Bomag BW 177 179 DH PDH-4 Single Drum Roller Service Training Manual 00809992 - PDF DOWNLOAD

Service Training

Single Drum Roller BW 177 / 179 DH / PDH-4

Teile-Nr. 008 099 92

10/2004

Service Training Table of contents Foreword

A1

Documentation

A2

General

A3

New developments

A5

Technical data and adjustment values

B1

Maintenance

C1

Maintenance chart

C2

DEUTZ diesel engine with EMR

D1

Service side

D2

Starter side

D3

Lubrication oil circuit

D4

Coolant circuit

D5

Fuel system

D6

EMR

D10

Trouble shooting

D22

Diagnose SERDIA

D24

Checking and adjusting the valve clearance

D26

Assembly of the plug-in injection pump

D28

Engine components

D44

Travel system

E1

Travel pump

E3

Control

E7

Charge pressure relief valve

E8

High pressure relief valve

E9

Pressure override

E11

Axle drive motor

E14

Drum drive motor

E17

Test and adjustment points, travel system

E19

Trouble shooting travel system

E27

BW 177 / 179 DH / PDH -4

Service Training Vibration

F1

Vibration pump

F3

High pressure relief valves

F6

Control

F7

Vibration motor

F8

Drum

F11

Test and adjustment points, vibration system

F13

Trouble shooting vibration

F15

Steering

G1

Charge pump

G2

Steering pump

G3

Steering valve

G5

Articulated joint

G7

Measuring and adjustment points

G9

Trouble shooting steering

G10

Electrics H1 Wiring diagram Hydraulic diagram

BW 177 / 179 DH / PDH -4

Service Training Foreword and novelties Reliable construction equipment is of greatest advantage for all parties involved: • for the customer/user it is a basis for an exact calculation of utilization periods and the completion of projects as scheduled.

• in the rental business it means that the equipment can be reliably used and planned without having to stock a large number of stand-by machines.

• for the manufacturer it means that customers are satisfied, provides him with a good image and gives him a feeling of confidence.

It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine: • the location of components in the machine eases maintenance work, • the high quality standard of BOMAG is the basis for the considerable extension of the service and maintenance intervals.

• the After Sales Service of BOMAG, including excellent operating and maintenance instruction manuals, high quality training courses and on-site machine demonstrations helps the customer to maintain their machines in good condition over a long period of time.

Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.

This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses.

This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses.

The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials .

The structure of this training manual enables us to change or up-date individual chapters in case of alterations to the machine.

BW 177 / 179 DH / PDH -4

-A1-

Service Training Documentation For the BOMAG machines described in this training manual the following documentation is additionally available: Attention!

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

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

BW 177 / 179 DH / PDH -4

-A2-

Service Training General The new single drum rollers BW 177 and 179 DH-4 from BOMAG are essentially further developments of their predecessors, the machines of product range BW 177 DH-3.

These machines have been successfully and reliably used for years on construction sites all over the world, especially in earth construction and on sanitary landfill sites.

High compaction power and excellent traction are characteristics, which are of utmost importance for this type of machine.

All components installed in these machines are manufactured in series production and are subjected to stringent quality tests. This guarantees a high level of reliability and safety.

As with many other BOMAG products, and here especially with the large single drum rollers of the new generation, we have decided to use the same successful drive concept with diesel engine (water cooled) and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the engine directly to drum, drive wheels and steering.

The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by slow running radial piston motors.

On construction machines the work place of the operator is of utmost importance. Under such working conditions the health and safety of the operator must be the greatest concern.

The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be individually adjusted for every operator, even for his weight.

All control elements and gauges are within the reach and in the sight of the operator.

A monitoring display with light emitting diodes and clear pictograms informs the operator about any operating faults. The operator is therefore always informed about the present condition of the machine.

The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens, as well as a heated rear windscreen, offers clear vision to all sides.

BW 177 / 179 DH / PDH -4

-A3-

Service Training Important characteristics of the new generation of single drum rollers are • strong ROPS/FOPS according to SAE-standard • wear free service brake by closed hydrostatic travel circuits • disc brakes in axle and drum drive motor serve as parking and emergency brakes • high stability due to low centre of gravity and the use of an articulated joint • operating safety due to the use of monitoring boards for all important system data • automatic engine shut-down at too engine temperature, too low hydraulic oil level (when reaching the lowest permissible level the engine will be shut down after 20 seconds) and too low engine oil pressure.

The machines of product ranges BW 177 and 179 DH-4 are well designed down to the smallest detail, so that they can meet the toughest demands on large scale construction sites all over the world.

BW 177 / 179 DH / PDH -4

-A4-

Service Training Novelties The multi-function travel lever and the display

BW 177 / 179 DH / PDH -4

-A5-

Service Training Control, operation, data collector,

BW 177 / 179 DH / PDH -4

-A6-

Service Training Diesel engine with EMR

BW 177 / 179 DH / PDH -4

-A7-

Service Training Technical data and adjustment values The following pages contain technical data valid at the date of printing (see front page of this manual).

Attention!

The currently valid technical data and adjustment values can be taken from the BOMAG Intranet or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.

BW 177 / 179 DH / PDH -4

-B1-

BOMAG Central Service

Seite 1 von 3

BOMAG Central Service - Technical data and adjustment values Status: 2004-10-19

Product type:

BW 177 DH Serie 4

Type No.: Serial numbers from:

582 21 101 582 21 1001

Engine: Manufacturer: Deutz Type: BF4M2012 EMR Combustion principle: 4-stroke-Diesel Cooling: Water Number of cylinders: 4 Power acc. to ISO 9249: 74,9 kW Power data at nominal speed of: 2200 1/min Low idle speed: 900+/-200 1/min High idle speed: 2200 +/-10 1/min Spec. fuel consumption: 235 g/kWh Valve clearance, inlet: 0,3 mm Valve clearance, outlet: 0,5 mm Opening pressure, injection valves: 220 bar Starter voltage: 12 V

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

Bosch-Rexroth A4VG 56 EP Axial piston-swash plate 56 cm3/U 123,2 l/min 475 bar 435+/-15 bar 25+/-1 bar

Reduction gear, drum: Manufacturer: Type: Transmission ratio:

Lohmann-Stolterfoht GFT 17 53,95

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

Sauer-Danfoss 51D80 RD3N Y7(EP) Axial piston-bent axle 80 cm3/U 15 cm3/U 2 + 10 l/min 10 l/min

Drum drive:

http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?... 19.10.2004

BOMAG Central Service

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

Seite 2 von 3

Sauer-Danfoss 51C 060 RD1N 7Y (EP) Axial piston-swash plate 60 cm3/U 12 cm3/U 2 + 7 l/min 7 l/min

Vibration pump: Manufacturer: Type: System: Max. displacement:

Bosch-Rexroth A10VG 45 EP Axial piston-swash plate

45 cm3/U Starting pressure: 360+/-20 bar Operating pressure, soil dependent: ca.100 bar

Vibration motor: Manufacturer: Type: System: Displacement: Frequency: Amplitude:

Sauer-Danfoss MMF 025 PPU Axial piston-swash plate 25 cm3/U 30-40 Hz 1,8/0,9 mm

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

Bosch-Rexroth HYZ/19 Gear pump 19 cm3/U 190 +/-10 bar

Steering valve: Manufacturer: Type: System:

Sauer-Danfoss OSPC 315 ON Rotary valve

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

Dana CHC 192/57LD No-Spin 100 % 43,7

Filling capacities: Engine coolant: Engine oil: Hydraulic oil:

15 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 8,5 l (SAE 15W-40, API SJ/CF) 60 l (HVLP 46 VI 150)

http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?... 19.10.2004

BOMAG Central Service

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

Seite 3 von 3

3,2 l (SAE 15W-40, API SJ/CF) 6,7 l (SAE 90 EP, API GL 5) 0,7 l (SAE 90 EP, API GL 5) 2,5 l (SAE 90 EP, API GL 5) 1300 g (R 134a) 100 ml (PAG Öl)

http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?... 19.10.2004

Service Training Maintenance Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth construction. To be able to meet these demands the machines must always be ready to be loaded up to their limits. Furthermore, all safety installations, protections and guards must always be in place and fully functional.

Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably higher functional safety, but also prolongs the lifetime of the machine and of important components.

The time required for thorough maintenance is only minor when being compared with the malfunctions and faults that may occur if these instructions are not observed.

The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance interval all the work for shorter preceding intervals must also be performed. During the 2000 hours interval you must also perform the work described for the service intervals after 50, 250 and 500 hours.

During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and lubricants (oils, fuels, grease etc.).

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

BW 177 / 179 DH / PDH - 4

-C1-

Service Training

5.7

Check the water separator

X

5.8

Check the fuel level

X

5.9

Check the hydraulic oil level

Inspection glass

5.10 Check dust precleaner

as required

Dipstick mark

every 5000 oper. hours

Check the engine oil level

every 3000 oper. hours

5.6

every 2000 oper. hours

Remark

every 1000 oper. hours

Maintenance work

every 500 oper. hours

No.

every 250 oper. hours

every 10 op. hours, daily

Running in instructions after 50 operating hours

Maintenance table

X

X X

5.11 Check tire pressure

X

5.12 Clean engine oil, fuel and hydraulic oil cooler

X

5.13 Check the drive axle oil level

X

5.14 Check oil level in wheel hubs

X

5.15 Check oil level in vibration bearings

X

5.16 Change engine oil and oil filter elementa

min. 1x per year

X

5.17 Battery service

pole grease

X

5.18 Drain the fuel tank sludge

X

5.19 Change the fuel prefilter element

X

5.20 Check V-belt tension, tighten, replace

X

5.21 Check tension of refrigerant compressor V-belt , tighten, replace

X

5.22 Service the air conditioning

X

5.23 Check, adjust the valve clearance Inlet = 0,3 mm

X

exhaust = 0,5 mm on cold engine

BW 177 / 179 DH / PDH - 4

-C2-

5.24 Oil change in vibration bearingsb

see footer, min. X 1x per year

X

5.25 Oil change in drive axle

min. 1x per year X

X

5.26 Oil change in wheel hubs

min. 1x per year X

X

5.27 Replace the fuel filter cartridge

as required

every 5000 oper. hours

every 3000 oper. hours

X

5.28 Check the engine mounts

X

5.29 Retighten fastening of axle to frame

X X

5.30 Tighten the wheel nuts

X

5.31 Check the ROPS 5.32 Clean the oil bath air filter

every 2000 oper. hours

every 1000 oper. hours

every 500 oper. hours

Remark

every 250 oper. hours

Maintenance work

every 10 op. hours, daily

No.

