor pressure switch (not used) 6 not used 7 Evaporator 8 Expansion valve 9 Inspection glass 10 Filter dryer 11 Fluid container 12 Condenser 13 Manual shut-off valve (not used) 14 Pressure switch with high and low pressure contacts 15 Defroster thermostat 16 Vacuum meter 17 Low pressure gauge 18 High pressure gauge 19 Pressure reducing valve 20 Vacuum pump 21 Nitrogen bottle 22 Refrigerant bottle 23 Pressure gauge bar Filling instructions Filling instructions 1 Connect the service adapter with the blue hand wheel in the suction side. 1 Connect the service adapter with the blue hand wheel in the suction side. 1 Connect the service adapter with the blue hand wheel in the suction side. 2 Connect the service adapter with the red hand wheel in the pressure side (the hand wheels on the service adapters must be fully backed out - left hand stop) 3 Connect the blue suction hose below the blue hand wheel on the pressure gauge bar to the blue service adapter. 4 Connect the red pressure hose below the red hand wheel on the pressure gauge bar to the red service adapter. 5 Connect the yellow hose below the yellow hand wheel on the manometer bar to the 2-stage vacuum pump. 6 Connect the last hose below the black hand wheel on the nitrogen bottle via the pressure reducing valve. 7 Check on the pressure gauge bar that all hand wheels are closed. 8 Turn the hand wheels on both service adapter clockwise. This opens the valves (right hand stop). 9 Open the valve on the nitrogen bottle (only via pressure reducer); pressure approx. 20 bar. 10 Open the black and red hand wheels on the pressure gauge bar and fill nitrogen into the system, until a pressure of approx. 3.5 to 5.0 bar is indicated on the suction side. 11 Then open the blue hand wheel and raise the pressure in the suction side (max. 10 bar). Check for leaks with a leak detection fluid or soapsuds. 12 If the system is leak tight, release the nitrogen from the system. For this purpose disconnect the hose from the nitrogen bottle and open the red, blue and black hand wheels on the pressure gauge bar. 13 Then connect the hose to the refrigerant bottle. 14 Switch on the vacuum pump and open all hand wheels on the pressure gauge bar. In case of a leak no or only an insufficient vacuum will be reached. In this case proceed as described under point 9-12. Once the leak is sealed continue with point 14. 15 Once a sufficient vacuum is reached, both pressure gauges show -1, close all hand wheels on the pressure gauge bar. 16 Switch off the vacuum pump, watch the pressure gauges to see whether the vacuum is maintained. 17 Open the valve on the refrigerant bottle and open the black and red hand wheels on the pressure gauge bar. Fill refrigerant into the system, until a pressure equilibrium between suction and pressure side is reached (reading of pressure gauges). 18 Close the red hand wheel. 19 Perform a leak test with the electronic leak detector. 20 Start the engine and switch on the system. 21 Open the blue hand wheel and continue filling in refrigerant until the inspection glass is free or air bubbles (in fluid container 22 Close the blue hand wheel on the pressure gauge bar. 23 Preparing the test run: -Close windows and doors -Fan on full speed stage -Mount measuring feelers to air discharge and air intake. 24 Run the system for approx. 20 minutes with medium engine speed. 25 The temperature difference between air discharge and air intake should be (depending on type of air condition) 8-10�C. The ambient temperature thereby is approx. 20�C. (These data are only reference values, which may be influenced by possible in... 26 Switch off system and engine and check for leaks again. 27 Turn out (left hand stop) and remove the hand wheels on both service adapters. 28 Fit all valves with dust caps. 29 Perform a leak test. 30 Mark the system with the corresponding type plates and information decals, such as type of oil and refrigerant. 10.16 Trouble shooting in refrigerant circuit, basic principles Basic principles Basic principles Requirements Requirements For trouble shooting two requirements must be fulfilled: l Expert knowledge l Expert knowledge l technical equipment Technical equipment Technical equipment The most important aids for trouble shooting are pressure gauges and thermometer. The refrigerant conditions, like overheating and excessive cooling provide important Information when searching for faults. Even your own senses are important aids for ... The following tools and auxiliary materials should be available for trouble shooting: l Service station l Service station l Pressure gauge l Thermometer l dry nitrogen l Refrigerant bottle for new refrigerant l Container for old oil l Vacuum pump l Hoses l Scales l Suction station l Leak detector The measuring equipment must be checked at regular intervals. Calibration can only be made by an approved testing authority. Pressure gauge Pressure gauge Most pressure gauges used in practice are (for cost reasons) excess pressure gauges. These pressure gauges measure the excess pressure in relation to the ambient pressure (air pressure). In order to achieve the absolute (actual) pressure the ambient ... P abs amb e P abs P amb P e Fig. 2 Pressure gauge Example: A totally empty air conditioning system holds an atmospheric pressure of approx. P amp Filling the system with refrigerant causes an excess pressure of P e P abs amb e Evacuating the system down to P e P abs amb e Pressure gauge with saturation temperature scale Pressure gauge with saturation temperature scale Fig. 3 Absolute pressure gauge Temperature scales on the pressure gauges always refer to the absolute pressures Pabs. Please note that it is not possible to measure a temperature directly with a pressure gauge. The indicated temperatures are just reference values. Only the saturat... If the refrigerant is fluid, the temperature is below the saturation temperature. If the refrigerant is gaseous, the temperature is above the saturation temperature. Pressure gauges must indicate 0 bar when not connected to the system. Low pressure gauges have a blue, high pressure gauges a red border. Thermometer Thermometer Normally digital thermometers with surface or contact feelers are used. Especially for high temperature differences excellent heat insulation of the measuring location is of utmost importance. The sparing use of a heat conducting paste is highly reco... Overheating Overheating Common overheating values Due to its design a refrigerant compressor can only deliver gaseous or vaporous substances. Fluids are not compressible and must therefore not enter into the compression chamber of the compressor. If the suction condition of the compressor is directly on the dew line, an e.g. incorrect evaporator load can cause "wet suction". This can lead to two processes, which are destructive for the compressor. The liquid refrigerant washes off the lubrica... Apart from protecting the compressor against fluid, overheating has further advantages. Since the fluid proportions in the drawn in steam reduces the flow rate of the compressor, it may be increased by a overheating. Overheating also improves the oil... Common overheating values Common overheating values The optimal overheating value is approx. 5 - 8 Kelvin. With this overheating the maximum system power is reached. However, the thermostatic expansion valve is unable to regulate this value exactly. Depending on design and operating conditions overhea... Overheating is calculated as follows: Overheating is calculated as follows: D t D o2h o2h o D t D o2h t o2h t o � h Supercooling Supercooling Common supercooling values It is the function of the expansion valve to reduce the refrigerant to a lower pressure level (evaporation pressure) after it has been liquefied. For an optimal function of the valve pure fluid must be applied to its inlet port. The refrigerant must "squeeze" (literally speaking) through a throttle gap inside the expansion valve. When comparing a certain mass of refrigerant in fluid and in vaporous state (with constant pressure), the vaporous refrigerant requires a much high... Vaporous refrigerant in front of the expansion valve reduces the flow rate and results in an undersupply of the evaporator with refrigerant. Evaporation pressure and evaporator power will drop. If the refrigeration system is operated with the "expansion valve inlet" condition directly on the boiling curve, slightest fluctuations in operating condition may cause a formation of bubbles in front of the expansion element. For this reason one shifts the condition "Expansion Valve Inlet" away from the boiling curve into the fluid area and refers to this condition as Supercooling. This supercooling ensures a fluid supply in front of the expansion valve. Common supercooling values Common supercooling values In systems with fluid container the supercooling at the fluid container outlet is approx. Zero "0" Kelvin (assumed that the system is filled with the correct refrigerant quantity). In this case the fluid container provides the required fluid supply. Supercooling is calculated as follows: Supercooling is calculated as follows: D t D c2u c c2u D t D c2u t c2u t c � u Fig. 1 Refrigerant circuit with t, h- diagram 1 Hot gas line (overheated steam) 1 Hot gas line (overheated steam) 2 Deheating (overheated steam) 3 Condenser 4 Condensation (wet steam) 5 Fluid line (supercooled fluid) 6 Expansion valve 7 Injection line (wet steam) 8 Evaporation (wet steam) 9 Evaporator 10 Overheating (overheated steam) 11 Suction steam line (overheated steam) 12 Compressor 13 Supercooling (fluid) 14 Compression 15 Expansion 10.17 Trouble shooting, refrigerant circuit diagram Fig. 1 Refrigerant circuit diagram 1 Cold air 1 Cold air 2 Evaporator 3 Thermostat 4 Warm air 5 Fan 6 Inspection glass 7 Expansion valve 8 Pressure gauge, high pressure 9 Pressure switch with high and low pressure contacts 10 Dryer 11 Fluid container 12 Hot air 13 Compressor 14 Condenser 15 Cooling air 16 Pressure gauge, low pressure 10.18 Trouble shooting procedure Procedure Procedure Knowledge Knowledge Trouble shooting is not possible with exact knowledge about the system design, the installed components and their function in the system trouble shooting is not possible: Visual inspection Visual inspection With the appropriate experience some faults can be visually detected or felt. Frequently occurring condenser soiling or formation of steam bubbles in the inspection glass can be quickly detected. In case of unusual formation of hoarfrost on the evaporator the hoarfrost pattern provides useful information. Hoarfrost only occurring at the inlet side is a clear indication of insufficient refrigerant feed, which in turn indicates an incorrectly w... Even overheating can sometimes be detected with the naked eye. At the end of the evaporator there should be an area which is dry or at least drier at evaporator temperatures above -2 �C. The fluid line in the refrigeration system is warm. If a local cooling can be felt or if condensation develops, this is a clear indicator for an extreme pressure drop in the line. Similar phenomena can be noticed in case of blocked filters. Unusually cold pressure lines indicate "wet" intake of the compressor. The oil level in the compressor sight glass provides information about the oil quantity and the oil recirculation in the system. However, the oil level may also be considerably influenced by condensing refrigerant. Discoloration informs about the sta... Water in the system can simply be detected through the inspection glass with moisture indicator. The dangerous part of common rules is that they apply in most, but not in all cases. The refrigerant states in the individual piping sections or components must therefore be exactly determined by means of pressure and temperature measurements. The dangerous part of common rules is that they apply in most, but not in all cases. The refrigerant states in the individual piping sections or components must therefore be exactly determined by means of pressure and temperature measurements. Test prerequisites Test prerequisites l Cooler and condenser are clean, clean if necessary. l Cooler and condenser are clean, clean if necessary. l The ribbed belt for compressor and generator is correctly tightened. l All air ducts, covers and seals are OK and correctly fitted. Flaps reach their end positions. l The engine has operating temperature. l Evaporator and heating (with highest fresh air fan speed) do not draw leak air. l The fresh air fan runs when the engine is running and the air conditioning system is set to max. cooling power. l Ambient temperature above 15 �C. l The thermostat is correctly installed and the switching temperatures are correct. Example: Measurement of overheating Measuring points and measurements Fig. 2 Flow diagram with measuring points l C, condenser measuring points l C, condenser measuring points l E, expansion valve measuring points l O, evaporator measuring points l V, compressor measuring points The flow diagram contains "Minimum Requirements" which must be fulfilled to be able to check the system or perform trouble shooting. Example: Measurement of overheating Example: Measurement of overheating l a) Which measuring equipment is required? l a) Which measuring equipment is required? l b) Where to measure with which size? l c) A pressure gauge connected to the evaporator indicates "P eo2 o l d) How high is the evaporator temperature "t o l e) A thermal sensor attached to the evaporator outlet measures the temperature "t o2h D o2h l f) Evaluation of the measured overheating. Solution: Solution: l a) Pressure gauge, thermometer, steam table l a) Pressure gauge, thermometer, steam table l b) Evaporation pressure "P eo2 o2h l c) P o eo2 amb l d) "P c o l e) D o2h o2h o l f) The determined overheating is within the usual range of 4 - 12 Kelvin. Example: Measuring supercooling Example: Measuring supercooling l a) Which measuring equipment is required? l a) Which measuring equipment is required? l b) Where to measure with which size? l c) A pressure gauge connected to the condenser indicates "P ec2 c l d) How high is the condensing temperature "t c l e) A thermal sensor attached to the condenser outlet measures the temperature "t c2u D c2u l f) Evaluation of the measured supercooling. Solution: Solution: l a) Pressure gauge, thermometer, steam table l a) Pressure gauge, thermometer, steam table l b) Condensing pressure "P ec2 c2u l c) P c ec2 amb l d) "P c c l e) D c2u c c2u l f) The determined overheating is within the usual range of approx. "0" Zero Kelvin. Typical faults and possible causes Typical faults and possible causes Most faults in the refrigerant side of the system can be clearly assigned with the help a checklist. r Occurring faults frequently have a similar appearance, but different causes. An evaporator showing hoarfrost may be quite normal. However, there ma... The following list contains pressure values in a system, that can be expected at various ambient temperatures (measured at medium speeds). Suction pressure (low pressure gauge) Ambient temperature in �C Ambient temperature in �C Excess pressure in bar Excess pressure in bar 25 25 approx. 2,0 approx. 2,0 30 30 approx. 2,5 approx. 2,5 35 35 approx. 3 approx. 3 High pressure (high pressure gauge) Ambient temperature in �C Ambient temperature in �C Excess pressure in bar Excess pressure in bar 25 25 approx. 8,0 approx. 8,0 35 35 approx. 13 approx. 13 40 40 approx. 16 approx. 16 45 45 approx. 18 approx. 