Running in instructions after 50 operating hours

Service Training

X X

min. 1x per year

X

5.33 Change hydraulic oil and breather min. every 2 filterc years

X

5.34 Replace the hydraulic oil filterd

X

min. every 2 years

5.35 Check the injection valves

X

5.36 Replace the toothed belts

min. every 5 years

5.37 Service the combustion air filter

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

X X

5.38 Adjust the scrapers

X

5.39 Adjust the parking brake

X

5.40 Change the tires

X

5.41 Replace the fresh air filter in the cabin

X

5.42 Tightening torques

X

5.43 Engine conservation

X

a. Oil change intervals depend on quality of oil and fuel (sulphur content)

BW 177 / 179 DH / PDH - 4

-C3-

Service Training b. Oil change intervals after 50 h, after 500 h, after 1000 h and then every 1000 h. c. Also after repairs in the hydraulic system d. Also after repairs in the hydraulic system

Note: When changing filters use only the original filters specified in the operating and maintenance instructions for this machine. The installation of incorrect filters (e.g. insufficient pressure resistance) can lead to severe damage on engine or hydraulic components.

When using diesel fuel with a sulphur content of more than 0.5%, the oil change intervals must be halved. The same applies when using engine oils of specification API CF/CF-4.

BW 177 / 179 DH / PDH - 4

-C4-

Service Training Deutz diesel engine The single drum roller of product range BW 177 / 179 DH-4 are driven by a Deutz diesel engine series BF4M 2012 COM2 with electronic engine management (EMR) . The engine is cooled by an external radiator. The cooling fan is mounted to the engine fan block and is directly driven by the engine.

These engines are characterized by the following positive features: • short and compact design, • low noise level, • almost vibration-free running, • low fuel consumption, • low exhaust emissions (EPA II), • high power reserves and • good access to all service points.

Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and ensures high wear resistance.

The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These weights compensate manufacturing tolerances with respect to weight and centre of gravity.

The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the middle at its side walls are inclined for 10° towards the inside. All pistons are fitted with three piston rings and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist.

The forged crankshaft is equipped with integrated counterweights.

The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of high-grade steel and are also shrink fitted.

BW 177 / 179 DH / PDH -4

-D1-

Service Training Service side 3

4

2

5

1

6

14

7

13

12

11

10

9

8

Fig. 1: Service side BFM 2012 1

Oil filler neck

8

Fuel pump

2

Valve, boost fuel supply

9

Engine mounting

3

Engine solenoid

10

Fuel filter

4

Oil pressure switch

11

Lubrication oil filter

5

Cooling air blower

12

Oil sump

6

Coolant pump

13

Dipstick

7

V-belt pulley

14

Steering/charge pump

BW 177 / 179 DH / PDH -4

-D2-

Service Training Starter side

6

5 4 3 1 2

Fig. 2: Starter side 1

Flywheel

2

Ground cable

3

Starter

4

Turbo charger

5

Generator

6

Coolant temperature switch

BW 177 / 179 DH / PDH -4

-D3-

Service Training Lubrication oil circuit 3

4

2

5

6

9

7

8

22

21

1

10

11

20

12

13

19 18

14

17

15

16

Fig. 3: Lubrication oil circuit 1

Oil sump

12 Piston cooling nozzle

2

Return flow turbo charger to crankcase

13 Camshaft bearing

3

Turbo charger

14 Main oil channel

4

Oil line to turbo charger

15 Lubrication oil cooler

5

Line to mass balance wheel (2 x)

16 Lubrication oil pump

6

Oil pressure sensor

17 Pressure relief valve

7

Valve with pulse lubrication

18 Leak oil return line

8

Push rod, oil supply to rocker arms

19 Lubrication oil filter

9

Line to spray nozzles

20 Suction line

10 Rocker arm

21 Crankshaft bearing

11 Return flow to oil sump

22 Conrod bearing

BW 177 / 179 DH / PDH -4

-D4-

Service Training Lubrication oil circuit

8 7

6 1

3

2

5

4

Fig. 4: Lubrication oil circuit 1

Cooler

2

To cooler

3

From cooler

4

Coolant pump

5

Lubrication oil cooler

6

Cylinder cooling

7

Cylinder head cooling

8

Ventilation connection between cylinder head and heat exchanger

BW 177 / 179 DH / PDH -4

-D5-

Service Training Fuelsystem 7

6

4

1a

1b

1c

Fuel tank

1d

Fig. 5: Fuel system BW 177 / 179 DH / PDH -4

-D6-

Service Training Legend Fig. 6: 1a

Manual fuel pump

1b

Fuel prefilter

1c

Water separator

1d)

Water proportion sensor

2

Feed to fuel lift pump

3

Fuel lift pump

4

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

5

Main fuel filter (pressure resistant)

6

Connecting line main filter – supply for injection pump

7

Single injection pump

8

High pressure line

9

Injection nozzle

10

Leakage line

11

Pressure retaining valve - 5 bar

12

Return flow to tank

BW 177 / 179 DH / PDH -4

-D7-

Service Training Fuel prefilter with water separator 1 2

3

4

5

6

Fig. 6: Fuel prefilter with water separator 1)

Hand pump

2)

Breather valve

3

Filter element

4)

Water and dirt collecting bowl

5

Drain valve

6

Electric connection for water level sensor

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

BW 177 / 179 DH / PDH -4

-D8-

Service Training Function:

The fuel lift pump draws fuel through both filters.

The water resistant filter element retains remaining smaller dirt and water particles.

Once the water level reaches the height of the warning connections, the warning light in the dashboard lights up.

Draining off water or fuel: If the filter element is clogged before a service is due (indicated by e.g. a power drop), the filter may be regenerated as follows to keep up operation of the engine: • Open the bleeding screw (this applies atmospheric pressure to the filter element and releases bigger dirt particles from the bottom side of the filter, which will then sink down.

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

• Close the drain valve.

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

Bleed the system with the manual fuel pump and then tighten the bleeding screw.

Main fuel filter Attention!

The main fuel filter is subjected to approx. 10 bar fuel pre-pressure from the fuel lift pump. This pressure is considerably higher than on other engines. For this reason only original filter elements must be used. Filter elements of similar design or with adequate dimensions are not necessarily pressure resistant!

A filter element of insufficient pressure resistance will be damaged by the high pressure and will disintegrate. This causes severe damage to the injection system!

BW 177 / 179 DH / PDH -4

-D9-

Service Training Electronic engine control EMR II The Deutz engines in single drum roller BW 177 / 179 DH-4 are equipped with an electronic engine speed control (Deutz EMR II).

The most important benefits of this system are: • shorter response times compared with mechanically controlled engines, i.e. the response times are significantly better. This improvement is achieved without increasing the acceleration fumes or the fuel consumption.

• electronic idle speed control enabling a higher starting torque • no mechanical throttle control (light moving, maintenance free, less susceptible for faults) • in comparison with the first version of the Deutz-EMR this system has the essential advantage that faults can be indicated directly by the fault indicator light on the machine in form of a flashing code, with the necessity of additional software.

The EMR-injection system is based on the approved Deutz-injection system of series 1012/1013 with individual injection pumps for each cylinder. However, the fuel quantity per stroke is not regulated mechanically via a throttle cable, but is controlled by the EMR II-system by means of an electromagnetic actuator acting on the governor rod.

The essential components of the EMR II-system for engine speed control are: • the control unit EMR II [A48] is installed on the left hand side under the operator's platform.

• The control unit processes the input signals from: •

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

•

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

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

BW 177 / 179 DH / PDH -4

- D 10 -

Service Training

These input signals are processed, sent as output signals to the EMR actuator Y 137 and there they are converted to the required fuel quantity per stroke.

In ECO-mode (position "AUTO") the travel lever determines the nominal speed value. The control unit compares this nominal value with the actual speed value detected by the engine speed sensor. If the nominal value corresponds with the actual value, the signal to the EMR actuator will remain unchanged.

However, if the nominal speed deviates from the actual speed (e.g. when changing the position of the engine speed potentiometer or under higher load), the control unit uses the current turbo charger pressure and the coolant temperature to determine the necessary change in fuel quantity to achieve the nominal speed value. The control unit then sends a signal to the EMR actuator to change the control rod position and thereby the engine speed.

This automatic rotary speed adaptation only takes place in ECO-mode (i.e. with throttle control in position "AUTO") „AUTO“ steht.

BW 177 / 179 DH / PDH -4

- D 11 -

BW 177 / 179 DH / PDH -4

Y 137

Pressure

B 113

B 114

B 88

Coolant Flywheel Engine oil

Temperature Speed

B 115

Charge air

Pressure

EMR central plug engine [X57]

EMR-actuator

EMR II

B 130

Speed Crankshaft

EMR engine wiring harness

Pin assignment complies with X 31

14 17 18 9 13 22 20 21 11 2 1 5 7

Plug on vehicle [X30]

Connecting cable Engine wiring harness Control unit EMR II

Control unit

15 19 16 8 12 21 25 23 10 3 4 6 Pin assignment X 31

Plug, engine side [X31]

Service Training

Fig. 7 Connection overview EMR sensors/actuators on engine

- D 12 -

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

1

3

2

Fig. 8 Pos.

Designation

1 2 3

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

BW 177 / 179 DH / PDH -4

Pos. in wiring diagram A 48 X 31 X 30

Deutz designation EMR II

Measuring values

- D 13 -

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

BW 177 / 179 DH / PDH -4

Pos.

Deutz designation

Description

1 2 3 4 5 6 7 8

Spare

9

Input: Analogue 7

10

GND

11

Input: Speed 2

12

GND

13

Input: Speed 1

14

STG -

15

STG +

16 17

Screen RF -

18

RF REF

19

RF MESS

20

GND

21

Input: Analogue 4

22

+5V REF

23

GND

24

Input: Analogue 2

25

+ 5V LDA

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

Output: Digital 4

GND

- D 14 -

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

Pos.

Designation

Description

1 2 3 4 5

U Batt -

Vehicle ground through X1:182

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

empty

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

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

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

22 23 24 25

BW 177 / 179 DH / PDH -4

- D 15 -

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

BW 177 / 179 DH / PDH -4

- D 16 -

Service Training • In case of a fault in the path measuring system the engine is shut down and an error code is displayed.

8

2 Stg+

7

3 RF -

1 Stg+

9

6

4 RFMeß

5 RF Ref

Pin assignment of EMR-actuator looking towards actuator (plug pins mirror inverted) Fig. 9 EMR-actuator Pos.

Designation

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

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

8 9

EMR-plug EMR-actuator

Pos. in wiring diagram

Deutz designation

Measuring values

STG STG + RF RF MESS RF REF

X 57 Y 137

Temperature sensor B 113 The EMR coolant temperature sensor is located on the flywheel end of the engine. is the bottom sensor.

BW 177 / 179 DH / PDH -4

The EMR sensor

- D 17 -

Service Training The coolant temperature influences the calculated injection quantity of the EMR. Except for the EMR itself the EMR sensor value is also used by the control light for too high coolant temperature in the display.

• In case of a too high temperature the EMR will shut the engine down and the display will show and error code.

• In case of a sensor failure the engine will continue to run and an error code is displayed.

1

Pos.

Designation

Pos. in wiring diagram

1

EMR temperature sensor for coolant

B 113

Deutz designation

Measuring values

Speed sensors: Camshaft B114 and crankshaft B 130 The sensors for camshaft and crankshaft speeds are installed on the side of the engine block.

The sensor delivers the actual engine speed value for the EMR control unit.