18 Noise in system Values effecting the operating pressures Since the pressures occurring in a refrigeration system are highly dependent on environmental conditions, it is mandatory to know these dependencies. The following table contains some of these dependencies. Measuring value Measuring value Suction pressure Suction pressure High pressure High pressure increases increases drops drops increases increases drops drops Compressor speed Compressor speed increases increases X X X X drops drops X X X X Vehicle interior temperature Vehicle interior temperature increases increases X X X X drops drops X X X X Ambient temperature Ambient temperature increases increases X X X X drops drops X X X X Humidity Humidity increases increases X X X X drops drops X X X X Noise in system Suction pressure too low (1), high pressure too low to normal (2) Fig. 3 Cause Cause Possible effect Possible effect Remedy Remedy Lack of refrigerant Lack of refrigerant no supercooling, bubbles in inspection glass, high overheating, hoarfrost on evaporator no supercooling, bubbles in inspection glass, high overheating, hoarfrost on evaporator Check for leaks, refill Check for leaks, refill Evaporator fins or air filter soiled Evaporator fins or air filter soiled Cooling power too low Cooling power too low clean clean Evaporator fan failed Evaporator fan failed Low pressure shut off Low pressure shut off Repair the fan Repair the fan Expansion valve defective Expansion valve defective Suction pressure gauge shows vacuum, because the valve has closed Suction pressure gauge shows vacuum, because the valve has closed Replace the valve Replace the valve Screen or nozzle in expansion valve clogged Screen or nozzle in expansion valve clogged high overheating high overheating clean clean Filter dryer clogged Filter dryer clogged Bubbles in inspection glass, high overheating, filter dryer cold Bubbles in inspection glass, high overheating, filter dryer cold Change filter dryer Change filter dryer Heat power too low Heat power too low Frequent low pressure shut off, thawing thermostat Frequent low pressure shut off, thawing thermostat Check the control Check the control Noise in system Suction pressure normal (1), high pressure too high (2) Fig. 4 Cause Cause Possible effect Possible effect Remedy Remedy Condenser dirty Condenser dirty high hot gas temperature, low cooling power high hot gas temperature, low cooling power clean clean Condenser fan failed Condenser fan failed high hot gas temperature, high pressure shut down high hot gas temperature, high pressure shut down repair repair overfilled overfilled high hot gas temperature, low supercooling, low cooling power high hot gas temperature, low supercooling, low cooling power Correct the filling capacity Correct the filling capacity Leak gas (air) Leak gas (air) high hot gas temperature, low measured supercooling, low cooling power high hot gas temperature, low measured supercooling, low cooling power renew filling renew filling Restriction between compressor and condenser Restriction between compressor and condenser high hot gas temperature, low cooling power high hot gas temperature, low cooling power Check lines and valves Check lines and valves Noise in system Suction pressure too high (1), high pressure too low to normal (2) Fig. 5 Cause Cause Possible effect Possible effect Remedy Remedy Compressor defective Compressor defective Cooling power too low Cooling power too low Replace the compressor Replace the compressor Noise in system Suction pressure too high (1), high pressure too high (2) Fig. 6 Cause Cause Possible effect Possible effect Remedy Remedy Expansion valve defective Expansion valve defective overheating too low, wet operation of compressor overheating too low, wet operation of compressor Replace the valve Replace the valve Noise in system Other faults Symptom Symptom Cause Cause Possible effect Possible effect Remedy Remedy Hot gas temperature too high, the hot gas line becomes so hot that it cannot be touched long with a hand Hot gas temperature too high, the hot gas line becomes so hot that it cannot be touched long with a hand Lack of refrigeration oil Lack of refrigeration oil increased compressor wear increased compressor wear Refill refrigeration oil Refill refrigeration oil Compressor does not start Compressor does not start Pressure switch or any other safety feature has triggered, electrical fault, cylinder filled with liquid refrigerant Pressure switch or any other safety feature has triggered, electrical fault, cylinder filled with liquid refrigerant System stopped System stopped Check the control units, check cause for switching and rectify Check the control units, check cause for switching and rectify Compressor switches continuously Compressor switches continuously Switching difference too small, triggering of a switching element (overpressure switch, low pressure switch), lack of refrigerant, fan defective, overfilled Switching difference too small, triggering of a switching element (overpressure switch, low pressure switch), lack of refrigerant, fan defective, overfilled Cycling of compressor, increased wear, too low cooling power Cycling of compressor, increased wear, too low cooling power Check the control units, check cause for switching and rectify Check the control units, check cause for switching and rectify Excessive overheating Excessive overheating Expansion valve deadjusted or screen blocked, lack of refrigerant Expansion valve deadjusted or screen blocked, lack of refrigerant low cooling power, hot gas temperatures too high low cooling power, hot gas temperatures too high Replace the expansion valve, clean the screen, fill in refrigerant, leak test Replace the expansion valve, clean the screen, fill in refrigerant, leak test Hoarfrost on inlet side of evaporator Hoarfrost on inlet side of evaporator incorrectly working expansion valve, lack of refrigerant incorrectly working expansion valve, lack of refrigerant too low infeed of refrigerant into the evaporator too low infeed of refrigerant into the evaporator Check the expansion valve, check the refrigerant filling Check the expansion valve, check the refrigerant filling Evaporator fully covered with hoarfrost Evaporator fully covered with hoarfrost Load problem, too low air flow volume Load problem, too low air flow volume low cooling power of system low cooling power of system Clean the evaporator, check the evaporator fan Clean the evaporator, check the evaporator fan Fluid line is warm and shows condensation Fluid line is warm and shows condensation Pressure drop in fluid line, filter dryer clogged Pressure drop in fluid line, filter dryer clogged low cooling power low cooling power Eliminate the pressure drop, replace the filter dryer Eliminate the pressure drop, replace the filter dryer Exceptionally cold pressure lines Exceptionally cold pressure lines "Wet intake" of the compressor due to insufficient overheating of evaporator "Wet intake" of the compressor due to insufficient overheating of evaporator low cooling power, excessive wear of compressor low cooling power, excessive wear of compressor Clean the compressor, replace if necessary, replace the expansion valve if necessary Clean the compressor, replace if necessary, replace the expansion valve if necessary Noise in system Noise in system Faults Faults Possible cause Possible cause Remedy Remedy V-belt loose or excessively worn V-belt loose or excessively worn V-belt slips and generates noise V-belt slips and generates noise Retention or renew the V-belt Retention or renew the V-belt Magnetic clutch loud Magnetic clutch loud Magnetic clutch runs until high pressure builds up, then the clutch starts to slip Magnetic clutch runs until high pressure builds up, then the clutch starts to slip Repair or replace the magnetic clutch Repair or replace the magnetic clutch Refrigerant compressor is loud Refrigerant compressor is loud Mounting bracket is loose, internal parts worn, low oil level in compressor Mounting bracket is loose, internal parts worn, low oil level in compressor Repair the mounting bracket, replace the compressor, renew the refrigeration oil Repair the mounting bracket, replace the compressor, renew the refrigeration oil Fan is loud, fan motor excessively worn Fan is loud, fan motor excessively worn Replace the fan motor Replace the fan motor Whistling and rattling noise in operation, noticeable unevenness when turning by hand Whistling and rattling noise in operation, noticeable unevenness when turning by hand V-belt pulley and bearing worn V-belt pulley and bearing worn Replace the bearing, check V-belt pulley for wear Replace the bearing, check V-belt pulley for wear Rattling noise or vibration of high pressure line, knocking noise in compressor, ball in inspection glass floating at the top Rattling noise or vibration of high pressure line, knocking noise in compressor, ball in inspection glass floating at the top System overfilled System overfilled Draw out refrigerant Draw out refrigerant Expansion valve loud Expansion valve loud excessive moisture in system excessive moisture in system Replace the dryer Replace the dryer Hissing noise in evaporator housing, on expansion valve, turbidity in inspection glass or ball does not float Hissing noise in evaporator housing, on expansion valve, turbidity in inspection glass or ball does not float refrigerant level in system too low refrigerant level in system too low Perform a leak test, fill up the system Perform a leak test, fill up the system Inspection glass Inspection glass Faults Faults Possible cause Possible cause Remedy Remedy Steam bubbles in inspection glass Steam bubbles in inspection glass No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryer No supercooling before expansion valve, lack of refrigerant in system, pressure loss in system, supercooling caused by excessively soiled filter dryer Fill up the system, replace the filter dryer, perform a leak test Fill up the system, replace the filter dryer, perform a leak test Discolouration of inspection glass (black from inside) Discolouration of inspection glass (black from inside) Lubricant destroyed by excessive operating temperatures Lubricant destroyed by excessive operating temperatures Replace the refrigeration oil, examine the temperature increase Replace the refrigeration oil, examine the temperature increase Moisture indicator changes to pink Moisture indicator changes to pink Moisture level of drying agent too high Moisture level of drying agent too high Replace the filter dryer Replace the filter dryer Ball floats at bottom Ball floats at bottom lack of refrigerant lack of refrigerant Fill the system Fill the system Monitoring devices Monitoring devices Faults Faults Possible cause Possible cause Remedy Remedy The high pressure contact has switched off the magnetic clutch The high pressure contact has switched off the magnetic clutch System pressure exceeded, condenser excessively soiled, condenser fan defective, expansion valve defective System pressure exceeded, condenser excessively soiled, condenser fan defective, expansion valve defective Clean the condenser, replace the expansion valve, check the condenser fan Clean the condenser, replace the expansion valve, check the condenser fan The low pressure contact has switched off the magnetic clutch The low pressure contact has switched off the magnetic clutch System pressure fallen short of, refrigerant level too low, expansion valve defective, evaporator fan defective, heat load too low, ambient temperature below 1.5 �C System pressure fallen short of, refrigerant level too low, expansion valve defective, evaporator fan defective, heat load too low, ambient temperature below 1.5 �C Clean the evaporator, replace the expansion valve, check the evaporator fan Clean the evaporator, replace the expansion valve, check the evaporator fan The thermostat has switched off the magnetic clutch The thermostat has switched off the magnetic clutch Ambient temperature below 1�C, expansion valve defective, thermostat defective, air flow volume too low Ambient temperature below 1�C, expansion valve defective, thermostat defective, air flow volume too low Check the thermostat switching point, replace the expansion valve, clean the evaporator, check the evaporator fan Check the thermostat switching point, replace the expansion valve, clean the evaporator, check the evaporator fan Steam table for R134a Temperature Temperature Pressure Pressure Density Density spec. volume spec. volume spec. enthalpy spec. enthalpy Evaporation heat Evaporation heat of the fluid of the fluid of the steam of the steam of the fluid of the fluid of the steam of the steam of the fluid of the fluid of the steam of the steam Module A108 11 Hydraulics 11 Hydraulics 11.1 Hydraulic circuit Open circuit Open circuit Fig. 1 Open circuit Open in this case means that the suction line of a pump (Fig. 1) In an open circuit the hydraulic fluid is fed to the consumer Closed circuit Closed circuit Fig. 2 Closed circuit One talks about a closed hydraulic system, when the hydraulic oil flows from the consumer (Fig. 2) pump The closed circuit consists of a high and a low pressure side, depending on the load direction (take-off moment on the consumer). The high pressure side is protected by pressure relief valves Only the permanent leakage on pump and motor needs to be replenished. This is accomplished by a charge pump check valve charge pressure relief valve pump List of components Fig. 1 Overall view of machine 1 Hydraulic oil cooler and radiator 1 Hydraulic oil cooler and radiator 2 Diesel engine 3 Charge oil filter in rotor circuit (right and left) 4 Travel motor with L+S wheel drive gear 5 triple pump (1+2: rotor pumps, 3: travel pump) 6 Hydraulic return flow filter 7 Pressure test bar 8 Rotor 9 Rotor gear 10 Rear travel motor 11 Steering axle with planetary gears 12 Gear pump for water injection, 16 cm 3 13 Gear pump (steering 3 14 Combustion air filter 15 Intercooler 16 Tandem gear pump (intercooler 19 cm 3 3 11.3 Pumps on diesel engine Gear pump on auxiliary output Gear pump on auxiliary output Fig. 1 Auxiliary drive Pos. Pos. Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Steering and charge pump, 22.5 cm3 Steering and charge pump, 22.5 cm 3 04 04 max. 150 bar max. 150 bar 2 2 Pump for intercooler fan motor, 19 cm3 Pump for intercooler fan motor, 19 cm 3 05 05 max. 200 bar max. 200 bar 3 3 Pump for working hydraulics, 8 cm3 Pump for working hydraulics, 8 cm 3 06 06 max. 210 bar max. 210 bar 4 4 Optional, pump for bitumen system, 22 cm3 Optional, pump for bitumen system, 22 cm 3 46 46 5 5 Optional, pump for water injection, 8 cm3 Optional, pump for water injection, 8 cm 3 10 10 max. 200 bar max. 200 bar Primary hydraulic units Fig. 2 Hydraulic pump drive Pos. Pos. Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Rotor pump 1, 180 cm3 Rotor pump 1, 180 cm 3 03 03 Pressure override 420 bar, Pmax. 470 bar Pressure override 420 bar, P max. 2 2 Rotor pump 2, 180 cm3 Rotor pump 2, 180 cm 3 02 02 Pressure override 420 bar, Pmax. 470 bar Pressure override 420 bar, P max. 3 3 Travel pump, 56 cm3 Travel pump, 56 cm 3 01 01 Pressure override 420 bar, Pmax. 470 bar Pressure override 420 bar, P max. Pressure test bar Fig. 1 Pressure test bar, left side under cab Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points M1 M1 Charge pressure test port, rotor pump 1 Charge pressure test port, rotor pump 1 21 bar 21 bar M2 M2 Charge pressure test port, rotor pump 2 Charge pressure test port, rotor pump 2 21 bar 21 bar M3 M3 Charge pressure test port, travel pump Charge pressure test port, travel pump 32 bar 32 bar M4 M4 Steering pressure test port Steering pressure test port max. 185 bar max. 185 bar M5 M5 Pressure test port, travel pressure forward Pressure test port, travel pressure forward MB MB max. 420 bar, pressure override max. 420 bar, pressure override M6 M6 Pressure test port, travel pressure reverse Pressure test port, travel pressure reverse MA MA max. 420 bar, pressure override max. 420 bar, pressure override M7 M7 Pressure test port, down-cut milling Pressure test port, down-cut milling MB MB max. 420 bar, pressure override max. 420 bar, pressure override M8 M8 Pressure test port, up-cut milling Pressure test port, up-cut milling MA MA max. 420 bar, pressure override max. 420 bar, pressure override Variable displacement pumps, A4VG28EP to A4VG180EP Travel pump A4VG56 EP Variable displacement pumps, A4VG28EP to A4VG180EP Variable displacement pumps, A4VG28EP to A4VG180EP EP control with proportional solenoid EP control with proportional solenoid The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow. It has been designed for mobile applications, e.g. in construction equipment. The A4VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed circuits. The volumetric flow is proportional to the drive speed and the displacement. The volumetric flow can be infinitely changed by adjus... Fig. 2 A4VG 1 1 Drive shaft Drive shaft 7 7 Auxiliary pump (optional) Auxiliary pump (optional) 2 2 Retracting plate Retracting plate 8 8 High pressure side High pressure side 3 3 Control piston Control piston 9 9 Cylinder Cylinder 4 4 Control unit Control unit 10 10 Piston Piston 5 5 Valve plate Valve plate 11 11 Slipper pad Slipper pad 6 6 Low pressure side Low pressure side 12 12 Swashing cradle Swashing cradle The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines. The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines. Hydraulic diagram Hydraulic diagram Fig. 3 Hydraulic diagram, A4VG EP A A Work connection Work connection PS P S Control pressure inlet Control pressure inlet B B Work connection Work connection R R Ventilation Ventilation G G Pressure port for charge circuit Pressure port for charge circuit T1 T 1 Leak oil Leak oil MA M A Pressure test port, pressure A Pressure test port, pressure A T2 T 2 Leak oil Leak oil MB M B Pressure test port, pressure B Pressure test port, pressure B X1 X2 X 1 2 Port for control pressures, pressure in front of nozzle Port for control pressures, pressure in front of nozzle MH M H Port for balanced high pressure Port for balanced high pressure Connection overview Connection