BW 177 / 179 DH / PDH -4

- D 18 -

Service Training • If the engine speed is too high (pushing operation) the governor rod is returned to zero position, until the speed has dropped to the permissible range.

• In case of a sensor failure the engine is shut down and the error code is displayed.

• With a missing rotary speed signal from standstill the engine will not start, however, no fault message will be displayed, because the EMR assumes that the engine is at standstill and does therefore not release any fuel.

The EMR speed sensor has a fixed stop and does not need to be adjusted after installation.

1

2

Fig. 10 Speed sensor Pos.

Designation

Pos. in wiring diagram

1

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

B 114

2

BW 177 / 179 DH / PDH -4

Deutz designation

Measuring values

B 130

- D 19 -

Service Training Engine oil pressure sensor B88 The engine oil pressure sensor is mounted on the engine oil filter housing. The oil pressure is permanently monitored by the EMR. In case of a too low oil pressure an error code is displayed.

• In case of a too low pressure the EMR will shut the engine down and the display will show and error code.

• In case of a sensor failure the engine will continue to run and an error code is displayed.

• .

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

1 Ventilation

Ventilation

Fig. 11 Oil pressure sensor Pos.

Designation

Pos. in wiring diagram

1

EMR oil pressure sensor

B 88

BW 177 / 179 DH / PDH -4

Deutz designation

Measuring values

- D 20 -

Service Training Charge air pressure sensor B 115

The charge air pressure sensor measures the pressure in the air intake manifold. The sensor is located on a bracket at the EMR-actuator. The charge air pressure informs the EMR about the actual load state of the engine.

1

1

Fig. 12 Charge air pressure sensor Pos.

Designation

Pos. in wiring diagram

1

Charge air pressure sensor

B 115

BW 177 / 179 DH / PDH -4

Deutz designation

Measuring values

- D 21 -

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

1 2

2

High current relay K14 1

Fig. 13: Heating flange

Pos.

Designation

Pos. in wiring diagram

1 2

Heating flange High current relay

R 19 K14

BW 177 / 179 DH / PDH -4

Deutz designation

Measuring values

- D 22 -

Service Training Trouble shooting

Selected codes displayed on screen !!!

A detailed description and operation of how to read out error codes and about the display can be found in chapter "Electrics" (Service Training "Electrics" ).

BW 177 / 179 DH / PDH -4

- D 23 -

Service Training

BW 177 / 179 DH / PDH -4

- D 24 -

Service Training Possible diagnostics with SERDIA for error code 5140: a fault diagnose is only possible via SERDIA SERDIA is a software program from Deutz which can be used in connection with a laptop computer to perform more detailed fault analyses, especially reading out of the error log.

This displays information on • Fault location (e.g. ’sensor’, ’coolant temperature sensor’) • Nature of fault (e.g. ’limit value exceeded’, ’sporadic fault’) • Environmetal data / operating data (speed and operating hours at the time of the last fault occurrence) • Number of fault locations • Frequency of fault • Fault status (active – fault present / passive- fault no longer present) Fault messages for non-present / rectified faults can be deleted with SERDIA.

Further display possibilities: • Function test: With the engine shut down the control outputs and the travel of the governor rod can be activated.

• Assignment of inputs/outputs Display of the current input/output assignment of the EMR-control • Representation of measuring values: There are a lot of measuring values available which can be used if no EMR II fault is present (starting performance, engine sawing, lack of power).

• Operation of SERDIA is described in a separate operation manual.

BW 177 / 179 DH / PDH -4

- D 25 -

Service Training

Connection of SERDIA For this purpose the PC or Laptop is connected to the diagnostic interface with a special interface cable.

This connection is in the control box.

Replacement of system components • Replacement of the EMR II control unit: Each control unit is clearly designated to the engine, in accordance with the respective application.

In case of a replacement the control unit therefore needs to be completed with the engine specific data set. When ordering a new control unit you must not only specify the part-number, but also the engine serial number (see sticker on EMR-control unit).

Note: The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue.

• Replacement of the EMR-actuator (Y137) On engines of series 1013 and 2012 the actuators can be replaced without any additional programming of the control unit.

BW 177 / 179 DH / PDH -4

- D 26 -

Service Training • Replacement of other EMR-components All other EMR-components (sensors etc.) must not be repaired, but should only be replaced if they are faulty. Programming of the control unit is not required

Checking and adjusting the valve clearance Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the intervals specified in the operating and maintenance instructions.

Note:

The valve clearance must be checked and adjusted when the engine is cold.

Intake valve: = 0.3 mm Exhaust valve= 0.5 mm • Turn the crankshaft until both valves on cylinder 1 are overlapping (the exhaust valve is not yet closed, the intake valve starts to open).

Flywheel side

1

2

3

4

Fig. 14: Crankshaft position 1 • Check and adjust the valve clearance by following the black marking in the adjustment schematics.

For control purposes mark the respective rocker arm with chalk.

Flywheel side

1

BW 177 / 179 DH / PDH -4

2

3

4

- D 27 -

Service Training Fig. 15: Crankshaft position 2 • Turn the crankshaft one full turn (360°) further.

Check and adjust the valve clearance by following the black marking in the adjustment schematics.

BW 177 / 179 DH / PDH -4

- D 28 -

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

BW 177 / 179 DH / PDH -4

- D 29 -

Service Training plug-in injection pump Deutz diesel engines of product range 2012 are equipped with plug-in injection pumps of series PF 33 from Bosch.

The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in combination with a low fuel consumption.

Plug-in fuel injection pumps have the following plunger dimensions: •

Stroke

12 mm

•

Diameter

9 mm

Cavitation in the injection lines and injection overrun, which is normally associated with high pressures, is prevented by a return flow nozzle arranged after the pressure valve Das The constant volume relief is 50 mm³.

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

the fuel consumption,

•

the power

•

the exhaust emission

of the engine.

On engines of series 2012 the start of delivery is adjusted without tolerance. The start of delivery is enered in degree of crank angle measured from the top dead centre of the piston and depends on application, power and speed setting of the engine.

The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply bore in the plunger sleeve.

BW 177 / 179 DH / PDH -4

- D 30 -

Service Training On engines with inline injection pumps the engine drive is turned to start of delivery position and closing of the fuel supply bore is determined by means of a high pressure pump. Occurring tolerances are compensated in the coupling of the injection pump drive, whereby the injection pump camshaft is turned to start of delivery position against the fixed engine drive.

The injection pump cams on engines of series 2012 are arranged on the camshaft of the engine. For this reason the conventional adjustment method for the start of delivery cannot be used.

The start of delivery of the injection pump must be adjusted using the new method.

For this the conventional adjustment method is subdivided into length measurements of individual engine parts and calculations.

The permissible manufacturing tolerances for the components •

cylinder crankcase,

•

camshaft,

•

plunger

•

plug-in injection pump

are measured and eliminated by the adjustment of the start of delivery.

However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but individual injection pumps will be replaced.

Crankcase, camshaft and plunger remain unchanged.

This results in a certain installation measurement for the engine drive, which is stamped on the engine type plate.

In column „EP“ iit is stamped as „CODE“ for each cylinder.

Note: If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and nozzle must also be replaced..

1. Remove crankcase ventilation and cylinder head cover.

BW 177 / 179 DH / PDH -4

- D 31 -

Service Training Fig. 16: 2. Remove the engine solenoid

Fig. 17: 3. Insert the pressing device WILBÄR No. 100 830 carefully into the groove of the governor rod and fasten it.

Fig. 18: 4. Turn the knurled fastening screw to press the governor rod to stop position.

Note: Tighten the knurled fastening screw by hand.

Fig. 19:

BW 177 / 179 DH / PDH -4

- D 32 -

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

Note: View on flywheel

Fig. 20: 6. Remove injection line and injection pump.

Fig. 21: 7. Take the compensation shim carefully out with the rod magnet.

Fig. 22: Determine the thickness of the new compensation shim:

BW 177 / 179 DH / PDH -4

- D 33 -

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

295

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

Fig. 23: Injection pump code BFM 2012

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

BW 177 / 179 DH / PDH -4

- D 34 -

Service Training EK (mm)

EP code

EK (mm)

EP code

EK (mm)

EP code

EK (mm)

EP code

119,250

230

119,850

254

120,450

278

121,050

302

119,275

231

119,875

255

120,475

279

121,075

303

119,300

232

119,900

256

120,500

280

121,100

304

119,325

233

119,925

257

120,525

281

121,125

305

119,350

234

119,950

258

120,550

282

121,150

306

119,375

235

119,975

259

120,575

283

121,175

307

119,400

236

120,000

260

120,600

284

121,200

308

119,425

237

120,025

261

120,625

285

121,225

309

119,450

238

120,050

262

120,650

286

121,250

310

119,475

239

121,075

263

120,675

287

121,275

311

119,500

240

120,100

264

120,700

288

121,300

312

119,525

241

120,125

265

120,725

289

121,325

313

119,550

242

120,150

266

120,750

290

121,350

314

119,575

243

120,175

267

120,775

291

121,375

315

119,600

244

120,200

268

120,800

292

119,625

245

120,225

269

120,825

293

119,650

246

120,250

270

120,850

294

119,675

247

120,275

271

120,875

295

119,700

248

120,300

272

120,900

296

119,725

249

120,325

273

120,925

297

119,750

250

120,350

274

120,950

298

119,775

251

120,375

275

120,975

299

119,800

252

120,400

276

121,000

300

119,825

253

120,425

277

121,025

301

Fig. 24: Injection pump code table BFM 2012 Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from table 1.

BW 177 / 179 DH / PDH -4

- D 35 -

Service Training During the manufacture of the plug-in fuel injection pump the high pressure method is used to determine the wear in the fuel supply bore. In this position – injection pump plunger in start of fuel delivery position - the distance between pump contact face and plunger foot contact face is measured.

Measurement "A" in 1/100 mm has been written on the pump with an electric marker.

64

Fig. 25: Plunger code inscription

BW 177 / 179 DH / PDH -4

- D 36 -

Service Training

A=XXX

Fig. 26: Individual injection pump

BW 177 / 179 DH / PDH -4

- D 37 -

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

Lo A = XX

A/100

Fig. 27: Presentation of measurement „A“

• Lo = 117,5 mm - BFM 2012

BW 177 / 179 DH / PDH -4

- D 38 -

Service Training

Ek

Lo+A/100 Z Ts

Fig. 28: Drive in start of delivery position after determination of „Ts“ The plug-in fuel injection pump is now positively connected with the drive, which has been set to start of delivery by inserting a compensation shim "Z" of calibrated thickness..

The illustration explains that according to calculation: (Ek) - (Lo + A/100) there is a gap „Ts“ between injection pump plunger foot and roller plunger. This gap has to be compensated with a compensation shim "Z" of appropriate (calculated) thickness.

BW 177 / 179 DH / PDH -4

- D 39 -

Service Training Theor. thickness „Ts“

Theor. thickness „Ts“

(mm)

Thickness of compensation shims "Ss" (mm)

(mm)

Thickness of compensation shims "Ss" (mm)

0.95 - 1.049

1.0

2.45 - 2.549

2.5

1.05 - 1.149

1.1

2.55 - 2.649

2.6

1.15 - 1.249

1.2

2.65 - 2.749

2.7

1.25 - 1.349

1.3

2.75 - 2.849

2.8

1.35 - 1.449

1.4

2.85 - 2.949

2.9

1.45 - 1.549

1.5

2.95 - 3.049

3.0

1.55 - 1.649

1.6

3.05 - 3.149

3.1

1.65 - 1.749

1.7

3.15 - 3.249

3.2

1.75 - 1.849

1.8

3.25 - 3.349

3.3

1.85 - 1.949

1.9

3.35 - 3.449

3.4

1.95 - 2.049

2.0

3.45 - 3.549

3.5

2.05 - 2.149

2.1

3.55 - 3.649

3.6

2.15 - 2.249

2.2

3.65 - 3.749

3.7

2.25 - 2.349

2.3

3.75 - 3.850

3.8

2.35 - 2.449

2.4

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

BW 177 / 179 DH / PDH -4

- D 40 -

Service Training Exemplary calculation for BFM 2012 EP-code read off engine type plate: 295 • see table 1 corrected injection pump measurement „Ek“: 120,875 mm Lo = 117,5 mm (fixed measurement) Value for A/100 read off new injection pump A/100 = 42 • Ts = Ek - (Lo + A/100) Ts = 120.875 mm - (117.5 + 42/100 mm) Ts = 2.995 mm see also table 1 Ss = 3.0 mm

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

Fig. 29:

BW 177 / 179 DH / PDH -4

- D 41 -

Service Training 9. Turn the injection pump control lever to approx. middle position.

Fig. 30: 10. Apply some oil to the locating bore in the crankcase and the O-rings on the injection pump. Carefully insert the injection pump control lever into the governor rod.

Fig. 31: 11. Attach the flange.

Note: The chamfer must face towards the injection pump body

Fig. 32:

BW 177 / 179 DH / PDH -4

- D 42 -

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

Fig. 33: 13. Loosen the screws again for 60°.

Fig. 34: 14. Carefully turn the injection pump with and open end spanner in anti-clockwise direction against the noticeable stop

Fig. 35:

BW 177 / 179 DH / PDH -4

- D 43 -

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

Fig. 36: 16. Back out the knurled screw of the pressing device, remove the pressing device.

17. Reinstall the engine solenoid with a new Oring.

18. Reinstall the cylinder head cover. Tightening torque: 9 +/-1 Nm. Note: If necessary replace the gasket.

Fig. 37: 19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening torque 9 +/- 1Nm Note: If necessary replace the gasket.

Tools BW 177 / 179 DH / PDH -4

- D 44 -

Service Training The following tools can be ordered from the respective supplier (in brackets) under the stated partnumber.

For tools from Hazet and Bosch you should consult your nearest representative, orders to Wilbär should be addressed to: Co. Wilbär P.O.Box 140580 D - 42826 Remscheid

Fig. 38 • Pressing device for governor rod

BW 177 / 179 DH / PDH -4

100 830 (Wilbär)

- D 45 -

Service Training Electrical components and measuring point on the engine

1

2

Fig. 39: Diesel engine, right

Pos.

Designation

Pos. in wiring diagram

EMR - central plug

X 57

BW 177 / 179 DH / PDH -4

Pos. in hydraulic diagram

Measuring values

- D 46 -

Service Training

1

Fig. 40: Diesel engine starter side

Pos.

Designation

Pos. in wiring diagram

Air filter vacuum switch

B 03

BW 177 / 179 DH / PDH -4

Pos. in hydraulic diagram

Measuring values

50 mbar

- D 47 -

Service Training Fig. 41: Diesel engine auxiliary power take-off

Pos.

Designation

Steering/charge pump

BW 177 / 179 DH / PDH -4

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

09

- D 48 -

Service Training

1

2

1 2

Fig. 42: Engine compartment left, starter side

Pos.

Designation

Pos. in wiring diagram

1

Heating flange High current relay for heating flange

R 19

2

BW 177 / 179 DH / PDH -4

Pos. in hydraulic diagram

Measuring values

K 14

- D 49 -

BW 177 / 179 DH / PDH -4

Diesel engine

2

Axle drive motor

Drum drive motor

3

4

2 Travel pump

1Charge pump

M

1

to vib. pump

to steering system Charge pressure

3

T

from brake valve

4

T

Service Training

Travel system

Fig. 1 Travel system hydraulic diagram

-E1-

Service Training On the machines described in this training manual the travel system consists of a closed hydraulic circuit. It mainly consists of the travel pump with the integrated safety elements, two travel motors, the hydraulic oil filter and the hydraulic oil cooler.

The installation of a hydraulic pump with variable displacement into a closed hydraulic circuit is a perfect solution for a hydrostatic travel system, because with this design the travel direction can be reversed without any problems.

The travel pump is flanged to the flywheel side of the diesel engine. It is directly driven by the engine with constant speed.

In addition to its function of serving the steering system the gear pump driven by the auxiliary drive of the engine has also the function of a charge pump for the closed hydraulic circuit. The return flow from the steering valve is fed through the charge oil port into the travel pump.

The oil is cleaned by a charge pressure filter, which is hydraulically arranged directly after the gear pumps for steering/charge system.

Besides its function of supplying the closed circuit with cool and filtered oil as replacement for leakage and flushing losses, the oil from the charge circuit is also needed for the following machine functions: • to control the variable displacement pumps for travel and vibration systems, • to release the hydraulic multi-disc brakes.

• to support the proportional travel motor control •

The two travel motors are electrically proportionally controlled and conected parallel to each other.

The travel motors are fitted with flushing valves for the closed circuit.

All safety and control elements needed for the operation in a closed hydraulic circuit are integrated in the travel pump. These are: • High pressure relief valves (pressure setting see technical data) with integrated boost check valves • Charge pressure relief valve (pressure setting see technical data) • Pressure override (pressure setting see technical data) • Servo control

BW 177 / 179 DH / PDH -4

-E2-

Service Training Travel pump The travel pump is a swash plate operated axial piston pump with variable displacement from Bosch Rexroth-Hydromatik, type A4 VG 56 EP. The pump flow is determined by the displacement and the actual rotary speed of the pump.

Due to the possibility of an infinite adjustment of the swash plate the pump flow rate and therefore the travel speed can also be infinitely changed within the pre-selected travel speed range.

Fig. 2 Hydraulic diagram for travel pump 1

Pump drive

2

Control piston

3

4/3-way servo valve

4

Charge pressure relief valve

5

High pressure relief valves

6

Pressure override

BW 177 / 179 DH / PDH -4

-E3-

Service Training The pump is equipped with all control and safety elements needed for operation in a closed hydraulic circuit, such as: • high pressure relief valves, • charge pressure relief valve, • pressure override and • electric proportional servo control •

6 5 7

1

4 2

1

8

4

3

Fig. 1 Cross-sectional view of travel pump 1

Drive shaft

2

Swashing cradle

3

Cylinder block

4

Working pistons

5

control piston

6

Control unit

7

Slipper pad

8

Valve plate

BW 177 / 179 DH / PDH -4

-E4-

Service Training The spherical valve plate centres the cylinder block, which is tightly connected with the drive shaft, and avoids the appearance of undesired transverse forces.

Belleville springs hold the complete drive (valve plate, cylinder block, swash plate) tightly together and compensate appearing wear in axial direction immediately. This design principle gives the pump a very high rate of efficiency throughout its entire lifetime.

Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction (direction of oil flow).

An electrically operated proportional 4/3-way valve directs the pilot oil flow (from the charge circuit) to the corresponding control piston side in the servo control. The 4/3-way proportional valve is controlled with special current signals from the ESX in dependence on the travel lever position and setting of the travel speed range switch.

In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way valve pilot oil (from the charge circuit) is directed to one of the control piston sides in dependence on the position of the pressure reducing valve and moves the control piston to the corresponding direction.

The swashing lever between the control piston and the swash plate transfers the control piston movement to the swash plate. The needle bearing mounted swash plate swivels to the chosen direction.

This causes the axial movement of the pistons inside the cylinder block. The axial movement draws oil into the pump and presses it to the travel motors.

All working pistons are drilled through their entire length. Pressure fluid flows through these bores into the areas between the slipper pads and the surface of the swash plate. This forms a hydraulically balanced field, on which the slipper pads can slide without any metal to metal contact between swash plate and slipper pads. The feedback lever on the control piston detects when the swash plate has reached a position that corresponds with the displacement of the travel lever. This feedback lever controls a pilot oil portioning valve which interrupts the pilot oil flow to the control chambers when the swashing angle corresponds with the position of the travel lever. Swashing angle and displacement of the working pistons (oil flow rate) remain constant, until a new control command requires a different swashing angle.

When changing the swashing angle through the neutral position to the opposite side, the flow direction of the oil and the sense of rotation of the travel motors will change.

BW 177 / 179 DH / PDH -4

-E5-

Service Training When actuating the travel pump pressure will build up in the line between pump outlet and motor inlet.

This pressure depends on the load acting on the travel motors. This pressure keeps the boost check valve inside the high pressure relief valve for this particular side of the closed hydraulic circuit closed.

Cool and filtered oil can now only enter into the closed circuit on the opposite side (low pressure side).

The high pressure relief valve limits possibly occurring extreme pressure peaks to the adjusted value.

If one of these valves responds, hydraulic oil will flow out of the high pressure side and enter the low pressure side through the corresponding boost check valve.

Since the cross-sections of these valves are very small and the hydraulic oil enters the low pressure side already inside the pump, the system would very quickly overheat if the pressure in the system would be relieved via the high pressure relief valves. For this reason the pump is fitted with an additional pressure override valve. The pressure override valve interrupts the pilot oil flow to the control piston, thereby maintaining the pressure level at the adjusted value of the pressure override valve. If the pressure drops again, the pressure override valve will open and the pump can swash back to the previously chosen position. This installation prevents overheating of the hydraulic system and overloading of the diesel engine.

BW 177 / 179 DH / PDH -4

-E6-

Service Training Control 1

2

3

Fig. 2 Pump control The servo control of the pump is integrated in the pump housing and consists mainly of: • 1) the electrically controlled proportional 4/3-way valve • 2) the control piston • 3) the feedback lever • If the current in the solenoids Y16 (forward) or Y17 (reverse) increases above the threshold value (values see electric training), the 4/3-way valve will move out of neutral position to the desired direction and guide the pilot oil flow through the pilot oil portioning valve to the corresponding control piston side.

The control piston moves to the corresponding direction and operates the swash plate via the swashing lever accordingly.

The pump is now able to deliver oil to the travel motors. The feedback lever, which is mounted with its ball head in the pump control shaft, follows the control piston and interrupts the pilot oil flow wen the control piston has reached a position corresponding with the displacement of the travel lever. The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump housing.

BW 177 / 179 DH / PDH -4

-E7-

Service Training Charge pressure relief valve The charge pressure relief valve belongs to the group of safety elements in a closed hydraulic circuit.

This valve limits the pressure in the charge circuit to the adjusted value.