overview A4VG28 Fig. 4 A4VG 28 A4VG 40 to 56 Fig. 5 A4VG 40 to 56 A4VG 71 to 180 Fig. 6 A4VG 71 to 180 High pressure relief and charge pressure valve High pressure relief and charge pressure valve Fig. 7 Valve plate High pressure relief valves with integrated boost check valves and bypass (only travel pump Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safeguarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and relieve oil into the low pressure side. Th... HP-valves are always adjusted 10% higher than the pressure override. The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to compensate leaks and fl... Bypass control In this case the travel system is switched to free circulation. For this purpose the high pressure relief valves integrated in the variable displacement pump have a so-called bypass function. This means that by turning the screw (1) (Fig. 8) Fig. 8 Bypass control l Shut down the engine. l Shut down the engine. l Loosen the counter nuts by turning them with a hexagon spanner (SW 134) half a turn in anti-clockwise direction. l Use an Allen key (SW 4) to turn the screws clockwise, until the screw touches the spring cup, which can be noticed by the increasing resistance. l Turn the screw half a turn into the spring cup. Towing finished After towing back the screw out again. This resets the high pressure valves to their original setting. Tightening torque for counter nut 22 Nm. Tightening torque for counter nut 22 Nm. Charge pressure relief valve The charge pressure valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the pre-adjusted value. Pressure override valve The pressure override limits the operating pressure. The pressure override is a kind of pressure regulation, which, when the adjusted nominal pressure is reached, reduces the displacement of the pump to such an extent, that the adjusted pressure is j... EP - control EP - control Fig. 9 EP - control 1 1 Setscrew for mechanical neutral position Setscrew for mechanical neutral position 5 5 Proportional solenoid valve Proportional solenoid valve 2 2 Neutral setting spring Neutral setting spring 6 6 Valve spool Valve spool 3 3 Control piston Control piston 7 7 Feedback lever Feedback lever 4 4 Control chamber Control chamber Fig. 10 EP control Depending on the pre-selected ampacity "I" on the two proportional solenoids, the control cylinder on the pump is supplied with control pressure through the EP control unit. This way the swash plate and thus the displacement of the pump can be infini... The spring reset in the control unit is no safety feature. The spring reset in the control unit is no safety feature. Internal contamination � like e.g. contaminated hydraulic fluid, abrasion or dirt residues from system components � can cause blockage of the spool valve in the control unit. The flow volume from the variable displacement pump will in this case n... Variable displacement pumps, A4VG28EP to A4VG180EP Rotor pump, A4VG180 EP Variable displacement pumps, A4VG28EP to A4VG180EP Variable displacement pumps, A4VG28EP to A4VG180EP EP control with proportional solenoid EP control with proportional solenoid The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow. It has been designed for mobile applications, e.g. in construction equipment. The A4VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed circuits. The volumetric flow is proportional to the drive speed and the displacement. The volumetric flow can be infinitely changed by adjus... Fig. 11 A4VG 1 1 Drive shaft Drive shaft 7 7 Auxiliary pump Auxiliary pump 2 2 Retracting plate Retracting plate 8 8 High pressure side High pressure side 3 3 Control piston Control piston 9 9 Cylinder Cylinder 4 4 Control unit Control unit 10 10 Piston Piston 5 5 Valve plate Valve plate 11 11 Slipper pad Slipper pad 6 6 Low pressure side Low pressure side 12 12 Swashing cradle Swashing cradle The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines. The variable displacement axial piston pump must be filled with pressure fluid and purged during start- up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines. Hydraulic diagram Hydraulic diagram Fig. 12 Hydraulic diagram, A4VG EP A A Work connection Work connection MH M H Port for balanced high pressure Port for balanced high pressure B B Work connection Work connection PS P S Control pressure inlet Control pressure inlet G G Pressure port for charge circuit Pressure port for charge circuit R R Ventilation Ventilation Fa Fa Filter outlet Filter outlet S S Suction line for charge oil Suction line for charge oil Fa1 Fa1 Filter outlet (attachment filter) Filter outlet (attachment filter) T1 T 1 Leak oil Leak oil Fe Fe Filter inlet Filter inlet T2 T 2 Leak oil Leak oil FS FS Port from filter to suction line (cold start) Port from filter to suction line (cold start) X1 X2 X 1 2 Port for control pressures, pressure in front of nozzle Port for control pressures, pressure in front of nozzle MA M A Pressure test port, pressure A Pressure test port, pressure A MB M B Pressure test port, pressure B Pressure test port, pressure B Connection overview Connection overview A4VG28 Fig. 13 A4VG 28 A4VG 40 to 56 Fig. 14 A4VG 40 to 56 A4VG 71 to 180 Fig. 15 A4VG 71 to 180 High pressure relief and charge pressure valve High pressure relief and charge pressure valve Fig. 16 Valve plate High pressure relief valves with integrated boost check valves without bypass Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safeguarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and relieve oil into the low pressure side. Th... The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure side and allow cool and filtered oil flow from the charge oil circuit to flow into the closed hydraulic circuit, in order to compensate le... HP-valves are always adjusted 10% higher than the pressure override. Pressure override valve The pressure override limits the operating pressure. The pressure override is a kind of pressure regulation, which, when the adjusted nominal pressure is reached, reduces the displacement of the pump to such an extent, that the adjusted pressure is j... EP - control EP - control Fig. 17 EP - control 1 1 Setscrew for mechanical neutral position Setscrew for mechanical neutral position 5 5 Proportional solenoid valve Proportional solenoid valve 2 2 Neutral setting spring Neutral setting spring 6 6 Valve spool Valve spool 3 3 Control piston Control piston 7 7 Feedback lever Feedback lever 4 4 Control chamber Control chamber Fig. 18 EP control Depending on the pre-selected ampacity "I" on the two proportional solenoids, the control cylinder on the pump is supplied with control pressure through the EP control unit. This way the swash plate and thus the displacement of the pump can be infini... The spring reset in the control unit is no safety feature. The spring reset in the control unit is no safety feature. Internal contamination � like e.g. contaminated hydraulic fluid, abrasion or dirt residues from system components � can cause blockage of the spool valve in the control unit. The flow volume from the variable displacement pump will in this case n... Auxiliary pump Auxiliary pump The auxiliary pump permanently delivers a sufficient amount of fluid (charging volume) from a small tank through a check valve into the low pressure side of the closed circuit, in order to replace internal leakages in variable displacement pump and c... Swash plate principle Axial piston swash plate principle. Swash plate principle Swash plate principle Fig. 19 The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive shaft. The pistons are thereby supported by the swash plate. Description of function Description of function Fig. 20 1 1 Drive shaft Drive shaft 8 8 Through drive Through drive 2 2 Piston Piston 9 9 Valve plate Valve plate 3 3 Piston area Piston area 10 10 Top dead centre TDC Top dead centre TDC 4 4 Piston stroke Piston stroke 11 11 Bottom dead centre BTC Bottom dead centre BTC 5 5 Slipping disc Slipping disc 12 12 Control slots in suction side of swash plate (for sense of rotation shown) Control slots in suction side of swash plate (for sense of rotation shown) 6 6 Adjusting angle Adjusting angle 13 13 Control slot on pressure side Control slot on pressure side 7 7 Cylinder Cylinder Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection. The cylinder rotates with the drive shaft and drives the 9 pistons. The pistons rest with their slipper pads on the sliding face of the swashing cradle an... 11.8 Troubleshooting axial piston pumps The following table should be of help when performing troubleshooting This table is by no means complete. The following table should be of help when performing troubleshooting This table is by no means complete. In practice you may encounter problems that have not been listed here. Procedure Procedure l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected. l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected. l Get an overview over the function of the product in connection with the overall system. l Try to clarify whether the product was able to deliver the required function within the overall system before the fault occurred. l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine driver. Try to detect changes to the overall system, the product is installed in: l Have conditions or area of application of the product been changed? l Have conditions or area of application of the product been changed? l Were changes (e.g. changeovers) or repairs made to the overall system (machine l Has the product or the machine been operated as intended? l How does the fault occur? Fault Fault Possible cause Possible cause Remedy Remedy Unusual noises Unusual noises Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line. Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line. Machine or system manufacturer (e.g. optimize feed conditions, use suitable pressure fluid). Machine or system manufacturer (e.g. optimize feed conditions, use suitable pressure fluid). Completely purge the axial piston unit, fill the suction line with pressure fluid. Completely purge the axial piston unit, fill the suction line with pressure fluid. Remove foreign bodies from inside the suction line. Remove foreign bodies from inside the suction line. Inappropriate fastening of the axial piston unit. Inappropriate fastening of the axial piston unit. Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques. Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques. Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines. Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines. Fasten attachment parts as specified by the coupling or fittings manufacturer. Fasten attachment parts as specified by the coupling or fittings manufacturer. Pressure relief valves of the axial piston unit (charge pressure, high pressure, pressure override). Pressure relief valves of the axial piston unit (charge pressure, high pressure, pressure override). Purge the axial piston unit, check the viscosity of the pressure fluid, consult the service department. Purge the axial piston unit, check the viscosity of the pressure fluid, consult the service department. Mechanical damage to the axial piston unit. Mechanical damage to the axial piston unit. Replace the axial piston unit, consult the service department. Replace the axial piston unit, consult the service department. No or insufficient volumetric flow No or insufficient volumetric flow Faulty mechanical drive (e.g. defective coupling). Faulty mechanical drive (e.g. defective coupling). Check and repair the drive. Check and repair the drive. Drive speed too low. Drive speed too low. Consult the service department. Consult the service department. Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line. Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line. Completely purge the axial piston unit, fill the suction line with pressure fluid. Completely purge the axial piston unit, fill the suction line with pressure fluid. Remove foreign bodies from inside the suction line. Remove foreign bodies from inside the suction line. Pressure fluid not within the optimal viscosity range. Pressure fluid not within the optimal viscosity range. Use appropriate pressure fluid. Use appropriate pressure fluid. External control and setting facilities defective. External control and setting facilities defective. Check the external control. Check the external control. Pilot or control pressure too low. Pilot or control pressure too low. Check pilot and control pressure, consult the service department. Check pilot and control pressure, consult the service department. Functional disturbance in the control facility or the regulator on the axial piston unit. Functional disturbance in the control facility or the regulator on the axial piston unit. Consult the service department. Consult the service department. Wear of the axial piston unit. Wear of the axial piston unit. Replace the axial piston unit. Replace the axial piston unit. Mechanical damage to the axial piston unit. Mechanical damage to the axial piston unit. Replace the axial piston unit. Replace the axial piston unit. No or insufficient pressure No or insufficient pressure Faulty mechanical drive (e.g. defective coupling). Faulty mechanical drive (e.g. defective coupling). Check and repair the drive. Check and repair the drive. Poor drive power. Poor drive power. Consult the service department. Consult the service department. Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line. Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line. Completely purge the axial piston unit, fill the suction line with pressure fluid. Completely purge the axial piston unit, fill the suction line with pressure fluid. Remove foreign bodies from inside the suction line. Remove foreign bodies from inside the suction line. Pressure fluid not within the optimal viscosity range. Pressure fluid not within the optimal viscosity range. Use appropriate pressure fluid. Use appropriate pressure fluid. External control and setting facilities defective. External control and setting facilities defective. Check the external control. Check the external control. Pilot or control pressure too low. Pilot or control pressure too low. Check pilot and control pressure. Check pilot and control pressure. Functional disturbance in the control facility or the regulator on the axial piston unit. Functional disturbance in the control facility or the regulator on the axial piston unit. Consult the service department. Consult the service department. Wear of the axial piston unit. Wear of the axial piston unit. Replace the axial piston unit. Replace the axial piston unit. Mechanical damage to the axial piston unit. Mechanical damage to the axial piston unit. Replace the axial piston unit. Replace the axial piston unit. Drive unit defective (e.g. hydraulic motor or cylinder). Drive unit defective (e.g. hydraulic motor or cylinder). Check the drive unit, replace if necessary. Check the drive unit, replace if necessary. Fluctuations in pressure Fluctuations in pressure Axial piston unit not or insufficiently purged. Axial piston unit not or insufficiently purged. Completely purge the axial piston unit. Completely purge the axial piston unit. Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line. Insufficient suction conditions, e.g. air in the suction line, inadequate diameter of the suction line, excessive viscosity of the pressure fluid, extreme suction height, too low suction pressure, foreign bodies in the suction line. Completely purge the axial piston unit, fill the suction line with pressure fluid. Completely purge the axial piston unit, fill the suction line with pressure fluid. Remove foreign bodies from inside the suction line. Remove foreign bodies from inside the suction line. Pressure fluid too hot. Pressure fluid too hot. Excessive input temperature on axial piston unit. Excessive input temperature on axial piston unit. Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low. Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low. Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller). Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller). Consult the service department. Consult the service department. Malfunction of the flushing valve (not for nominal size 18). Malfunction of the flushing valve (not for nominal size 18). Consult the service department. Consult the service department. Wear of the axial piston unit. Wear of the axial piston unit. Replace the axial piston unit. Replace the axial piston unit. External gear pumps External gear pumps External gear pumps External gear pumps External gear pumps mainly consist of the friction bearing mounted gear pair and the housing with front and rear covers. The drive shaft, which is sealed with a radial seal, protrudes from the front cover. The bearing forces are absorbed by friction ... External gear pumps mainly consist of the friction bearing mounted gear pair and the housing with front and rear covers. The drive shaft, which is sealed with a radial seal, protrudes from the front cover. The bearing forces are absorbed by friction ... Fig. 21 Axial compensation of gear pump Internal sealing of the pressure chambers is achieved by flow volume dependent forces. This results in an excellent rate of efficiency. On the rear side the moveable bearing bushings are pressurized and thus tightly pressed against the gears. The pre... Function Function Fig. 22 The increasing volume caused by a tooth exiting a tooth gap results in a vacuum in the suction chamber. The pressure fluid is transported into the pressure chamber. There the meshing of teeth and tooth gaps displaces the pressure fluid into the upper... Fig. 23 1 1 Cover Cover 6 6 Gear (driven) Gear (driven) 2 2 Seals and gaskets Seals and gaskets 7 7 Shaft Shaft 3 3 Housing Housing 8 8 Flange Flange 4 4 Gear (driving) Gear (driving) 9 9 Bearing plate Bearing plate 5 5 Displacement chamber Displacement chamber 10 10 Bearing plate Bearing plate Multiple gear pumps Multiple gear pumps Gear pumps are most suitable for multiple pump arrangements, whereby the drive shaft of the first pump is extended to a second and third pump. The shafts are connected by drivers in between. The individual pump stages are sealed to each other, i.e. t... Fig. 24 11.10 Travel system All travel motors and the travel pump of the MPH 122 are electrically proportionally (EP) adjustable. The current signals required for this purpose are provided by the ESX-control. These electric signals are calculated on the basis of the input signa... All travel motors and the travel pump of the MPH 122 are electrically proportionally (EP) adjustable. The current signals required for this purpose are provided by the ESX-control. These electric signals are calculated on the basis of the input signa... Fig. 1 Block diagram 1 1 Travel lever, S55 Travel lever, S55 11 11 Pressure transducer travel pressure control, B112 Pressure transducer travel pressure control, B112 2 2 Speed controller, S155 Speed controller, S155 12 12 Rotary speed sensors, B107, B108 and B109 Rotary speed sensors, B107, B108 and B109 3 3 Rotary switch for travel speed ranges, S54 Rotary switch for travel speed ranges, S54 13 13 Travel pump Y16, Y17 Travel pump Y16, Y17 4 4 Rotary switch for automatic power limit control, S148 Rotary switch for automatic power limit control, S148 14 14 Travel motor FL, Y132 Travel motor FL, Y132 5 5 Fault diagnostics Fault diagnostics 15 15 Travel motor FR, Y132 Travel motor FR, Y132 6 6 CAN-module, P18 CAN-module, P18 16 16 Travel motor, rear, Y31 Travel motor, rear, Y31 7 7 Instrument cluster, A81 Instrument cluster, A81 17 17 Emergency Stop, S01 Emergency Stop, S01 8 8 Diesel engine Diesel engine 18 18 Contgrol chamber short-circuit valve, Y11 Contgrol chamber short-circuit valve, Y11 9 9 RPM-sensor RPM-sensor 19 19 Brake valve, Y04 Brake valve, Y04 10 10 ESX, A66 ESX, A66 Control and adjustment logic in the travel system Front motors Front motors Rear motor Rear motor Travel pump Travel pump travel speed range travel speed range Basic setting Basic setting influenced by: influenced by: Basic setting Basic setting influenced by: influenced by: Basic setting dependent on travel lever and Tempomat setting: Basic setting dependent on travel lever and Tempomat setting: influenced by: influenced by: 1 1 Qmax Q max 220 mA ASR: with slippage adjustment towards Qmin ASR: with slippage adjustment towards Q min Qmax Q max 220 mA ASR: with slippage adjustment towards Qmin ASR: with slippage adjustment towards Q min Q = 0 to Qmax Q = 0 to Q max approx. 230 - 680 mA AGLR (switchable): if the engine speed drops below 1900 rpm, adjustment towards 0 within the selected milling range I I approx. 420 mA approx. 420 mA Pressure regulation: above 330 bar adjustment towards Qmax; when rotor height shut-down is reached, motors to Qmax Pressure regulation: above 330 bar adjustment towards Q max max approx. 500 mA approx. 500 mA Pressure regulation: above 330 bar adjustment towards Qmax; when rotor height shut-down is reached, motors to Qmax Pressure regulation: above 330 bar adjustment towards Q max max Q = 0 to Qmax Q = 0 to Q max approx. 230 - 680 mA II II approx. 500 mA approx. 500 mA Q = 0 Q = 0 Q = 0 to Qmax Q = 0 to Q max approx. 220 - 680 mA Fig. 2 Travel circuit Travel circuit The travel drive of the MPH 122 is a closed hydrostatic circuit and consists mainly of: The travel drive of the MPH 122 is a closed hydrostatic circuit and consists mainly of: l the travel pump with control and safety elements, l the travel pump with control and safety elements, l the axle drive motor, l the two drive motors on the planetary gears of the front wheels and l the pressure resistant connecting hoses Travel pump and rotor pumps for the milling system are connected to a triple pump unit. Viewed from the diesel engine the travel pump is the 3rd pump element. The pump delivers the hydraulic oil to the motors for front wheel and rear axle drive. All travel motors are connected parallel to each other. This compensates displacement differentials between the individual motors. The travel motors are designed for variable displacement. This results in a higher travel speed when using minimum displacement, which is mainly used when transporting the machine without rotor operation. The pressure in the closed travel circuit generated by the rolling resistance of the wheels is limited by the pressure override in the pump to maximum 420 bar. A flushing valve in the axle drive motor flushes a certain quantity of oil out of the closed circuit when the machine is driving. These flushing quantities and possible leaks in the closed circuit are immediately replenished by the charge oil circuit... Return flow filter block Return flow filter block All leakages and flushing quantities central return flow filter block Fig. 3 The return flow filter block contains two 80 � filters, one magnetic sensor (B19), one pressure switch (B25), one temperature control valve, one pressure test port and eight magnetic plugs. All return flows pass through the primary filter, followed by a temperature controlled valve (thermostat). This valve guides the oil flow directly back to the tank, until the operating temperature is reached. At an oil temperature of 55 �C the valve... If the primary filter is dirty, the oil flow is guided through the secondary filter. The oil can only pass through this filter when the static pressure in front of the primary filter is > 2 bar. In this case the oil is no longer cooled. The pressure ... In addition to this the dirt sensor (B19) reports any metallic contamination in the oil via a visual indicator in the cabin. Charge circuit Charge circuit The charge pump (with the additional function of a steering pump) required for the charge circuit Besides the supply of fresh and filtered oil for the closed travel circuit the charge circuit is also needed to control travel pump and rotor pumps. The charge circuit (Fig. 4) bypass valve D The differential pressure switch D Fig. 4 Charge circuit filter Fig. 5 Charge circuit Priority valve Priority valve In load sensing (LS) steering systems both the steering system as well as other hydraulic circuits (in this case the charge circuit) can be supplied by one common pump. A priority valve makes sure that the steering system always has top Brake operation and control chamber short-circuit valve Brake operation and control chamber short-circuit valve Fig. 6 Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Electric circuit diagram Electric circuit diagram Measuring values and switching points Measuring values and switching points 1 1 Brake release solenoid valve Brake release solenoid valve 21 21 Y04 Y04 32 bar on measuring bar port M3 32 bar on measuring bar port M3 2 2 Pressure relief valve Pressure relief valve 23 23 max. 35 bar on test port for cabin tilting cylinder max. 35 bar on test port for cabin tilting cylinder 3 3 Ball valve, brake releasing system Ball valve, brake releasing system 22 22 32 bar 32 bar 4 4 Hand pump, cabin tilting cylinder + brake releasing device. Hand pump, cabin tilting cylinder + brake releasing device. Serves the purpose of an emergency pump in case of hydraulic 26 26 max. 210 bar on cabin tilting cylinder max. 210 bar on cabin tilting cylinder 5 5 Ball valve for emergency operation Ball valve for emergency operation 48 48 During operation the closed hydrostatic travel circuit has the function of a service brake. When switching the travel control to neutral, the solenoid valve on the travel pump is de-energized and the pump returns to neutral position. Pumping of oil i... However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause creeping of the machine when it is parked on a slope with the engine running, the machine is additionally equipped with multi-disc brakes in the pla... The gearbox integrated wet hydraulic multi-disc brake serves has the function of a parking brake. It is permanently closed by spring force and opened by feeding in charge oil. Fig. 7 Travel pump, short-circuit valve Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Electric circuit diagram Electric circuit diagram Measuring values and switching points Measuring values and switching points Travel pump, short-circuit valve Travel pump, short-circuit valve 45 45 Y11 Y11 open without current open without current The control chamber short-circuit valve is closed during travel operation. The control chamber short-circuit valve is closed during travel operation. Travel gear Travel gear The planetary gear GFT 50 is a three-stage planetary gear. The gearbox includes an integrated, hydraulically vented multi-disc parking brake. In order to assure optimal load compensation, the planet stage is fitted with planet gears sorted by sets. T... Travel motors Travel motors The drive motors for the front wheel planetary drives and for the rear axle are HYDROMATIK bent axle motors of type A6VE 107 EP2 (front wheels) or A6VM 107 EP2 (rear axle). The motors are designed with variable displacement and can therefore be opera... Once the respective piston has passed its dead centre (max. extended position), it will change to the low pressure side. The continuing rotation forces the piston back into the cylinder block. This presses the oil in the cylinder chamber through the ... Charge pressure can be applied to the control unit on the travel motor via a solenoid valve. This changes the angle position of the piston drum to the output shaft. In this context a large angle corresponds with a high displacement. In low speed range the motor works with a high torque. With small angle the conditions are reversed. The displacement values thereby only depend on the control current applied to the proportional solenoids. The high pressure in the system has no hydraulic effect on the actual displacement of the travel motors. When de-energized the motors are in high displacement position (Q max min Fig. 8 Hydraulic diagram of rear axle motor with flushing valve The flushing valve (4) is fitted with a downstream 16 bar pressure relief valve. This valve makes sure that only a certain quantity of hydraulic oil is flushed out of the low pressure side. This oil flows back to the hydraulic tank. The flushed out oil is immediately replaced with fresh and filtered oil through the corresponding boost check valve. A, from B, from 1 1 motor motor 5 5 Flushing pressure relief valve Flushing pressure relief valve 2 2 Control piston Control piston 6 6 Check valves Check valves 3 3 Proportional valve with solenoid, Y31 Proportional valve with solenoid, Y31 7 7 Rear axle layshaft Rear axle layshaft 4 4 Flushing valve Flushing valve 8 8 Rear axle Rear axle Fig. 9 Front wheel motor with planetary gear and brake A, from B, from 1 1 motor motor 4 4 Check valves Check valves 2 2 Control piston Control piston 5 5 Multi-disc brake on planetary gear Multi-disc brake on planetary gear 3 3 Proportional valve with solenoid, Y33 Proportional valve with solenoid, Y33 Cross-sectional drawing rear axle travel motor Fig. 10 A6VM 107 EP2 1 1 Output shaft Output shaft 7 7 Control piston Control piston 2 2 Working pistons Working pistons 8 8 Control solenoid Control solenoid 3 3 Cylinder block Cylinder block 9 9 Electric control start adjustment screw - do not turn! Electric control start adjustment screw - do not turn! 4 4 Qmax setscrew Q max 10 10 Qmin setscrew Q min 5 5 Valve plate Valve plate 11 11 Flushing pressure relief valve Flushing pressure relief valve 6 6 Swivel journal Swivel journal 12 12 Flushing valve Flushing valve Description of function Description of function The travel motors A6VM and A6VE just differ by a different housing. The travel motors A6VM and A6VE just differ by a different housing. The A6VM The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines. The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines. Fig. 11 1 1 Drive shaft Drive shaft 6 6 Cylinder Cylinder 2 2 Control piston Control piston 7 7 Piston Piston 3 3 Control piston Control piston 8 8 Setscrew for control start Setscrew for control start 4 4 Connecting plate Connecting plate 9 9 Setscrew, Vg min Setscrew, Vg min 5 5 Valve plate Valve plate In variable displacement axial piston in bent axle design the pistons (7) are arranged in an inclined position to the drive shaft (1). The pistons perform an axial movement, which is then converted to a rotary movement by the piston joint on the driv... Motor function Motor function A variable displacement axial piston motor converts the hydrostatic energy into mechanical energy. Pressure fluid is fed through the connecting plate (4) and the valve plate (5) into the cylinder bores. The pistons (7) inside the cylinder bores perfo... Sensors Sensors The A6VM Fig. 12 The DSM sensor is fastened to the specially intended connection with a fastening screw Control Control In a variable displacement axial piston motor the angle of the bent axle can be infinitely adjusted within certain limits. The change in swashing angle of the bent axle causes a difference in stroke length and thus a change in displacement. The swash... 11.11 Trouble shooting, variable displacement axial piston motor The following table should be of help when performing troubleshooting This table is by no means complete. The following table should be of help when performing troubleshooting This table is by no means complete. In practice you may encounter problems that have not been listed here. Procedure Procedure l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected. l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected. l Get an overview over the function of the product in connection with the overall system. l Try to clarify whether the product was able to deliver the required function within the overall system before the fault occurred. l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine driver. Try to detect changes to the overall system, the product is installed in: l Have conditions or area of application of the product been changed? l Have conditions or area of application of the product been changed? l Were changes (e.g. changeovers) or repairs made to the overall system (machine l Has the product or the machine been operated as intended? l How does the fault occur? Fault Fault Possible cause Possible cause Remedy Remedy Unusual noises Unusual noises Inappropriate fastening of the axial piston unit Inappropriate fastening of the axial piston unit Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques! Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques! Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines. Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines. Fasten attachment parts as specified by the coupling or fittings manufacturer. Fasten attachment parts as specified by the coupling or fittings manufacturer. Mechanical damage to the axial piston unit. Mechanical damage to the axial piston unit. Replace the axial piston unit Replace the axial piston unit Fluctuations in pressure Fluctuations in pressure Axial piston unit not or insufficiently purged. Axial piston unit not or insufficiently purged. Completely purge the axial piston unit. Completely purge the axial piston unit. Operation data are not reached. Operation data are not reached. Insufficient flow from hydraulic pump Insufficient flow from hydraulic pump Check the function of the hydraulic pump Check the function of the hydraulic pump Minimum displacement incorrectly set Minimum displacement incorrectly set Consult the service department. Consult the service department. External control and setting facilities defective. External control and setting facilities defective. Check the external control. Check the external control. Control pressure too low Control pressure too low Check control pressure, consult the service department. Check control pressure, consult the service department. Functional disturbance in the control facility or the regulator on the axial piston unit. Functional disturbance in the control facility or the regulator on the axial piston unit. Consult the service department. Consult the service department. Pressure fluid not within the optimal viscosity range. Pressure fluid not within the optimal viscosity range. Use appropriate pressure fluid. Use appropriate pressure fluid. Wear of the axial piston unit Wear of the axial piston unit Replace the axial piston unit Replace the axial piston unit Mechanical damage to the axial piston unit. Mechanical damage to the axial piston unit. Replace the axial piston unit Replace the axial piston unit Pressure fluid too hot. Pressure fluid too hot. Excessive input temperature on axial piston unit. Excessive input temperature on axial piston unit. Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low. Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low. Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller). Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller). Consult the service department. Consult the service department. Failure of the flushing valve Failure of the flushing valve Consult the service department. Consult the service department. Wear of the axial piston unit Wear of the axial piston unit Replace the axial piston unit Replace the axial piston unit 11.12 Rotor drive Rotor drive Rotor drive Asphalt recyclers and soil stabilizers of series MPH 122 are equipped with a hydrostatically driven rotor. The rotors for statbilizer and recycler differ in working depth, diameter and number of teeth: Asphalt recyclers and soil stabilizers of series MPH 122 are equipped with a hydrostatically driven rotor. The rotors for statbilizer and recycler differ in working depth, diameter and number of teeth: The rotor is driven by radial piston motors on both ends. These motors are mounted inside the tube of the rotor. The rotor is almost completely covered by a rotor hood. This ensures that the processed material is neatly held in the track. MPH with a milling width of 2530 mm MPH with a milling width of 2530 mm MPH with a milling width of 2330 mm MPH with a milling width of 2330 mm Working depth Working depth 420 mm 420 mm 500 mm 500 mm Diameter Diameter 1225 mm 1225 mm 1125 mm 1125 mm Number of teeth Number of teeth 210 mm 210 mm 194 mm 194 mm Fig. 1 Rotor with rotor hood The rotor hood is fitted with moveable hood gates on the rear. These are opened more or less, in dependence on the cutting depth. Baffle plates inside the rotor hood help to pulverize the cut material and prevent blocking of the hood. The rotor circuit consists of: l two axial piston pumps l two axial piston pumps l two radial piston motors l a valve block and l a flushing valve. Both rotor pumps Fig. 2 Function logic of the rotor drive Function logic of the rotor drive The two rotor pumps on the MPH 122 are electrically proportionally controlled. Always one pump supplies one rotor motor with pressure oil. The return flow from the motors then flows to the low pressure port on the corresponding pump. This obviously h... The two rotor pumps on the MPH 122 are electrically proportionally controlled. Always one pump supplies one rotor motor with pressure oil. The return flow from the motors then flows to the low pressure port on the corresponding pump. This obviously h... For this purpose both pumps are electrically controlled to different oil supply directions. If solenoid Y39 is triggered on pump 1, solenoid Y40 on pump 2 will be supplied with current. This diverse electrical control results in the following hydraulic arrangement (see hydraulic diagram): l The rotor pump (02) delivers oil from port (B) to inlet port (B) on the radial piston motor (29) (high pressure). l The rotor pump (02) delivers oil from port (B) to inlet port (B) on the radial piston motor (29) (high pressure). l From outlet (A) of rotor motor (29) the oil flows to port (B) on rotor pump (03) (low pressure). l At the same time rotor pump (05) delivers oil from port (A) to inlet (B) on rotor motor (07) (high pressure). l The return flow from outlet (A) of rotor motor (07) now flows to port (A) on rotor pump (04) (low pressure). The electric signals for triggering are calculated by the ESX-control in dependence on the switching position of the rotor speed switch. rotor motors rotor motors Rotor pumps Rotor pumps Effects on the travel circuit Effects on the travel circuit Fixed displacement motors; speed only dependent on pump flow volume Fixed displacement motors; speed only dependent on pump flow volume Electrical proportional control in dependence on the switching position of the rotor speed switch: Electrical proportional control in dependence on the switching position of the rotor speed switch: The machine load caused by cutting operation is indirectly sensed through the diesel engine speed. In automatic operation the travel pump displacement is reduced when the engine speed is forced below 1900 rpm. This slows down the travel speed and red... The machine load caused by cutting operation is indirectly sensed through the diesel engine speed. In automatic operation the travel pump displacement is reduced when the engine speed is forced below 1900 rpm. This slows down the travel speed and red... Rotary speeds at an engine speed of 2250 rpm: Rotary speeds at an engine speed of 2250 rpm: Stage 1: 125 rpm. Stage 1: 125 rpm. Stage 1: 480 mA Stage 1: 480 mA Stage 11: 185 rpm Stage 11: 185 rpm Stage 11: 660 mA Qmax Stage 11: 660 mA Q max no sensing of rotary speed (feedback) no sensing of rotary speed (feedback) no sensing of rotary speed (feedback) no sensing of rotary speed (feedback) when the rotor top height shut-down is reached, the pumps return to Q = 0, the rotor stops when the rotor top height shut-down is reached, the pumps return to Q = 0, the rotor stops When reaching the rotor height limit switch in travel speed ranges I+ II the travel motors change to Qmax. This corresponds with milling range 3. When reaching the rotor height limit switch in travel speed ranges I+ II the travel motors change to Q max Function logic of tool change control Function logic of tool change control l Rotor or rotor hood must be in top shut-off position. l Rotor or rotor hood must be in top shut-off position. l The diesel engine speed must be below 1000 rpm. l When pressing the tool change push button the rotor drive is always enabled for 2 seconds. Fig. 3 Distributor block Distributor block Before the rotor motors all hoses are connected to a distributor block. On this distributor block the respective pressurized lines (high pressure and low pressure are connected among each other. This compensates differences in the pumping quantities ... Check valves Check valves As a measure to avoid overheating of the rotor motors both motors are cross flushed (10 l Flushing valve Flushing valve The distributor block is fitted with a flushing valve. This flushing valve is controlled by the high pressure side of the rotor circuit and releases oil from the low pressure side. At a pressure differential of 3 - 5 bar in the work system lines A an... Charge circuit Charge circuit The control oil required for the control of the rotor pumps is provided by the internal charge pumps Both charge circuits are fitted with one 12 �m fine filter each. Both charge circuits The charge oil filters (Fig. 4) by-pass valves D The differential pressure switches D Fig. 4 Charge circuit filter Return flow filter block Return flow filter block Fig. 5 Return flow filter block All leakages and flushing quantities central return flow filter block The return flow filter block contains two 80 � filters, one magnetic sensor (B19), one pressure switch (B25), one temperature control valve, one pressure relief valve, one test port and eight magnetic plugs. All return flows pass through the primary filter, followed by a temperature controlled valve (thermostat). This valve guides the oil flow directly back to the tank, until the operating temperature is reached. At an oil temperature of 55 �C the valve... If the primary filter is dirty, the oil flow is guided through the secondary filter. The oil can only pass through this filter when the static pressure in front of the primary filter is > 2 bar. In this case the oil is no longer cooled. The pressure ... In addition to this the dirt sensor (B19) reports any metallic contamination in the oil via a visual indicator in the cabin. Control chamber short-circuit valves Control chamber short-circuit valves Fig. 6 Control chamber short circuit valve rotor pumps Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Control chamber short circuit valve from rotor pump 1 Control chamber short circuit valve from rotor pump 1 43 43 Y28, page 007 Y28, page 007 open without current open without current 2 2 Control chamber short circuit valve from rotor pump 2 Control chamber short circuit valve from rotor pump 2 44 44 Y49, page 007 Y49, page 007 open without current open without current Rotor gear Fig. 7 Sectional drawing of rotor The rotor is driven by two planetary gears (GFT50) with flange-mounted hydraulic motors series A2FE107 Plug-in fixed displacement motors A2FE and A2FM Plug-in fixed displacement motors A2FE and A2FM Product description Product description A plug-in fixed displacement motor converts the hydrostatic volumetric flow into mechanical rotary motion. It has mainly been designed for installation into mechanical gear drives. Description of unit Description of unit The A2FE Design of the axial piston motor Design of the axial piston motor In fixed displacement motors in bent axle design the pistons (2) (Fig. 8) Fig. 8 1 1 Drive shaft Drive shaft 4 4 Valve plate Valve plate 2 2 Piston Piston 5 5 Connecting plate Connecting plate 3 3 Cylinder Cylinder 6 6 Flushing valve (optional) Flushing valve (optional) Description of function Description of function A fixed displacement plug-in motor converts the hydrostatic energy into mechanical energy. Pressure fluid is fed through the connecting plate (5) and the valve plate (4) into the cylinder bores. The pistons (2) inside the cylinder bores perform an ax... 11.13 Trouble shooting, variable displacement axial piston motor The following table should be of help when performing troubleshooting This table is by no means complete. The following table should be of help when performing troubleshooting This table is by no means complete. In practice you may encounter problems that have not been listed here. Procedure Procedure l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected. l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and changing of settings can lead to a situation in which the original cause of a fault can no longer be detected. l Get an overview over the function of the product in connection with the overall system. l Try to clarify whether the product was able to deliver the required function within the overall system before the fault occurred. l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine driver. Try to detect changes to the overall system, the product is installed in: l Have conditions or area of application of the product been changed? l Have conditions or area of application of the product been changed? l Were changes (e.g. changeovers) or repairs made to the overall system (machine l Has the product or the machine been operated as intended? l How does the fault occur? Fault Fault Possible cause Possible cause Remedy Remedy Unusual noises Unusual noises Inappropriate fastening of the axial piston unit Inappropriate fastening of the axial piston unit Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques! Check the fastening of the axial piston unit as specified by the machine or plant manufacturer. Observe the tightening torques! Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines. Inappropriate fastening of attachment parts, e.g. coupling and hydraulic lines. Fasten attachment parts as specified by the coupling or fittings manufacturer. Fasten attachment parts as specified by the coupling or fittings manufacturer. Mechanical damage to the axial piston unit. Mechanical damage to the axial piston unit. Replace the axial piston unit Replace the axial piston unit Fluctuations in pressure Fluctuations in pressure Axial piston unit not or insufficiently purged. Axial piston unit not or insufficiently purged. Completely purge the axial piston unit. Completely purge the axial piston unit. Operation data are not reached. Operation data are not reached. Insufficient flow from hydraulic pump Insufficient flow from hydraulic pump Check the function of the hydraulic pump Check the function of the hydraulic pump Minimum displacement incorrectly set Minimum displacement incorrectly set Consult the service department. Consult the service department. External control and setting facilities defective. External control and setting facilities defective. Check the external control. Check the external control. Control pressure too low Control pressure too low Check control pressure, consult the service department. Check control pressure, consult the service department. Functional disturbance in the control facility or the regulator on the axial piston unit. Functional disturbance in the control facility or the regulator on the axial piston unit. Consult the service department. Consult the service department. Pressure fluid not within the optimal viscosity range. Pressure fluid not within the optimal viscosity range. Use appropriate pressure fluid. Use appropriate pressure fluid. Wear of the axial piston unit Wear of the axial piston unit Replace the axial piston unit Replace the axial piston unit Mechanical damage to the axial piston unit. Mechanical damage to the axial piston unit. Replace the axial piston unit Replace the axial piston unit Pressure fluid too hot. Pressure fluid too hot. Excessive input temperature on axial piston unit. Excessive input temperature on axial piston unit. Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low. Check the system, e.g. malfunction of the cooler, pressure fluid level in tank too low. Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller). Malfunction of the pressure control valves (e.g. high pressure relief valve, pressure override, pressure controller). Consult the service department. Consult the service department. Failure of the flushing valve Failure of the flushing valve Consult the service department. Consult the service department. Wear of the axial piston unit Wear of the axial piston unit Replace the axial piston unit Replace the axial piston unit OSP steering valve 11.14 Articulated steering The machines are equipped with two steering wheels. The machines are equipped with two steering wheels. Hydrostatic steering Hydrostatic steering The steering circuit is an open hydraulic circuit and consists mainly of: The steering circuit is an open hydraulic circuit and consists mainly of: l the steering pump, l the steering pump, l the pressure relief valve l the priority valve l the steering valves l the steering cylinders l the pressure resistant connecting hoses Fig. 1 Articulated joint The pump (with the additional function of a charge pump) required for the The pump (with the additional function of a charge pump) required for the steering circuit Besides the supply of fresh and filtered oil for the closed travel circuit the charge circuit is also needed to control travel pump and rotor pumps. Fig. 2 Priority valve Priority valve In load sensing (LS) steering systems both the steering system as well as other hydraulic circuits (in this case the charge circuit) can be supplied by one common pump. A priority valve makes sure that the steering system always has top OSP steering valve OSP steering valve The OSP steering unit works hydrostatically, i.e. there is no mechanical connection between the steering wheel and the wheels to be steered (articulated joint, drum, etc.). The mechanical link is replaced by hydraulic piping and hoses between the ste... When the steering wheel is operated, the steering unit measures the exact oil quantity proportional to the rotation of the steering wheel. This oil quantity is directed to the steering cylinders. The steering unit mainly comprises of a rotary spool valve and a rating pump (gear set). The steering column connects the steering unit to the steering wheel of the vehicle. When operating the steering wheel the rotary spool valve makes sure that oil... Fig. 3 1 1 Check valve Check valve 8 8 Outer spool Outer spool 2 2 Shock valve Shock valve 9 9 Universal shaft Universal shaft 3 3 Pressure relief valve Pressure relief valve 10 10 Distributor