The charge pressure relief valve is a valve with a fixed setting, so that the pressure value of 26 +/- 1 bar cannot be altered. from the charge pump

pilot oil fixed spring (26 bar)

to the oil tank

Fig. 3 Charge pressure relief valve The charge circuit is needed for the compensation of leak oil and flushing quantities in the closed hydraulic circuit.

Since feeding of cool and filtered oil is only possible on the low pressure side of the closed circuit, the pressure in the low pressure side is identical with charge pressure. If the travel pump is in neutral position, both boost check valves can open and let in oil from the charge circuit. In this case the pressure in both sides of the closed circuit is identical with charge pressure.

BW 177 / 179 DH / PDH -4

-E8-

Service Training High pressure relief valves, (with bypass for towing) High pressure relief valves are safety elements, which are needed in every hydraulic circuit.

These valves limit the pressure in the hydraulic circuit to the value determined by the adjustment spring.

1 2

3

2

High pressure relief valves bypass

Fig. 4 Valve plate with high pressure relief valves 1

Pressure override

2

High pressure relief valves (fixed) with bypass for towing

3

Charge pressure relief valve (fixed)

The high pressure relief valves in both sides of the hydraulic circuit protect the hydraulic system, the diesel engine and all other machine components against overloads.

BW 177 / 179 DH / PDH -4

-E9-

Service Training to travel motors

3 4

4 1 2 from the charge circuit from front travel mot

Fig. 5 : High pressure relief valves, hydraulic diagram 1

Travel pump

2

Control piston (actuated)

3

4/3-way valve (actuated)

4

High pressure relief valves

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 flushing quantities.

BW 177 / 179 DH / PDH -4

- E 10 -

Service Training Pressure override

2

5 1

3

6

4

Fig. 6 Pressure override, hydraulic presentation of function 1

Charge pump

2

Pressure override (400 bar)

3

Travel pump

4

Control piston

5

3/4-way proportional valve

6

Shuttle valve

Y16 Solenoid valve, forward Y17 Solenoid valve, reverse

BW 177 / 179 DH / PDH -4

- E 11 -

Service Training Since the cross-sections of the high pressure relief valves are very small, longer responding of these valves would cause very quick overloading of the hydraulic circuit and would subsequently lead to severe damage in pump or other components. In order to avoid this, the travel pump is equipped with another safety device, the pressure override.

Fig. 7 Pressure override 1

Valve piston

8

Pressure spring

2

Bore

9

Adjustment screw

3

Valve seat

10

Pilot pressure channel

4

Piston

11

Housing channel

5

Valve bush

12

High pressure circuit

6

Control piston

13

High pressure circuit

7

Spring plate

BW 177 / 179 DH / PDH -4

- E 12 -

Service Training The pressure override is hydraulically arranged in the pilot oil flow to the pump control before the 4/3way valve and consists mainly off: • axial spool with control edges, • adjustment spring and • adjustment screw with counter nut.

Via a shuttle valve the spool of the pressure override is always subjected to the highest pressure in the closed circuit. As long as the pressure in the closed circuit is lower than the adjustment value of the pressure override, the pilot oil connection via the 4/3-way valve to the corresponding control chamber is released. The pump can now be actuated up to maximum displacement.

If the pressure reaches the setting of the pressure override, the spool inside the valve will move and cut off the pilot oil flow to the control piston. The pump cannot be actuated any further. The system pressure is maintained at the setting of the pressure override, until the resistance causing this high pressure in the system is overcome or the pump is returned to neutral position by the operator.

Should the pressure in the closed circuit drop below the setting of the pressure override, the valve spool will be forced back by spring force, whereby the passage between charge circuit and pump control is opened again. Now pilot oil can flow to the corresponding control piston side again and the pump can be actuated. The spring force of the pressure override and its reaction value can be adjusted via the adjustment screw.

Due to the design and the hydraulic arrangement of pressure override the high pressure relief valves will not respond at all under normal conditions. This type of pressure limitation ensures that no oil will be relieved from the closed circuit via the very tight cross sections of the high pressure relief valves. This avoids overheating of the hydraulic oil.

In order to ensure a safe function, the pressure override should always be approx. 10% lower than the setting of the fixed high pressure relief valves.

High pressure relief valve Pressure override

BW 177 / 179 DH / PDH -4

= 430 +/- 5 bar = 420 +/- 10 bar

- E 13 -

Service Training Axle drive motor,

The axle drive motor is a swash plate controlled (electrically proportional) Sauer-Sundstrand axial piston motor (series 51 C 080) with variable displacement.

High pressure pumpBrake valve

Charge pressure

5 4 2

Leakag

3

High pressure pump

Fig. 3 Hydraulic diagram, axle drive motor 1

Motor drive

2

Control piston

3

Proportional control with proportional solenoid

4

Flushing valve with flushing pressure limitation valve

5

Axle with brake

BW 177 / 179 DH / PDH -4

- E 14 -

Service Training .

5

8

7

6 9

1

11 4

2

10

3 Fig. 4: Axle drive motor, 1

Control piston

7

Cylinder block

2

Flushing valve

8

Universal joint

3

prop. control

9

Output shaft

4

Spindle with ball

10

Output shaft bearing

5

Qmin-screw

11

Working piston

6

Valve plate

BW 177 / 179 DH / PDH -4

- E 15 -

Service Training Function The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows under high pressure through the corresponding port to the back of the working pistons. Since the working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a stroke movement, thereby causing a rotation of the output shaft.

Once the respective piston has passed its dead centre (max. extended position), it will change to the low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is thereby displaced out of the cylinder chamber through the low pressure side back to the pump.

The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.

The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the connection between output shaft and pistons no other parts are required. The output shaft runs in two tapered roller bearings.

Control The motor is electrically proportionally adjusted.

The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle between cylinder block and output shaft.

With a large angle position the motor works with maximum displacement, slow speed and high torque.

When changing the swash plate position to minimal angle the motor works with minimum displacement, high speed and low torque.

The displacement is changed by a control piston, which is tightly connected with the valve segment.

The front travel motor (drum drive) is also an axial piston motor 51C060 from Sauer-Danfoss.

BW 177 / 179 DH / PDH -4

- E 16 -

Service Training Drum drive (51C060 + GFT17) on DH/PDH versions On the DH/PDH versions the drum is driven by a fast rotating axial piston motor 51C060 from Sauer-Danfoss and a reduction gear GFT17 from Lohmann + Stolterfoth.

The function of the axial piston motor is identical with the function of the axle drive motor and does therefore not need to be described in detail. A reduction gear with a reduction ration of i = 53.95 reduces the high output speed down to drum speed.

6 4 5 1 3 7 2

8

15

14

9

13 10

12

11

Fig. 1 Drum drive

1

Screw fastening front frame

9) Planet gear, stage 1

2

Fixed housing section = planet carrier stage 2

10) Drive shaft = sun gear stage 1

3

Screw fastening drum

4

Ball bearing

5

Fixation of bearing

6

Planet gear srage 2

7

Rotating housing = hollow wheel stages 1 and 2

8

Planet gear stage 1

BW 177 / 179 DH / PDH -4

11) Hollow shaft = receptacle of motor and brake shaft 12) Brake discs 13) Brake piston 14) Brake spring 15) Brake releasing connection

- E 17 -

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

Fig. 5: Manual releasing of rear axle brakes • Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.

• Turn the brake releasing screw (2) in against the stop.

• To release the brake tighten the screw for max. 1 complete turn.

Attention!

Turn the screws on both sides in uniformly (alternately by 1/4 of a turn) • Repeat this procedure on the opposite side of the axle.

BW 177 / 179 DH / PDH -4

- E 18 -

Service Training Test and adjustment points, travel system

4 5

4 3

4

3

1 2

5

2 Fig. 6: Steering/charge pump and charge pressure filter

Pos.

Designation

1 2 3 4

Steering/charge pump Steering pressure test port charge oil filter Charge oil filter pressure differential switch Pressure test port, charge pressure

5

BW 177 / 179 DH / PDH -4

Pos. in wiring diagram

Pos. in hydraulic diagram

09 MB 07

Measuring values

200 +/-10 bar ∆p 3,5 bar

B21 MA

25+/-11

- E 19 -

Service Training Fig. 7: Travel pump

1 2

2 Fig. 8 Travel pump test ports Pos.

Designation

1 2

Pressure test port, forward travel Pressure test port, reverse travel

BW 177 / 179 DH / PDH -4

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

10 - B - MC 10 - A - MD

420 +25/-5 bar 420 +25/-5 bar

- E 20 -

Service Training Travel pump

1

1

2

3

1 2

2 Fig. 9 Travel pump test ports Pos.

Designation

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

1 2 3

Pressure test port, reverse travel Pressure test port, forward travel Pressure test port, charge pressure

Y16 Y17

MC /b MD /a MA

12V / 0,4-1,2 A 12V / 0,4-1,2 A 25+/-1

BW 177 / 179 DH / PDH -4

- E 21 -

Service Training Travel motor (drum drive)

3

4 5

2

2

5 3

1

1

4

Fig. 10 Front travel motor (drum drive)

Pos.

Designation

1 2 3 4 5

Pressure, forward travel Pressure, reverse travel Connection X Prop. solenoid Flange mounted speed sensor PPU

BW 177 / 179 DH / PDH -4

Pos. in wiring diagram

Pos. in hydraulic diagram

12 - A 12 - B X1 Y30 B59

Measuring values

approx. 25bar 12V / 0,4-1,2 A

- E 22 -

Service Training Travel motor (axle drive)

1

4

2 3

5 4 6

3 5

1 7

2

Fig. 11 Rear axle motor Pos.

Designation

Pos. in wiring diagram

1 2 3 4

Prop. solenoid Connection X Travel pressure sensor High pressure from travel pump forward to drum drive motor High pressure from travel pump reverse to drum drive motor

Y31

5

BW 177 / 179 DH / PDH -4

Pos. in hydraulic diagram

X1 B112

Measuring values

12V / 0,4-1,2 A approx. 25bar 25 -400 bar

13 - B 13 - A

- E 23 -

Service Training

2 1 3

1

2

NEW : Flange mounted speed sensors in both travel motors and a travel pressure sensor in the frame front left under the operator's stand!

Pos.

Designation

Pos. in wiring diagram

1

Flange mounted speed sensor PPU Axle motor Flange mounted speed sensor PPU Drum drive motor Travel pressure sensor front left under operator's platform

B60

1 2

BW 177 / 179 DH / PDH -4

Pos. in hydraulic diagram

Measuring values

B59 B112

- E 24 -

Service Training Brake valve

(located in the frame rear right)

5

2

1 2

1

3

4

3

Fig. 12 Brake valve with brake release valve

Pos.

Designation

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

1

Brake valve with solenoid valve Brake release valve with integrated pressure relief valve Pressure test port, brake pressure Brake release button Hand pump

Y4

08

0V closed12V open 38+/-2

2 3 4 5

BW 177 / 179 DH / PDH -4

16 16 - MA 16 16

approx. 25bar

- E 25 -

Service Training Travel lever

5

4

Fig. 13 Travel lever (multi-function lever)

A detailed description of the travel lever button be found in chapter "Electrics" (Service Training "Electrics")

BW 177 / 179 DH / PDH -4

can

- E 26 -

Service Training Trouble shooting The display shows error codes

A detailed description of how to read out the error codes and on the display can be found in chapter "Electrics" (Service Training "Electrics") The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past.

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

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

BW 177 / 179 DH / PDH -4

- E 27 -

SYMPTOME

FEHLERSUCHE FAHRANTRIEB BW 177 DH-4

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

Service Training

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

1 2

2 3 1

2

3

2 1 2 3 3 2

3 3 1 2 3 3 3 2 1 2

3 3 3

3 1 2

2 1 1

1 2

FEHLERSUCHE BW 177 / 179 DH / PDH -4

- E 28 -

Service Training Vibration The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.

The main components of this circuit are • vibration pump, • Vibration motor • and the pressure resistant hydraulic hoses.

T1: to tank T2: Connection to travel pump

Charging to tank

1

2

Fig. 1 Vibration hydraulic diagram 1

Vibration pump

2

Vibration motor with flushing valve

Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the diesel engine.

When operating a 4/3 way proportional valve, pilot oil is guided to one of the control piston sides. This actuates the pump from neutral position to the required displacement to one of the two possible sides.

BW 177 / 179 DH / PDH -4

-F1-

Service Training When changing the swashing angle through the neutral position to the opposite side, the flow direction of the oil and the sense of rotation of the vibration motor will change.

Since the speed of the diesel engine is variable, the pump displacement always needs to be adapted proportionally in order to maintain the vibration frequency constant.

The vibration motor output shaft is joined with the exciter shaft in the drum via a Bowex coupling. The rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically suspended drums.

The eccentric weights on the vibrator shaft are fitted with additional change-over weights.

Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights.

• Basic weight + change-over weight = high amplitude • Basic weight - change-over weight = low amplitude The displacement of the pump may be different to both flow directions. This results in different exciter shaft speeds to the two directions of rotation of the motor.

The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.

Fig. 2 Sense of rotation of exciter shaft

BW 177 / 179 DH / PDH -4

-F2-

Service Training Vibration pump The vibration pump is a swash plate operated axial piston pump with variable displacement of type A10 VG 45 EP from Bosch-Rexroth. The pump is fitted with all control and safety elements needed for operation in a closed hydraulic circuit. These are: • servo control • High pressure relief valves with integrated boost check valves • Pressure override T2: Connection to travel pump T1: to tank

Internal connection to Travel pump Charge pressure valve

Charging

to / from Vibration motor

from/to Vibration motor

Fig. 3 Vibration pump, hydraulic diagram 1

Pump drive

2

Control piston

3

Proportional solenoid valve

4

High pressure relief valves

5

Pressure override

BW 177 / 179 DH / PDH -4

-F3-

Service Training The spherical valve plate centers the cylinder block which is driven by the drive shaft via a splined connection. This avoids the appearance of undesired transverse forces.

3

2

4

5

1

9

8

7

6

Fig. 4 Vibration pump 1

Drive shaft

2

Control piston

3

Pilot pressure port (X1/X2)

4

Servo control

5

Pressure override

6

Cylinder block

7

Working pistons

8

Slipper pad

9

Swash plate

The complete drive consisting of valve plate, cylinder block and swash plate is held together by Belleville springs. This results in a high efficiency over the entire lifetime of the pump.

BW 177 / 179 DH / PDH -4

-F4-

Service Training Pilot pressure is used to operate the pump out of neutral position to the desired pumping direction (direction of oil flow). A 4/3-way valve guides this pilot oil to the corresponding control piston side in the servo control. Due to the use of a remote control (electrically operated via solenoids) the pump can only be actuated from neutral to one of the two possible maximum displacement positions.

In neutral position both control chambers are loaded with case pressure. When opening the 4/3-way valve pilot oil (from the charge circuit) is directed to one of the control piston sides and moves the control piston to the corresponding direction. The pump swashes to the adjusted displacement.

When changing the swashing angle through the neutral position to the opposite side, the flow direction of the oil and the sense of rotation of the exciter shaft will change.

The displacements to both pumping directions have different adjustments.

This results in different speeds of the vibration motor to both travel directions.

This means: • High displacement – high speed (frequency).

• Low displacement – low speed (frequency).

The position of the change-over valves depends on the sense of rotation of the exciter shaft. The different positions of the change-over weight in relation to the basic weight results in the following vibration effects: • High displacement – high frequency – low amplitude • Low displacement – low frequency – high amplitude The resistance affecting the rotation of the exciter shaft causes pressure to build up between pump and motor. This pressure closes the boost check valve in the high pressure side of the closed circuit.

Feeding of cooled and filtered hydraulic oil can therefore only take place in the low pressure side.

Once the pressure reaches the adjusted value of the pressure override valve the pilot oil flow to the 4/ 3 way solenoid valve is interrupted. The pressure cannot increase any further.

Sudden pressure peaks are eliminated by high pressure relief valves. In this case hydraulic oil flows from the high pressure side through the boost check valve directly into the opposite side, the low pressure side.

BW 177 / 179 DH / PDH -4

-F5-

Service Training High pressure relief valves 1 2

8

3*

4*

6

5

Fig. 5 High pressure relief valves 1

Setscrew for pressure override

2

High pressure relief valve with integrated boost check valve

3

*(not in vibration pump)

4

*(not in vibration pump) (charge pressure relief valve)

5

High pressure relief valve with integrated boost check valve

6

Valve plate

7

Pressure override

When switching the vibration off the vibration motors for a short while have the function of a pump. They pump the oil back to the vibration pump. This effect is caused by the rotating exciter shafts with the attached eccentric weights.

Since the vibration pump is already in neutral position, the oil cannot pass through the pump. In this case the pressure override valve has no function. Under this condition the high pressure relief valves work as brake valves.

The functions of pressure override valve and high pressure relief valves in the vibration circuit are identical with the functions of these valves in the travel circuit. The description of these components does therefore not need to be repeated.

BW 177 / 179 DH / PDH -4

-F6-

Service Training Control The control is part of the pump and consists mainly of the 4/3-way solenoid valve, the control piston and the swash plate with swashing lever.

If one of the two magnets is energized by actuating the frequency selector switch and the vibration control switch, the 4/3 way solenoid valve is switched to open position. Pilot oil flows now to the corresponding control piston side. The control piston slides to the corresponding direction and moves the swash plate via the swashing lever. The pump delivers oil.

1

6 2

1 2

5

4

3 Fig. 6 Pump control 1

Solenoid valve

4

Neutral setting spring

2

Valve spool

5

Control piston

3

Setscrew for mechanical neutral position

6

Control chamber

The oil from the opposite control chamber flows through the 4/3-way valve as leak oil into the pump housing.

When the 4/3-way valve is in neutral position, the pressure values in both control chambers are identical (case pressure = max. 3 bar).

BW 177 / 179 DH / PDH -4

-F7-

Service Training Vibration motor The vibration motor is a swash plate type axial piston motor with fixed displacement of series MMF 052 from Sauer-Danfoss. Since the motor can be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits.

The output speed of the motor depends on the oil quantity supplied by the vibration pump.

2

3

4

5

1

6

10

9

8

7

Fig. 7 Cross-section of vibration motor 1

Flushing valve block

2

Flushing valve

3

Working pistons with slipper pads

4

Roller bearing for output shaft

5

Radial seal

6

Output shaft

7

swash plate

8

Retaining plate

9

Pre-tensioning spring

10

Flushing pressure relief valve

BW 177 / 179 DH / PDH -4

-F8-

Service Training The output torque raises with increasing pressure difference between low and high pressure side in the closed circuit.

Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.

When switching the vibration on the motor must first start to move the resting vibration shaft. This resistance causes a hydraulic starting pressure, which is limited by the pressure override to 385 bar.

Once the vibrator shaft has reached its final speed, the pressure will drop to a value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly depends on the condition of the ground (degree of compaction, material etc.).

• Hard ground = High operating pressure • Loose ground = Low operating pressure

MA

A 2

3

B

1

MB

Fig. 8 Circuit diagram of vibration motor 1

Vibration motor

2

Flushing valve

3

Flushing pressure relief valve

BW 177 / 179 DH / PDH -4

-F9-

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

1

A

2

B

Fig. 9 Flushing valve 1

Flushing spool

2

Flushing pressure relief valve

The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only a certain quantity of hydraulic oil is flushed out of the low pressure side.

This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately replaced with fresh and filtered oil through the corresponding boost check valve.

BW 177 / 179 DH / PDH -4

- F 10 -

Service Training Drum 8

9

10

11

*2) *8)

*6) *9)

*1)

1

2

3

4

5

6

*3)

7

Fig. 10 Cross-section of drum 1

Drum shell

7

Coupling vibr.-motor – vibrator shaft

2

Vibration bearing

8

Travel bearing

3

Basic weight

9

Travel bearing shield

4

Change-over weight

10

Rubber buffer

5

Vibrator housing

11

Vibration motor

6

Exciter shaft

BW 177 / 179 DH / PDH -4

- F 11 -

Service Training

Fig. 11 Assembly information to Fig 10 (footers)

BW 177 / 179 DH / PDH -4

- F 12 -

Service Training Test and adjustment points, vibration system Vibration pump

7 6

6

1

8 72

5 5

1 4

4

3

3

2 Pos.

Designation

1

Pressure test port, vibration pressure low amplitude Pressure test port, vibration pressure high amplitude Pressure override High pressure relief valve, high amplitude High pressure relief valve, low amplitude Solenoid valve, high amplitude Solenoid valve, low amplitude

2 3 4 5 6 7

BW 177 / 179 DH / PDH -4

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

11 - B - MF

11 11

Starting pressure 330 -400 bar Starting pressure 330 -400 bar 380+/-5bar 405 +/-5 bar

11

405 +/-5 bar

11 11

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

11 - A - ME

Y07 Y08

- F 13 -

Service Training Vibration motor

3

5 1

1

2 2

4

3 Fig. 12 Vibration motor

Pos.

Designation

1 2 3 4 5

High pressure port, high amplitude High pressure port, low amplitude Flushing valve RPM-sensor Leak and flushing oil

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

15 - A 15 - B 15 B16 15 - L1

approx. 2.5 l..

Flushing quantity

Trouble shooting

BW 177 / 179 DH / PDH -4

- F 14 -

Service Training The display shows error codes

A detailed description of how to read out the error codes and on the display can be found in chapter "Electrics" (Service Training "Electrics") The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past.

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

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

BW 177 / 179 DH / PDH -4

- F 15 -

SYMPTOME

FEHLERSUCHE VIBRATION BW 177DH-4

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

Service Training

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

1 1 1 2 2 1 1 2 2 2

2 2 3

2 2 1 1 1 1 1 1 1 2

FEHLERSUCHE

BW 177 / 179 DH / PDH -4

- F 16 -

Service Training Steering Single drum rollers of series BW 177 / 179 DH-4 are equipped with a hydrostatically operated articulated steering system.