plate Distributor plate 4 4 Housing with anti-cavitation valves Housing with anti-cavitation valves 11 11 Gear Gear 5 5 Inner spool Inner spool 12 12 Ring gear Ring gear 6 6 Neutral setting spring Neutral setting spring 13 13 Cover Cover 7 7 Pin Pin Control valve blocks SP-08 Control valve block Fig. 1 Load lowering load retaining The main function of these valves is the control of piston movements caused by negative loads. With their leak- free design the load is retained in any desired position, while the pressure relief valve protects the system against impermissible pressu... Y24 Y24 Rotor up Rotor up Y37 Y37 Cross-slope adjustment Cross-slope adjustment Y44 Y44 Rear rotor hood gate Rear rotor hood gate Y122 Y122 Plates up Plates up Y35 Y35 Rear steering Rear steering Fig. 2 Cross-slope adjustment Fig. 3 Vibratory plate Control valve blocks SP-08 Control valve blocks SP-08 The way valves are switchable valves or proportional valves 1 1 Housing Housing 8 8 Plug Plug 2 2 Main piston Main piston 9 9 Section pressure balance Section pressure balance 3 3 Adjustable orifice with load retaining function Adjustable orifice with load retaining function 10 10 Pressure balance spring Pressure balance spring 4 4 Pressure Pressure P P Pump Pump 5 5 hydraulically unlockable check valves hydraulically unlockable check valves A, B A, B consumers consumers 6 6 Magnet Magnet LS LS Load-Sensing (LS) Load-Sensing (LS) 7 7 Compression spring Compression spring T T Tank Tank Consumer control with electro-magnetic actuation Consumer control with electro-magnetic actuation The position of the main piston (2) relative to the housing (1) determines the flow direction and the volumetric quantity of the flow volume that is directed to the consumer ports (A or B). In non-operated condition the main piston is centred by compression spring (7). There is no connection from "P" to "A" or "B". If the electric control current exceeds the spring force, the main piston starts to move away from its middle position and opens the connection from P to A or P to B. Flow volume limitation Flow volume limitation The maximum flow volume can be mechanically adjusted via the adjusting orifice (3). Pressure relief setting Pressure relief setting Pressure valves with combined boost check function (4) protect the consumer ports "A" and "B" against pressure peaks and negative load conditions. Fig. 4 Pressure Unlockable check valves Unlockable check valves Optionally integrated hydraulically unlockable check valves (5) serve the purpose of leak-free locking of the consumers These can be integrated in one consumer line (B), but also in both consumer lines. Fig. 5 with hydraulically unlockable check valves Section pressure balance Section pressure balance With the main piston in middle position there is no connection between P and the consumer ports A and B. In this operating condition the pressure balance piston (9) is displaced to the left against the spring (10) by pump pressure. If a function is r... Fig. 6 Sectional pressure balance and pressure Inlet element for fixed displacement pumps (open center) Inlet element for fixed displacement pumps (open center) As long as none of the way valve axes has been actuated, the pump flow volume will flow through the Open- Center pressure balance to the tank. When one of the way valve axes is actuated, the load pressure works through the shuttle valve chain, which ... If the pump pressure exceeds the control pressure difference D Fig. 7 Inlet element with 3-way pressure balance "P" 11.17 Raising Hand pump Fig. 1 Fig. 2 Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Electric circuit diagram Electric circuit diagram Measuring values and switching points Measuring values and switching points 1 1 Brake release solenoid valve Brake release solenoid valve 21 21 Y04 Y04 32 bar on measuring bar port M3 32 bar on measuring bar port M3 2 2 Pressure relief valve Pressure relief valve 23 23 max. 35 bar on test port for cabin tilting cylinder max. 35 bar on test port for cabin tilting cylinder 3 3 Ball valve, brake releasing system Ball valve, brake releasing system 22 22 32 bar 32 bar 4 4 Hand pump, cabin tilting cylinder + brake releasing device. Hand pump, cabin tilting cylinder + brake releasing device. Serves the purpose of an emergency pump in case of hydraulic 26 26 max. 210 bar on cabin tilting cylinder max. 210 bar on cabin tilting cylinder 5 5 Ball valve for emergency operation Ball valve for emergency operation 48 48 Fig. 3 11.17 Raising 11.17 Raising Under normal conditions the cabin only needs to be lifted for repair work! Under normal conditions the cabin only needs to be lifted for repair work! Under normal conditions the cabin only needs to be lifted for repair work! Fig. 4 l Disconnect the water hose (1) l Disconnect the water hose (1) (Fig. 4) l Unscrew fastening screws (2) from the cabin. Fig. 5 l Turn the lever on hydraulic hand pump l Turn the lever on hydraulic hand pump (Fig. 5) On machines with ROPS platform raise the cabin only to the first possible locking position. On machines with ROPS platform raise the cabin only to the first possible locking position. l Operate the hydraulic hand pump, until the correct height for inserting the support rod is reached. l Operate the hydraulic hand pump, until the correct height for inserting the support rod is reached. Fig. 6 l Remove the support rod l Remove the support rod (Fig. 6) Fig. 7 Always secure the cabin with support rod, bolt and spring clip. Always secure the cabin with support rod, bolt and spring clip. l Assemble the support rod (1) l Assemble the support rod (1) (Fig. 7) l Remove the support rod and store it in the corresponding bracket before lowering the cabin. Fig. 8 l Turn the lever on hydraulic hand pump l Turn the lever on hydraulic hand pump (Fig. 8) The cabin moves down. Fig. 9 l Screw the fastening screws (2) into the cabin l Screw the fastening screws (2) into the cabin (Fig. 9) l Connect the water hose (1). 11.18 Towing 11.18 Towing Danger of accident! Danger of accident! Danger of accident! Before releasing the brake secure the machine against unintended rolling. Use a towing vehicle with sufficient traction and braking power for the unbraked towed load. Danger of accident! Danger of accident! You should always use a tow bar. Tow the machine only after releasing the parking brake. Tow the machine only after releasing the parking brake. Towing speed 1 km Releasing the multi-disc brake with the hydraulic hand pump Releasing the multi-disc brake with the hydraulic hand pump Fig. 10 l Turn the lever (1) on the hydraulic hand pump l Turn the lever (1) on the hydraulic hand pump (Fig. 10) l Unscrew the ball valve lock (2). l Unscrew the ball valve lock (2). Fig. 11 l Turn the ball valve l Turn the ball valve (Fig. 11) Fig. 12 l Operate the pump lever l Operate the pump lever (Fig. 12) Lifting the rotor with the hydraulic hand pump Lifting the rotor with the hydraulic hand pump Only lift the rotor with the hand pump in case of a hydraulic failure. Only lift the rotor with the hand pump in case of a hydraulic failure. Fig. 13 l Turn lever l Turn lever (Fig. 13) Fig. 14 l Unscrew the ball valve lock l Unscrew the ball valve lock (Fig. 14) l Set the ball valve to horizontal position. l Set the ball valve to horizontal position. l Keep operating the pump lever, until the rotor has reached transport position. l Keep operating the pump lever, until the rotor has reached transport position. Fig. 15 l Slacken both high pressure relief valves l Slacken both high pressure relief valves (Fig. 15) Fig. 16 Generally use a tow bar Generally use a tow bar (Fig. 16) After the towing process retighten the high pressure relief valves. After the repair return the brake to normal condition. Returning the brake to normal condition Returning the brake to normal condition Fig. 17 l Turn the lever on hydraulic hand pump l Turn the lever on hydraulic hand pump (Fig. 17) l Operate the ball valve back to initial position and turn the locking screw back in. l Operate the ball valve back to initial position and turn the locking screw back in. External gear motors Intercooler Fig. 1 External gear motors External gear motors Fig. 2 Gear motor In their design gear motors are quite similar to gear pumps. The only difference is the slightly different axial pressure field. The pressure fluid flowing into the gear motor works on the gears. It generates a torque, which is then transferred by th... External gear motors for one sense of rotation are of asymmetrical design, i.e. high and low pressure sides are predetermined. Reversing operation is not possible. The arising leak oil is internally fed to the outlet. The pressure load in the outlet ... 3-way flow control valve, adjustable 3-way flow control valve, adjustable Fig. 3 In a hydraulic system the flow control valve has the function of maintaining the oil flow volume for the connected consumer at a constant level, irrespective of the load pressure. The oil flow volume can be changed during operation.Changing of the tire pressure is possible during operation. l Turn the rotary button to the left (anti-clockwise) to increase the oil flow volume. l Turn the rotary button to the left (anti-clockwise) to increase the oil flow volume. l Turn the rotary button to the right (clockwise) to reduce the oil flow volume. The max. possible turning angle is limited by an end stop on the rotary button. The max. possible turning angle is limited by an end stop on the rotary button. Trouble shooting Trouble shooting Danger of injury Danger of injury Any work involved in trouble shooting must only be carried out with the drive shut down and the system depressurized. Fault Fault Cause of fault Cause of fault Remedy Remedy Pressure fluid leaking out of the valve Pressure fluid leaking out of the valve O-ring defective O-ring defective Replace the O-ring Replace the O-ring Valve housing leaking, e.g. due to a crack Valve housing leaking, e.g. due to a crack Disassemble the valve and replace it with a new one. Disassemble the valve and replace it with a new one. Thread on valve housing damaged. Thread on valve housing damaged. Disassemble the valve and replace it with a new one. Disassemble the valve and replace it with a new one. Pressure fluid leaking out of the suply line to the valve. Pressure fluid leaking out of the suply line to the valve. Pipe or hose damaged. Replace pipe or hose+ Replace pipe or hose+ Pipe of hose have come loose Pipe of hose have come loose Tighten fittings with the specified torque Tighten fittings with the specified torque Thread on valve housing damaged Thread on valve housing damaged Disassemble the valve and replace it with a new one. Disassemble the valve and replace it with a new one. Hydraulic function disturbed Hydraulic function disturbed The valve does not hold the adjusted pressure The valve does not hold the adjusted pressure Replace the seal rings or replace the valve Replace the seal rings or replace the valve Valve housing damaged Valve housing damaged Disassemble the valve and replace it with a new one Disassemble the valve and replace it with a new one Valve spool jammed Valve spool jammed Disassemble the valve and replace it with a new one Disassemble the valve and replace it with a new one Oil flow volume too low Oil flow volume too low The valve does not meet the requirements The valve does not meet the requirements Disassemble the valve and replace it with an appropriate one Disassemble the valve and replace it with an appropriate one Dirt in the valve Dirt in the valve Remove the valve and clean it. Make sure that the demanded oil cleanliness is met. Remove the valve and clean it. Make sure that the demanded oil cleanliness is met. Oil flow volume too high Oil flow volume too high Opening pressure of valve set too high Opening pressure of valve set too high Disassemble the valve and replace it with an appropriate one Disassemble the valve and replace it with an appropriate one Dirt in the valve Dirt in the valve Remove the valve and clean it. Make sure that the demanded oil cleanliness is met. Remove the valve and clean it. Make sure that the demanded oil cleanliness is met. Oil flow volume fluctuates Oil flow volume fluctuates The valve does not meet the requirements The valve does not meet the requirements Disassemble the valve and replace it with an appropriate one Disassemble the valve and replace it with an appropriate one 11.20 Cleaning the intercooler 11.20 Cleaning the intercooler Fig. 4 l Open the cleaning flaps l Open the cleaning flaps (Fig. 4) Fig. 5 l Remove dried on dirt with a suitable brush l Remove dried on dirt with a suitable brush (Fig. 5) Fig. 6 l Blow the cooling air channels out with compressed air l Blow the cooling air channels out with compressed air (Fig. 6) l In case of oily contamination spray the parts with cold cleansing agent and spray it off with a water jet after s sufficient soaking time. l In case of oily contamination spray the parts with cold cleansing agent and spray it off with a water jet after s sufficient soaking time. l If steam cleaning equipment is available, this should preferably be used. l If steam cleaning equipment is available, this should preferably be used. l After wet cleaning run the engine warm to evaporate all water residues and to avoid corrosion. l After wet cleaning run the engine warm to evaporate all water residues and to avoid corrosion. l Close the engine cover. l Close the engine cover. Fig. 7 If the charge air temperature warning light (c) If the charge air temperature warning light (c) (Fig. 7) 11.21 Checking the hydraulic oil level 11.21 Checking the hydraulic oil level In hydraulic systems filled with Panolin HLP Synth.46 use always the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer. In hydraulic systems filled with Panolin HLP Synth.46 use always the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer. In hydraulic systems filled with Panolin HLP Synth.46 use always the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer. If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks. If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks. Fig. 8 l Check the hydraulic oil level in the inspection glass l Check the hydraulic oil level in the inspection glass (Fig. 8) At a room temperature of approx. 20 �C the oil level should reach approx. 2 At a room temperature of approx. 20 �C the oil level should reach approx. 2 l If the oil level is too low top up hydraulic oil immediately. l If the oil level is too low top up hydraulic oil immediately. For quality and quantity of oil refer to the "table of fuels and lubricants". 11.22 Changing hydraulic oil and breather filter 11.22 Changing hydraulic oil and breather filter See also the notes on the hydraulic system in the chapter "General notes on maintenance". See also the notes on the hydraulic system in the chapter "General notes on maintenance". See also the notes on the hydraulic system in the chapter "General notes on maintenance". Danger of scalding! Danger of scalding! When draining off hot hydraulic oil! The hydraulic oil must also be changed after major repairs in the hydraulic system. The hydraulic oil must also be changed after major repairs in the hydraulic system. Perform the oil change when the hydraulic oil is warm. Replace the hydraulic oil filter elements with every hydraulic oil change. Change the filter only after the hydraulic oil change and after the test run. Clean the area round hydraulic oil tank, filler opening and breather filter. Do not start the engine after draining the hydraulic oil. Do not use any detergents to clean the system. Use only lint-free cleaning cloths. For quality and quantity of oil refer to the "table of fuels and lubricants". When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details. Catch running out hydraulic oil and dispose of environmentally. Catch running out hydraulic oil and dispose of environmentally. l Run the diesel engine for max. 3 minutes at low speed. l Run the diesel engine for max. 3 minutes at low speed. l Bleed the hydraulic system again for a short while after changing the filter. Fig. 9 l Replace the breather filter (1) l Replace the breather filter (1) (Fig. 9) Do not remove the filter element from the cover of the hydraulic oil tank. Do not remove the filter element from the cover of the hydraulic oil tank. Fig. 10 l Unscrew the plug l Unscrew the plug (Fig. 10) l Guide the drain hose into a vessel of appropriate size. l Open the drain cock and drain off the old oil. l Once all old oil has run out close the drain cock, remove the drain hose and screw the plug back on. Cleaning the hydraulic oil tank Cleaning the hydraulic oil tank Do not use any detergents, this will contaminate the hydraulic oil. Do not use any detergents, this will contaminate the hydraulic oil. If the hydraulic oil tank needs to be cleaned from inside the following work must be performed: Fig. 11 l Pull the plug off the temperature sensor (1) l Pull the plug off the temperature sensor (1) (Fig. 11) l Unscrew and remove the fastening screws (2) for the cover . l Wipe the inside of the hydraulic tank clean with the lint-free cloth. l Insert a new seal and reinstall the cover. l Push the plug back on the temperature sensor. Fill in hydraulic oil. Fill in hydraulic oil. Fig. 12 l Unscrew the plug (2) l Unscrew the plug (2) (Fig. 12) l Screw the plug back in with a new seal and tighten it. l Replace the breather filter (1). We recommend to use the BOMAG filling and filtering unit with fine filter to fill the system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system. We recommend to use the BOMAG filling and filtering unit with fine filter to fill the system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system. Fig. 13 l Check the oil level in the inspection glass l Check the oil level in the inspection glass (Fig. 13) At a temperature of approx. 20 �C the oil level should be at 2 At a temperature of approx. 20 �C the oil level should be at 2 l Perform a test run and check the system for leaks. l Perform a test run and check the system for leaks. Bleeding the hydraulic system Bleeding the hydraulic system l Run the engine for about 3 minutes with low speed, this will bleed the hydraulic system. l Run the engine for about 3 minutes with low speed, this will bleed the hydraulic system. 11.23 Checking the contamination of the hydraulic oil filters 11.23 Checking the contamination of the hydraulic oil filters only with binder metering system Fig. 14 l Check the degree of contamination in the display l Check the degree of contamination in the display (Fig. 14) 11.24 Change the hydraulic oil fine filter 11.24 Change the hydraulic oil fine filter Danger of scalding! Danger of scalding! Danger of scalding! Danger of scalding by hot oil when unscrewing the fine filter. Do not let old oil seep into the ground, but dispose off environmentally. Do not let old oil seep into the ground, but dispose off environmentally. If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run. If the filter has to be changed together with the hydraulic oil, the filter must only be changed after the oil change and after the test run. Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system. Apart from the normal oil change intervals, the filter element must also be changed after major repairs in the hydraulic system. l Open the right hand service door. l Open the right hand service door. Fig. 15 l Remove the locking wire, if present. l Remove the locking wire, if present. l Unscrew the spigot nut (Fig. 15) l Remove filter bowl (1) with filter element (2). Catch running out oil. Catch running out oil. l Do not use the oil in the filter bowl again. l Do not use the oil in the filter bowl again. l Take out the old filter elements, clean the filter bowls. l Take out the old filter elements, clean the filter bowls. l Clean the threads on the filter bowls. l Assemble the filter bowls with a new filter elements, check the condition of the seal rings (3). l Run the engine for about 3 minutes with low speed, this will bleed the hydraulic system. l Check for leaks after a short test run. 12 Water injection 12 Water injection Fig. 16 External gear motors Water dosing system The separate water spray bar supplies the necessary water to the bearing course material, in order to achieve the optimal moisture content for compaction. The separate water spray bar supplies the necessary water to the bearing course material, in order to achieve the optimal moisture content for compaction. In automatic mode the system adds the required water quantity in dependence on the actual working speed. The injection nozzles can be controlled independently, so that in case of overlaps or when working on hard shoulders well adapted working widths ... Water injection, options W10 and W14 Water injection, options W10 and W14 Fig. 17 W10, W14 Hydraulic circuit Hydraulic circuit Fig. 18 W10, W14 Proportional flow control valve, with integrated pressure balance (Y136) Proportional flow control valve, with integrated pressure balance (Y136) The proportional flow control valve is a direct controlled screw-in spool valve with integrated pressure balance. It controls the flow volume infinitely and proportionally to the input signal. Excess oil is returned to the hydraulic oil tank through ... The auxiliary actuating facility enables valve adjustment without excitation of the solenoid. The auxiliary actuating facility enables valve adjustment without excitation of the solenoid. Brake valve and shut-off valve Proportional valve, water injection Fig. 19 at front in front frame Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points Proportional flow control valve Proportional flow control valve 12 12 Y136 Y136 max. 200 bar max. 200 bar Brake valve and shut-off valve Brake valve and shut-off valve Fig. 20 Brake valve and solenoid valve in one block Pos Pos Designation Designation Position in hydraulic diagram Position in hydraulic diagram Position in wiring diagram Position in wiring diagram Measuring values and switching points Measuring values and switching points 1 1 Brake valve Brake valve 21 21 Y04, Bl. 007 Y04, Bl. 007 open without current open without current 2 2 Shut-off valve Shut-off valve 21 21 Y105, page 007 Y105, page 007 open without current open without current 3 3 Cylinder ball valve Cylinder ball valve 47 47 Water injection, options W19 and W20 Water injection, options W19 and W20 Water circuit Water circuit Fig. 21 W19, W20 Hydraulic circuit Hydraulic circuit Fig. 22 W19, W20 Fig. 23 W19, W20 External gear motors Axial piston pumps, A10VO This document is valid for pump types This document is valid for pump types VO VSO The pump delivers oil only to one direction, i.e. the swash plate moves out of neutral position only to one direction. It is therefore particularly suitable for the use in open hydraulic circuits. The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines. The axial piston pump must be filled with pressure fluid and purged during start-up and operation. This must also be considered for longer periods of rest, because the system may run empty through the hydraulic lines. Fig. 24 DFR1, pressure-flow controller DFR1, pressure-flow controller Pressure control valve The pressure control valve keeps the pressure in an hydraulic system at a constant level within the control range of the pump. This way the pump will only deliver as much hydraulic fluid as can be absorbed by the hydraulic consumers. The pressure can... DFR1 � pressure and flow controller In addition to the function of a pressure controller an orifice records the differential pressure before and after the orifice, which then controls the flow rate of the pump. The pump delivers the pressure fluid quantity actually required by the cons... The pressure controller is superimposed. Fig. 25 Sectional drawing Fig. 26 Hydraulic diagram B B Working line Working line S S Suction Suction L L Leak oil Leak oil X X Pilot pressure Pilot pressure Working principle Working principle Fig. 27 l When the l When the engine is not running (1) (Fig. 27) l When starting the engine pressure will build up at the pump outlet (no consumer active (2) flow controller Fig. 28 l If the system pressure increases because of active consumers (3) l If the system pressure increases because of active consumers (3) (Fig. 28) l If the pressure drops below the adjusted value (4), the spring in the pressure control valve will be able to close the pressure control valve again, the pump can return to a higher displacement. External gear motors External gear motors Fig. 29 Gear motor In their design gear motors are quite similar to gear pumps. The only difference is the slightly different axial pressure field. The pressure fluid flowing into the gear motor works on the gears. It generates a torque, which is then transferred by th... External gear motors for one sense of rotation are of asymmetrical design, i.e. high and low pressure sides are predetermined. Reversing operation is not possible. The arising leak oil is internally fed to the outlet. The pressure load in the outlet ... 12.2 Water dosing system 12.2 Water dosing system Optional equipment In water dosing systems with 1600 litres a separate nozzle is attached for water quantities of less than 500 litres. In water dosing systems with 1600 litres a separate nozzle is attached for water quantities of less than 500 litres. In water dosing systems with 1600 litres a separate nozzle is attached for water quantities of less than 500 litres. Depending on the water quantity to be dosed, the corresponding nozzle set must be installed. Fig. 30 l For this purpose loosen the two fastening screws (1) l For this purpose loosen the two fastening screws (1) (Fig. 30) l Fold the spray bar up in its guide. l Unscrew the nozzles, install and tighten the nozzles taken out of the tool box with Ominfit l Fold the spray bar back again and tighten the two fastening screws on the spray bar. 12.3 Water sprinkler system, maintenance in the event of frost 12.3 Water sprinkler system, maintenance in the event of frost l Open the left hand service door l Open the left hand service door l Open the left hand service door Fig. 31 l Unscrew the filter bowl (2) l Unscrew the filter bowl (2) (Fig. 31) l Clean the filter (1), replace if necessary. In case of frost drain the complete system. In case of frost drain the complete system. l Open the front service flap. l Open the front service flap. Fig. 32 l Open the drain valve (1) l Open the drain valve (1) (Fig. 32) Fig. 33 l On water dosing systems with a capacity of 1600 lites open also the ball valve l On water dosing systems with a capacity of 1600 lites open also the ball valve (Fig. 33) The ball valve is located in the front frame in front of the radiator unit. The ball valve is located in the front frame in front of the radiator unit. 13 Bitumen dosing system 13 Bitumen dosing system Control elements Fig. 34 No. 3 = Control panel for bitumen dosing system No. 3 = Control panel for bitumen dosing system Optional equipment a a Main switch control light Lights yellow when system is switched on b Main switch To switch the system on c Compressor switch To switch the compressor on d Selector switch foam bitumen not with emulsion system e Burner control light Lights green with the burner switched on f Burner switch To switch the burner on g Lack of thermal oil warning light Lights red if the thermal oil pressure is too low Check the thermal oil level h Temperature gauge for binder tank Display in �C i Display of binder flow rate Display in l j Display of reaction water flow rate* Display in l k Selector switch Spraying l Potentiometer reaction water flow rate* m Potentiometer binder flow rate n Switch spray sections To switch the individual spray sections on Fig. 35 No. 4 = Operating hour meter, burner for thermal oil heater No. 4 = Operating hour meter, burner for thermal oil heater only with binder metering system The operating hour meter is located at the side of the control panel. The operating hour meter is located at the side of the control panel. Fig. 36 No. 5 = Thermostats No. 5 = Thermostats only with binder metering system a a a Theramal oil thermostat, adjustable to the required thermal oil temperature (emulsion: max. 80 �C, bitumen: max. 200 �C) The burner is switched on when the thermal oil temperature drops below the adjusted value. The burner is switched on when the thermal oil temperature drops below the adjusted value. b b b Safety thermostat, unscrew the cover to adjust. For emulsion set to approx. 95 �C (not higher than 100 �C!), for bitumen set to approx. 220 �C. If the safety thermostat responds, the burner will be shut down. If the safety thermostat responds, the burner will be shut down. Do not start operation of the system before the cause has been found. To unlock remove the grey cap and operate the button under the cap. c c c After-running thermostat The after-running thermostat is used to set the after- running time of the fan motor on the burner. With a thermal oil temperature below 70 �C the fan motor is switched off. Only switch the main battery switch to position "0" after the fan on the thermal oil heater burner has stopped running. Only switch the main battery switch to position "0" after the fan on the thermal oil heater burner has stopped running. Heat exchanger and burner may otherwise be destroyed. Fig. 37 No. 6 = Pressure gauges No. 6 = Pressure gauges only with binder metering system a a a Spray bar b b Reaction water c c Thermal oil d d Binder pump e e Compressor With pressure differentials between spray bar (a) With pressure differentials between spray bar (a) (Fig. 37) No. 7 = Temperature gauge for thermal oil* No. 7 = Temperature gauge for thermal oil* f f f Thermal oil temperature Fig. 38 No. 8 = Temperature gauge for binder tank No. 8 = Temperature gauge for binder tank only with binder metering system Fig. 39 No. 9 = Water level gauge for reaction water tank No. 9 = Water level gauge for reaction water tank only with binder metering system Fig. 40 No. 10 = Ventilation lever No. 10 = Ventilation lever only with binder metering system Fig. 41 No. 11 = Test nozzle for foam bitumen No. 11 = Test nozzle for foam bitumen only with binder metering system 13.4 Checking the reaction water level Bitumen dosing system The BOMAG bitumen dosing system is available in the following designs: The BOMAG bitumen dosing system is available in the following designs: l Emulsion system l Emulsion system l Foam bitumen system, which can also be used for adding bitumen emulsion. Fig. 42 Extended range of applications in recycling by injection of bitumen emulsion or foam bitumen. In the field of stabilization the MPH 122 is employed to improve and reinforce existing soil materials by mixing in lime, fly ash or cement. In recycling applications the machine is used to cut and pulverize old, damaged black top and road pavements.... The pulverized material in then mixed with binder "In-Place" and finally reused as a new bonded bearing course. Application optimized dosing systems for water, bitumen emulsion and foam bitumen extend the range of application for the MPH 122, making ... The basic version is equipped with emulsion and foam bitumen systems for manual dosing control, whereby the desired bitumen flow quantity for a certain working speed must be adjusted as a fixed value. Both systems are also available with computer con... The basic version is equipped with emulsion and foam bitumen systems for manual dosing control, whereby the desired bitumen flow quantity for a certain working speed must be adjusted as a fixed value. Both systems are also available with computer con... The components of the corresponding system type are completely mounted on the machine. All bitumen conducting pipes are warmed up by a thermal oil heating. All injection nozzles and expansion chambers are protected inside the heat insulated spray bar... The components of the corresponding system type are completely mounted on the machine. All bitumen conducting pipes are warmed up by a thermal oil heating. All injection nozzles and expansion chambers are protected inside the heat insulated spray bar... Foam samples can be taken at any time from the laterally protruding test nozzle Foam bitumen Foam bitumen Inside a reaction chamber bitumen heated up to 160 �C is frothed up with atomized water (1.5-3.5%). In this state with relatively low viscosity it is possible to mix bitumen with the mix granulate at the prevailing ambient temperature. For the foaming process the water must be converted from liquid to gaseous state. Under normal atmospheric pressures the volume would expand by approx. 