The steering system mainly consists of steering pump, steering valve, steering cylinder and pressure resistant connecting hoses.

to charge system 1 7

6 5

3 2 4 from steering pump

Fig. 1 Steering hydraulics 1

Rating pump

2

Distributor valve

3

Steering pressure relief valve (∆p =175 bar)

4

Check valve (pre-loaded to 0.5 bar)

5

Anti-cavitation valve

6

Shock valves (240 bar)

7

Steering cylinders

The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve and the connected steering unit under the dashboard of the machine. If the steering is not operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel circuits.

When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.

The steering cylinders retract or extend and steer the machine.

The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175 bar. The charge pressure must, however, be added to this value, because the oil leaving the steering system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.

BW 177 / 179 DH / PDH -4

-G1-

Service Training Charge pump The charge pump for travel circuit and vibration works also as steering pump The pump is an external gear pump with fixed displacement.

The oil flow generated by the charge pump is joined together with the return flow from the steering valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration pump.

BW 177 / 179 DH / PDH -4

-G2-

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

9

9

6

1

7

9

3 8 2

4

5

Fig. 2 Steering pump 1

Housing

2

Flange

3

Shaft

4

Bearing plate

5

Bearing plate

6

Cover

7

Gear (driving)

8

Gear (driven)

9

Seals

BW 177 / 179 DH / PDH -4

-G3-

Service Training Working principle of the gear pumps The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of both gears mesh with minimum clearance when rotating.

The displacement chambers are created between the tooth flanks, the inside wall of the housing and the faces of the bearing plates.

When the pump is running the chambers transport hydraulic oil from the suction side to the pressure side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.

To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic fluid can be transported from the suction side to the pressure side without any losses.

For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial pressure field.

This pressure field is always under the actual system pressure.

BW 177 / 179 DH / PDH -4

-G4-

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

1 9

2

3 4

5 8

6 7

Fig. 3 Cross-sectional view of steering valve 1

Neutral setting springs

2

Housing

3

Inner spool

4

Outer spool

5

Universal shaft

6

Ring gear

7

Gear

8

Check valve

9

Pressure relief valve

When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating pump.

The rating pump guides the oil flow back through the distribution valve to the corresponding side of the steering cylinder. The rating pump measures the exact oil quantity according to the rotation angle of the steering wheel.

This oil flow to the steering cylinders articulates the machine and causes a steering movement.

BW 177 / 179 DH / PDH -4

-G5-

Service Training

240 bar

∆p = 175 bar 240 bar

0,5 bar

Fig. 4 Steering valve, hydraulic diagram The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.

The charge pressure value must be added to this pressure, because the oil leaving the steering system is fed into the charge circuit for the closed travel circuits.

The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks which may occur, e.g. when driving over obstructions, and protect the system against overloads.

Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond these anti-cavitation valves protect the system against cavitation damage.

A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would act as pumps and press the oil back to the pump.

BW 177 / 179 DH / PDH -4

-G6-

Service Training Articulated joint Front and rear frames of the single drum rollers BW 177 D-4 are connected by an oscillating articulated joint. This ensures that drum and wheels are at all times in contact with the ground, even when driving extreme curves.

Fig. 5 Articulated joint

BW 177 / 179 DH / PDH -4

-G7-

Service Training The rear console is tightly bolted to the rear frame.

The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.

This gives drum and wheels excellent ground contact, even under extremely severe conditions.

The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted in friction bearings.

The steering cylinder anchor point is welded to the front console.

When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the front console around the vertical bolts. This articulates the machine and results in a steering movement.

All bearings on the articulated joint are maintenance free and do not require any lubrication.

Notes on assembly: When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest importance.

Please follow the instructions in the repair manual for the articulated joint.

Test and adjustment points steering points

BW 177 / 179 DH / PDH -4

-G8-

Service Training

5

3

4 1

2

2

Fig. 6: Steering/charge pump

Pos.

Designation

1 2

Steering pump (and charge pump) Steering pressure test port

Pos. in wiring diagram

Pos. in hydraulic diagram

09 MB

Measuring values

200 +/-10 bar

Trouble shooting

BW 177 / 179 DH / PDH -4

-G9-

Service Training The display shows error codes

A detailed description of how to read out the error codes and on the display can be found in chapter "Electrics" (Service Training "Electrics") The following trouble shooting chart contains a small selection of possible faults, which may occur during operation of the machine. The fault list is by no means complete, however, the fault table is based on the experience of the central service department, i.e. the list covers almost all faults that have occurred in the past.

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

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

BW 177 / 179 DH / PDH -4

- G 10 -

SYMPTOME

FEHLERSUCHE LENKUNG BW 177-DH-4

Keine Lenkfunktion Endanschläge werden nicht erreicht Lenkung schwergängig

Service Training

MÖGLICHE URSACHEN Lenkorbitrol Lenk- Speisepumpe Lenkzylinder Knickgelenk

2 1 3 3

2 1 3 3

1 2 3 2

FEHLERSUCHE BW 177 / 179 DH / PDH -4

- G 11 -

Service Training Electrics Single Drum Rollers – 4 From -DH Version 1.10

Version 1.03 Status: Author:

19.10.04 Seis / TE

Dateiname:

c:\dokume~1\nickb\lokale~1\temp\schulung elektrik wz4 v1.03_gb.doc

Page 1 of 46

Service training WZ-4 from version DH

Table of contents

1

ÄNDERUNGSNACHWEIS _________________________________________ 4

2

AUSGEWÄHLTE FEHLERREAKTIONEN DER ESX STEUERUNG_________ 5

3

BESCHREIBUNG DER FEHLERANZEIGE IM LC DISPLAY ______________ 7

3.1

Servicemodus Aufrufen ___________________________________________________________ 7

3.2

Eingabecodes eingeben ____________________________________________________________ 7

3.3

Einstellen des Maschinentyps_______________________________________________________ 9

3.4

Ändern der Lenkeinheit bei BVC-4 Maschinen (ab Version 1.09) ________________________ 10

3.5

Fahrtrichtungssensor einlernen ____________________________________________________ 11

3.6

Sprungströme des Fahrantriebs automatisch ermitteln_________________________________ 11

3.7

Sprungströme der Lenkventile automatisch ermitteln (BVC)____________________________ 13

3.8

Elektronische Endanschläge des Lenkwinkelsensors einlernen (BVC) ____________________ 14

3.9

Gegen die geschlossene Bremse fahren ______________________________________________ 15

3.10

Gespeicherte Fehler anzeigen______________________________________________________ 15

3.11

Alle gespeicherten Fehler löschen __________________________________________________ 15

4

WAS IST BEIM AUSTAUSCH VON KOMPONENTEN ZU TUN? __________ 16

4.1

Was ist beim Austausch einer ESX-Steuerung zu tun? _________________________________ 16

4.2

Was ist beim Austausch einer Fahrpumpe / Fahrmotor Achse / Fahrmotor Bandage zu tun? _ 16

4.3

Was ist beim Austausch eines Lenkventils (BVC) zu tun?_______________________________ 16

4.4

Was ist beim Austausch eines Lenkwinkelsensors zu tun? ______________________________ 16

4.5

Was ist beim Austausch eines Achssensor vorne / hinten zu tun?_________________________ 16

4.6

Welche Komponenten können ohne anschließende Einstellprozedur getauscht werden? _____ 17

5

BESCHREIBUNG DER SIGNALE AN DER ESX STEUERUNG ___________ 18

6

BESCHREIBUNG DER SIGNALE AM DATENSAMMLER _______________ 23

7

BESCHREIBUNG DER SIGNALE AM FAHRHEBEL ___________________ 25

8

BESCHREIBUNG DER SIGNALE AM LC - DISPLAY __________________ 27

Status: Author:

19.10.04 Seis / TE

Dateiname:

c:\dokume~1\nickb\lokale~1\temp\schulung elektrik wz4 v1.03_gb.doc

Page 2 of 46

Service training WZ-4 from version DH 9 BESCHREIBUNG DER SIGNALE AN DEM DIOS MODUL (NUR BEI OPTION ANBAUPLATTEN) _________________________________________________ 28 10

FEHLERCODES DER ESX STEUERUNG __________________________ 29

10.1

Übersicht ______________________________________________________________________ 29

10.2

Beschreibung der Fehlerreaktionen ________________________________________________ 30

10.3

Detaillierte Beschreibung der Fehlercodes und möglicher Ursachen ______________________ 31

11

EINGABECODES FÜR ESX STEUERUNG _________________________ 38

11.1

Allgemein ______________________________________________________________________ 38

11.2

Bremse ________________________________________________________________________ 38

11.3

Fahrhebel / Fahren ______________________________________________________________ 39

11.4

Lenken ________________________________________________________________________ 41

11.5

Vibration ______________________________________________________________________ 42

11.6

Motor _________________________________________________________________________ 42

11.7

Hydraulik______________________________________________________________________ 42

11.8

Maschinencode ändern ___________________________________________________________ 42

12

BEGRIFFLICHKEITEN IM ZUSAMMENHANG MIT DER ESX___________ 43

Status: Author:

19.10.04 Seis / TE

Dateiname:

c:\dokume~1\nickb\lokale~1\temp\schulung elektrik wz4 v1.03_gb.doc

Page 3 of 46

Service training WZ-4 from version DH

1 List of changes No. 1 2 3 4

Date 23.04.2004 06.05.2004 11.05.2004 24.06.2004

Description of changes Creation of version 1.00 Revision, teach functions Revision, supplements to version 1.01 Revision, supplement to version 1.02

Ver. Date Description of changes 1.03 02.09.2004 ⇒ Jump currents travel drive teach function changed ⇒ Known faults ⇒ Fault - codes revised ⇒ Deactivation of electric steering on BVC machines ⇒ How to proceed when replacing components?

Status: Author:

19.10.04 Seis / TE

Dateiname:

c:\dokume~1\nickb\lokale~1\temp\schulung elektrik wz4 v1.03_gb.doc

resp.

Werner Fondel Seis Seis resp.

Schroeder, Fondel

Page 4 of 46

Service training WZ-4 from version DH

2 Selected fault reactions of the ESX control Reaktion

Symbol in fault message display

Signal

Warning

Warning

Engine stop

Code output without buzzer

Code output with buzzer

Code output with buzzer

5100 5112

5101 5112

Engine oil pressure (from EMR)

1)

Coolant temperature (from EMR)

5100 5116 1)

Coolant level

Engine air filter

2)

after 10s

5101 5116 2)

after 15s

5024

5025

after 5s

after 10s

5026

5027

after 5s

after 2min 3)

Charge control light

Pre-heating of engine

Brake

ASC

Different fault causes and reaction times.

See fault codes Hydraulic oil filter

Water separator on fuel filter

5502

5503

after 5s

after 2min

5028

5029

after 5s

after 2min

Theft warning system (Option)

Seat contact (Option) Fault in air conditioning (Option) 1) 2)

After reaching the warning limit!

After reaching the shut-down limit!