1500 times during this process. However, the pressure inside the reaction chamber is at least 3 ba... The bitumen foam emerges from the nozzles into the mixing chamber of the rotor hood. The short-term volumetric increase in bitumen and the mixing process that takes place at the same time, cause an evelopment of the mineral mix. Fig. 43 Formation of foam bitumen With subsequent intensive compaction foam bitumen reinforcements show good load bearing and elasticity properties as well as a considerably reduced tendency for cracking. Adding 1-2 % of hydraulic binder (lime or cement) for accelerating the developm... Advantages of foam bitumen l Suitable for almost all mineral mixes or recycling materials consisting of existing way and road constructions. l Suitable for almost all mineral mixes or recycling materials consisting of existing way and road constructions. l Has a considerably bigger surface than normal hot bitumen. l Has excellent enveloping characteristics with cold and moist construction mixes. l Is made of conventional road construction bitumen B60-B200. l Is almost insensitive to precipitation. Heating unit Heating unit The burner fan of the burner is controlled outside the burner control unit. Current flows directly from the vehicle battery through the after-running thermostat to the burner fan. Once the thermal oil temperature has reached 70 �C, the burner fan sw... When the electric master switch is switched on and the thermal oil temperature is below 70 �C, the burner fan will only come on when the heating unit is switched on. The thermal oil pump starts at the same time (hydraulically). The fan therefore always runs as soon as the thermal oil temperature is higher than 70 �C. When the machine is shut down after work, the burner fan will keep on running until the thermal oil temperature has dropped below 70 �C. Bitumen pump, internal gear pump Bitumen pump, internal gear pump Fig. 44 Bitumen pump Bypass valve loading belt Bypass valve loading belt Fig. 45 Pressure relief valve l Unscrew the screw cap. l Unscrew the screw cap. l Loosen or tighten the setscrew to reduce or increase the pressure setting of the bypass valve. Take care of the engine power. This setting can also be made during operation, because the leakage losses through the screw are only minimal. Do not loosen the screw too much. Do not loosen the screw too much. Once the spring pressure has been relieved, the setscrew can be easily loosened. In this case do not turn any further. 1 1 Housing Housing 6 6 Screw Screw 2 2 Cover Cover 7 7 Cap Cap 3 3 Valve Valve 8 8 Seal Seal 4 4 Plate Plate 9 9 Seal Seal 5 5 Spring Spring Axial adjustment of rotor Axial adjustment of rotor Fig. 46 Ball bearing cover l Loosen the screws of the inner cover for about 2 turns. l Loosen the screws of the inner cover for about 2 turns. l Tighten the screws of the outer cover, until the shaft can no longer be turned by hand. l Now loosen the screws of the outer cover uniformly by 5 l Retighten the inner cover. l Check free running of the rotor by hand. Bearing The friction bearings inside the pump are maintenance free, because they are either lubricated by the pumped fluid, or they are self-lubricating. The ball bearing with grease nipple mounted on the drive side should be lubricated after 500 operating hours or every 2 months. Compressor with (ESS) Energy Saving System Compressor with (ESS) Energy Saving System Fig. 47 Compressor As shown in (1.1), in the delivery phase the valve piston (A) closes the valve seat (B). The compressor piston draws in the air to be compressed through the suction bore (0) and in a second step delivers this air through port (2) to the system (1.2). During the idle phase (2.1 & 2.2) the valve piston is lifted off the valve seat (8) against spring force by the pilot pressure at port (4). The air delivered by the piston now passes along the opened valve seat into the connected chamber, the so called "Closed Room" (CR) and is compressed. With the additional volume of the (CR) and the back expansion, which supports the piston during the second stoke and moves it down (2.2), energy is saved when compared with the idle phase of a conventional compressor. Overflow valve with back flow Overflow valve with back flow Purpose: Release of the passage for compressed air to the second vessel only after the calculated system pressure in the first vessel has been achieved, resulting in a much quicker readiness for operation. Fig. 48 Overflow valve At the overflow valve comprtessed air flows in direction of arrow into the housing and through bore (g) under the mdiaphragm (d), which is pressed down onto its seat by compression spring (b) and piston (c). When the overflow pressure is reached, the... In the overflow valve with back flow the compressed air can flow back out of the 2nd vessel after opening the check valve (f), if the pressure in the 1st vessel has dropped by more than 0.1 bar. Thermal oil pump Thermal oil pump Fig. 49 Thermal oil gear pump Switchbox Switchbox Fig. 50 Switchbox Spray bar Spray bar Fig. 51 Spray bar Angle pressure relief valve Angle pressure relief valve Overflow valves and pressure relief valves are high quality fittings which must be handled with utmost care. The sealing faces on seat and taper are precision machined in order to achieve the required leak tightness. During assembly one must make abs... Adjusting the angle pressure relief valve, 7 bar l Unscrew the cross-hole screw 1 and take off the cap (2). l Unscrew the cross-hole screw 1 and take off the cap (2). l Loosen the locking nut (3). l Turn the pressure screw (4) accordingly. Turn clockwise to increase pressure, turn anti-clockwise to reduce pressure. l Tighten the locking nut (3). l Attach the cap (2) and turn the cross-hole screw (1) in. Water tank Water tank Fig. 52 Water tank Adjusting the pressure relief valve Adjusting the pressure relief valve Fig. 53 l Turn the pressure regulator (1) completely out. l Turn the pressure regulator (1) completely out. l Full engine speed. l Water pump capacity by the potentiometer, 35 l l Water pressure at full speed and closed spray bar, 8 bar l Adjust by slowly turning the pressure regulator (1) and checking the pressure gauge (b). l Press the relief lever (2) instantaneously down and return it to initial position, correct the 8 bar setting, if necessary. Adjustment values Adjustment values Speeds Speeds l Water pump: l Water pump: 350 rpm, 35 l l Bitumen pump: 520 rpm, 600 l l Compressor: 900 rpm l Thermal oil pump: 600 rpm Pressures Pressures l Bypass bitumen pump: l Bypass bitumen pump: 5 bar l Pressure relief valve reaction water pump at full speed and closed spray bar: 8 bar l Overflow valve from air vessel to air vessel: 8.5 bar l Pressure switch for thermal oil: 2 - 2.5 bar l Angle pressure relief valve on the spray bar: 7 bar l Compressor pressure regulator: 9 bar l Prescaler: 0.038 l Pressure switch for water: 3.5 bar l Bypass thermal oil pump: 15 bar Thermostats Thermostats l Control thermostat: l Control thermostat: max. 200 �C Pull off the rotary button, adjust the mechanical stop to 200 �C, adjust the temperature scale at 200 �C. Pull off the rotary button, adjust the mechanical stop to 200 �C, adjust the temperature scale at 200 �C. l After-running thermostat: l After-running thermostat: 70 �C l Safety thermostat: 200 �C Hydraulic connection to the machine Hydraulic connection to the machine Fig. 1 Hydraulic connection 13.4 Checking the reaction water level Binder circuit Binder circulation Binder circulation Switching status 1 1 on 0 off Fig. 2 circulation Binder spraying Binder spraying Fig. 3 spraying Accompanying heating Accompanying heating Fig. 4 Accompanying heating Reaction water Reaction water Fig. 5 Reaction water 13.4 Checking the reaction water level 13.4 Checking the reaction water level only with binder metering system Fig. 6 l Check the reaction water level l Check the reaction water level (Fig. 6) Fig. 7 l Fill completely with water l Fill completely with water (Fig. 7) 13.5 Reaction water tank 13.5 Reaction water tank only with binder metering system Fig. 8 l Unscrew the cover (2) l Unscrew the cover (2) (Fig. 8) l Open all valves and let all water run out. l Open all valves and let all water run out. Fig. 9 l Open the drain valve on the water filter l Open the drain valve on the water filter (Fig. 9) 13.6 Checking the oil level for the reaction water pump 13.6 Checking the oil level for the reaction water pump only with binder metering system For quality and quantity of oil refer to the "table of fuels and lubricants". For quality and quantity of oil refer to the "table of fuels and lubricants". For quality and quantity of oil refer to the "table of fuels and lubricants". Fig. 10 l Check the oil level in the inspection glass l Check the oil level in the inspection glass (Fig. 10) 13.7 Checking the oil level in compressor and service unit 13.7 Checking the oil level in compressor and service unit only with binder metering system For quality and quantity of oil refer to the "table of fuels and lubricants". For quality and quantity of oil refer to the "table of fuels and lubricants". For quality and quantity of oil refer to the "table of fuels and lubricants". Fig. 11 l Unscrew the oil dipstick (1) l Unscrew the oil dipstick (1) (Fig. 11) l The oil level must always be between the "MIN"- and "MAX"-marks, fill up oil if necessary. l Check the oil level in the sight glass (2) of the service unit, fill up oil if necessary. l If necessary drain the water from the service unit inspection bowl (3). 13.8 Checking the thermal oil 13.8 Checking the thermal oil only with binder metering system Check the oil level in cold condition. Check the oil level in cold condition. Check the oil level in cold condition. For quality and quantity of oil refer to the "table of fuels and lubricants". Fig. 12 l Unscrew the oil dipstick l Unscrew the oil dipstick (Fig. 12) l The oil level must always be between the "MIN"- and "MAX"-marks, fill up oil if necessary. 13.9 Checking the contamination of the hydraulic oil filters 13.9 Checking the contamination of the hydraulic oil filters only with binder metering system Fig. 13 l Check the degree of contamination in the display l Check the degree of contamination in the display (Fig. 13) 13.10 Checking the binder pump 13.10 Checking the binder pump only with binder metering system Fig. 14 l Check the binder pump l Check the binder pump (Fig. 14) l If necessary retighten the stuffing boxes evenly on both sides. Do not over tighten the stuffing boxes! Do not over tighten the stuffing boxes! During operation a small quantity of fluid must leak out of the packing, so that it is lubricated and cooled. If retightening is no longer possible, replace the stuffing boxes. If retightening is no longer possible, replace the stuffing boxes. 13.11 Checking the spraying sections 13.11 Checking the spraying sections only with binder metering system Fig. 15 l Check the spraying section l Check the spraying section (Fig. 15) l If necessary retighten the stuffing boxes evenly on both sides. Do not over tighten the stuffing boxes! Do not over tighten the stuffing boxes! During operation a small quantity of fluid must leak out of the packing, so that it is lubricated and cooled. If retightening is no longer possible, replace the stuffing boxes. If retightening is no longer possible, replace the stuffing boxes. 13.12 Checking, cleaning the additional fuel filter 13.12 Checking, cleaning the additional fuel filter only with binder metering system Fire hazard! Fire hazard! Fire hazard! When working on the fuel system do not use open fire, do not smoke, do not spill any fuel. Shut down the engine! Health hazard! Health hazard! Do not inhale any fuel fumes. Catch running out fuel, do not let it seep into the ground. Catch running out fuel, do not let it seep into the ground. l Open the right hand service door. l Open the right hand service door. Fig. 16 l Slacken the drain plug l Slacken the drain plug (Fig. 16) l Turn the plug tightly back in. Check for leaks, if necessary use a new seal ring. 13.13 Change the additional fuel filter 13.13 Change the additional fuel filter only with binder metering system Fire hazard! Fire hazard! Fire hazard! When working on the fuel system do not use open fire, do not smoke, do not spill any fuel. Shut down the engine! Health hazard! Health hazard! Do not inhale any fuel fumes. Catch running out fuel, do not let it seep into the ground. Catch running out fuel, do not let it seep into the ground. l Open the right hand service door. l Open the right hand service door. Fig. 17 l Loosen and pull off the fuel hose (1) l Loosen and pull off the fuel hose (1) (Fig. 17) l Loosen the hose clamp (2) and renew the fuel filter (2). l Tighten the hose clamp. l Assemble and tighten fuel lines. 13.14 Changing the thermal oil 13.14 Changing the thermal oil only with binder metering system Fig. 18 Perform this maintenance work at the latest after one year. Perform this maintenance work at the latest after one year. If the thermal oil pressure (c) (Fig. 18) For quality and quantity of oil refer to the "table of fuels and lubricants". Catch running out oil and dispose of environmentally. Catch running out oil and dispose of environmentally. Fig. 19 l Unscrew the plug (a) l Unscrew the plug (a) (Fig. 19) l Guide the drain hose into a vessel of appropriate size. l Open drain cock (b) and let the old oil run out. l Once all old oil has run out close the drain cock, remove the drain hose and screw the plug back on. Fig. 20 l Fill in new oil l Fill in new oil (Fig. 20) l Screw the oil dipstick back in and out again and read the oil level, correct as necessary. 13.15 Compressor oil change 13.15 Compressor oil change only with binder metering system Perform this maintenance work at the latest after one year. Perform this maintenance work at the latest after one year. Perform this maintenance work at the latest after one year. For quality and quantity of oil refer to the "table of fuels and lubricants". Catch running out oil and dispose of environmentally. Catch running out oil and dispose of environmentally. Fig. 21 l Unscrew the oil dipstick (1) l Unscrew the oil dipstick (1) (Fig. 21) l Unscrew oil drain plug (2), drain and catch running out old oil. l Screw the drain plug back in. l Fill in new oil. l Screw the oil dipstick back in and out again and read the oil level, correct as necessary. 13.16 Cleaning the bitumen filter 13.16 Cleaning the bitumen filter only with binder metering system Fig. 22 With pressure differentials between spray bar (a) (Fig. 19) Danger of burning! Danger of burning! The cover of the bitumen filter must be unscrewed before the bitumen has cooled down and solidified. Wear heat proof gloves! Fig. 23 l Loosen four nuts l Loosen four nuts (Fig. 20) Fig. 24 l Assemble the plate l Assemble the plate (Fig. 24) l Remove the filter element. l Wash out with suitable cleaning agent and burn out after. l Check the cover seal, renew if necessary. l Assemble the bitumen filter and retighten the nuts. 13.17 Faults in binder dosing system Fault Fault Possible cause Possible cause Remedy Remedy No or insufficient formation of foam No or insufficient formation of foam Bitumen temperature too low. Bitumen temperature too low. The bitumen temperature must be min. 180 �C, check the binder temperature, check the thermal oil temperature The bitumen temperature must be min. 180 �C, check the binder temperature, check the thermal oil temperature Reaction water pressure too high or too low Reaction water pressure too high or too low Check the reaction water pressure Check the reaction water pressure Bitumen quantity too low Bitumen quantity too low Speed of bitumen pump too low Speed of bitumen pump too low Increase the binder pump speed Increase the binder pump speed Bitumen filter dirty Bitumen filter dirty Clean the bitumen filter Clean the bitumen filter Diesel engine speed too low Diesel engine speed too low Increase the engine speed Increase the engine speed Bitumen temperature too low. Bitumen temperature too low. The bitumen temperature must be min. 180 �C, check the binder temperature, check the thermal oil temperature The bitumen temperature must be min. 180 �C, check the binder temperature, check the thermal oil temperature Bitumen filter dirty Bitumen filter dirty Clean the bitumen filter Clean the bitumen filter Bitumen tank no pre-pressure Bitumen tank no pre-pressure Set the pre-pressure on the bitumen tank to 0..5 to 1.0 bar Set the pre-pressure on the bitumen tank to 0..5 to 1.0 bar Peet valve not fully open Peet valve not fully open Check the Peet-valve on tank and suction hose Check the Peet-valve on tank and suction hose Spray nozzles are blocked or jammed and cannot open completely Spray nozzles are blocked or jammed and cannot open completely Check the spray nozzles, clean, replace if necessary Check the spray nozzles, clean, replace if necessary Insufficient power of hydraulic drives Insufficient power of hydraulic drives Engine speed too low because of overloading Engine speed too low because of overloading Reduce the travel speed Reduce the travel speed Excessive thermal oil temperature Excessive thermal oil temperature Safety thermostat has locked Safety thermostat has locked Allow to cool down, unlock the safety thermostat Allow to cool down, unlock the safety thermostat 14 Circuit diagrams 14 Circuit diagrams S S 14.1 Hydraulic diagram 593 301 24 S S S S 14.2 Wiring diagram 42 S S S S � S � 14.3 Bitumen metering system electrics 14.4 Bitumen metering system hydraulics 14.5 Bitumen metering system pneumatics 14.6 Bitumen metering system bitumen 14.7 Bitumen metering system heating 14.8 Bitumen metering system water 14.9 Bitumen-water-compressed air . 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