Status: Author:

19.10.04 Seis / TE

Dateiname:

c:\dokume~1\nickb\lokale~1\temp\schulung elektrik wz4 v1.03_gb.doc

3)

Shut-down currently deactivated by parameter Page 5 of 46

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

Effect: Display stay dark, no voltage

Cause: PIN in display plug X 28 bent

Status: Author:

19.10.04 Seis / TE

Dateiname:

c:\dokume~1\nickb\lokale~1\temp\schulung elektrik wz4 v1.03_gb.doc

Page 6 of 46

Service training WZ-4 from version DH

3 Description of fault display in the LC Display Apart from its normal display function the LC Display is also able to show fault codes, which were previously visualized by means of a 3-digit fault code display.

Existing faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes will change in a 3 second cycle.

Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible.

Negative values are marked with a "minus sign".

The following description deals with the operation of the LC-Display via the travel lever buttons.

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

INFO 1 Taste (gelb)

Werte ändern (grün)

INFO 2 Taste (gelb)

Navigieren (blau)

Werte ändern (grün) Navigieren (blau)

To activate the input mode the travel lever must be engaged in the brake lock! Input mode is activated by simultaneous pressing of both INFO – buttons over a period of approx. 3 seconds.

3.2 Entering input codes The input mode starts with flashing of the left hand digit. At this point you have the possibility to change into service mode by entering 9 9 9 9 . The green buttons are used to increase or reduce the values of the individual digits. Pressing one of the blue buttons brings you to the next digit (left or right). When pressing the right hand blue navigation key again after entering the last digit, the code will be transferred to the control.

If the access code has been entered correctly, the "Spanner" symbol will be displayed and the first input digit flashes again. By transferring input codes to the control (as described above) individual operating states of the machine can be interrogated.

When pressing both INFO buttons over a period of approx. 3 seconds a new input code can be entered. The service mode can be terminated by entering the code "0 0 0 0 ", or by switching off the ignition.

If the travel lever is shifted out of brake lock position in service mode, all machine function will become active again, except the reading in the LC.Display, which remains in service mode and shows the previously requested operation values.

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 7 of 46

Service training WZ-4 from version DH

Normalmodus (Fahrhebel in Bremsraste!)

Aufruf optionaler Anzeigen über INFO - Taste 1 und INFO - Taste 2

„Eingabe“ - Modus: Betätigen INFO 1 + INFO 2 ca. 3s

Bet. INFO 1 + INFO 2 ca. 3s oder Fahrhebel aus Bremsr.

Umschaltung Displayfunktion Einstellungen Display Plattenverstellung inaktiv!

Eingabe Zugangangscode 9999

„Service“- Modus: Eingabe Diagnosecodes Fehlerspeicher abrufen / löschen Maschinentypen umstellen Plattenverstellung inaktiv!

CODE - Eingabe „0000" oder Zündung aus

Fahrhebel aus Bremsraste: Diagnosemodus im Vordergrund aktiv!

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 8 of 46

Service training WZ-4 from version DH

3.3 Adjusting the machine type Since the same control is used for all single drum rollers of series DH-4 with electronically controlled engines (EPA II), it is necessary to adjust the machine type after installing a new control.

This work must be carried out during first time commissioning as well as in case of a spare parts installation. This type adjustment is absolutely necessary, because the machines have e.g. wheel and axle drive motors or different tire sizes and therefore different rolling speeds or are equipped with extension plates or other attachments.

For simple checking the currently set machine type is displayed for approx. 3 seconds on the display module of the central electrics when switching the ignition on. The machine type can also be checked by entering code 0720 .

The following machine types can be set: 0

1

2

3

4

5

6

7

8

9

0

Default

BW 177 PDH-4

BW 179 DH-4

BW 179 PDH-4

BW 213 DH-4

BW 213 PDH-4

BW 213 DH-4 USA

BW 213 PDH-4 USA

BW 216 DH-4

1

BW 216 PDH-4

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

BW 219 PDH-4

BW 226 DH-4 147kW

BW 226 PDH-4 147kW

BW 226 DH-4 174kW

BW 226 PDH-4 174kW

72XX DH

DH

2

DH

3

DH

4

DH

5

BW 177 DH-4 BVC

BW 213 DH-4 BVC

BW 213 DH-4 BVC w. plates

BW 226 DH-4 BVC 147 kW

BW 226 DH-4 BVC 174 kW

BVC

6

BVC

7

BVC

8

BVC

9

BVC

EXAMPLE: Machine code for BW 219 PDH-4:

Note:

7212

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

Note:

This function can only be activated / deactivated when the travel lever is in brake lock position. (! ! Input mode) The following method must be used for initial start-up of a control:

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 9 of 46

Service training WZ-4 from version DH • Control was installed in the machine.

• Switch on the machine. After switching on the inscription C O D E is automatically displayed for approx. 3 seconds. After this the code 7200 appears in the display.

• Use the arrow up or down keys to select the correct machine code from the listed codes.

• Confirm the selection by pressing the arrow right key.

• After approx. 7 seconds the set machine type code, e.g. 7 2 1 2 is displayed for approx. 3 seconds. The new parameters are loaded according to the newly set machine type. Do not switch the ignition off during this time!

• Then switch the ignition off and on again to accept the configuration.

• This is followed by the normal display reading.

The following applies for correcting the machine type code is a code is already set.

• Enter code number 9 9 9 9 (activation of service mode).

• Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.

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

• Select the machine code from the table above and confirm with the arrow to right key. Pressing the arrow to right key automatically switches the control off and on again.

• After approx. 7 seconds the set machine type code, e.g. 7 2 1 2 is displayed for approx. 3 seconds. The new parameters are loaded according to the newly set machine type. Do not switch the ignition off during this time!

• Then switch the ignition off and on again to accept the configuration.

• This is followed by the normal display reading.

Attention:

A machine must not be operated with a wrong type adjustment, because in such a case the correct function of the control cannot be assured!

New controls are delivered with a default machine type setting 7 2 0 0 . This does not allow driving or steering the machine. It solely serves the purpose of commissioning.

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

• • •

Enter code number 9999 (activation of service mode).

Enter code number 2 0 6 0 . This code number activates the function "Adjusting steering unit“.

The following code numbers are available to activate the installed steering unit.

Hydraulic steering Electric steering

•

2062 2061

The display shows O K

Attention:

Status: Author:

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

19.10.04 Seis/ TE

Functions of the ESX control

Page 10 of 46

Service training WZ-4 from version DH

3.5 Teaching the travel direction sensor Teaching of the travel direction sensor is required for first commissioning or after replacing a travel motor. Use the following procedure.

• Turn the travel stage switch to "MAX" • Slowly displace the travel lever, until the speedometer shows a reading of approx. 1 km/h.

• If one of the two travel direction sensors detects an opposed direction after the machine has travelled approx. one machine length, fault code 1106 or/and 1116 is displayed. Otherwise no fault code is displayed. The travel direction detection has now been automatically set.

However, should one of these error messages still be displayed after this measure, there must be a sensor fault present.

3.6 Automatic detection of surge currents in the travel system This function sequence is only valid from software version 1.09!

For a sensitive and exact travel function the surge currents in the travel system must be determined for both travel directions. The surge currents are automatically determined after entering a code number, so that no electric meter is required.

The surge currents must only be determined during initial commissioning in the factory, after a service during which the control on a steering valve or the complete steering valve has been replaced and after the replacement of the ESX-control.

The measurement is identical for both travel directions: After entering the respective code number the current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250 mA..

After each current increase the system waits for 3 seconds. If a considerable drum movement is measured during the waiting time, the surge current is reached. In order to enhance the measuring result this measurement is performed three times. The final surge current is the mean value of these three measurements. This surge current is automatically stored and is valid from the next start of the machine.

Before the measurement you should strictly make sure that the machine is parked on level ground and has a sufficient distance for movement to front and back, because the machine will move to the respective direction when performing the measurement.

Attention! Set the machine to input mode first (code 9 9 9 9 ). It must be strictly assured that the speed sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code number 1 1 0 6 at the display module. This code can be used to display the number path pulses from the speed sensor. The displayed value must change when the machine is driven.

If this value does not change even though the machine is moving, the measurement must not be performed!

The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not be detected. (See also: „Resetting the surge currents in the travel system”) Attention!

During the measurement the machine will move when the surge current is reached!

Do not leave the machine while the measurement is progressing!

During the measurement keep an eye on your environment!

To stop the machine reset the travel lever to neutral position!

The automatic measurement of the travel system surge currents is performed as follows: • The switch for rotary speed preselection must be set to ECO • If necessary enter code number 9 9 9 9 to enter into service mode.

• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents"; the display now shows the value 0 0 0 0 with the first zero flashing. This code number must be entered before the following steps can be performed. From this point the machine can

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 11 of 46

Service training WZ-4 from version DH no longer be operated with the travel lever! The travel lever will only be in function again after the steering function has been ended or the engine has been restarted.

• The measurement (forward/reverse) must be started by entering a code number. The code number for teaching the travel direction is as follows: Determination of surge currents

1 0 9 1

• After entering the above code number the display will show " F O R E". The travel lever must now be actuated forward, this will also start the measurement for the surge current in forward.

• During the measurement the actual current is displayed (display value = current in mA).

• Once the measurement of the surge current in forward is finished, the display will show O K for 5 seconds.

• After this wait time the display will show the reading "B A C K". The travel lever is now moved backward, this will start the surge current measurement in reverse.

• During the measurement the actual current is displayed (display value = current in mA).

• Once this measurement is finished the display will show O K again.

• The travel lever must now be returned to brake position.

• Once both jump currents have been learned correctly and the travel lever is back in "brake position", the display will show the message "D O N E", the values are saved and the function is finished. Now the machine can be operated again by the travel lever. The new surge current values for the travel system are valid from the next start.

• The teach function can at any point be aborted by simply pressing the emergency stop button or via the ignition switch.

With software versions 1.07 and 1.08 use the following procedure: The automatic measurement of the travel system surge currents is performed as follows: • The seat must be adjusted for travel direction forward!

• The switch for rotary speed preselection must be set to ECO • If necessary enter code number 9 9 9 9 to enter into service mode.

• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents"; the display now shows the value 0 0 0 0 with the first zero flashing. This code number must be entered before the next steps are possible. From this point the machine can no longer be operated with the travel lever! The travel lever will only be in function again after the steering function has been ended or the engine has been restarted.

• Both measurements (forward/reverse) must be started by entering a code number. The code numbers for both travel directions are: Determine surge current for control forward

1 0 9 1

Determine surge current for control reverse

1 0 9 2

• After entering one of the above code numbers the measurement of the surge current will only start after moving the travel lever to the respective travel direction.

ATTENTION: During the teach process the ASC-lamp will come on. In this case this is without any meaning. Restarting the machine eliminates the warning.

• During the measurement the actual current is displayed (display value = current in mA).

• Teaching must be performed for both travel directions.

• When returning the travel lever to neutral after the two measurements, O K is displayed for 3 seconds and the determined values will be memorized.

• After both surge currents have been measured the machine can again be driven with the travel lever. The new surge current values for the travel system are valid from the next start.

• The teach function can at any point be aborted by simply pressing the emergency stop button or via the ignition switch.

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 12 of 46

Service training WZ-4 from version DH

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

Does not apply for BVC machines with the optional hydraulic steering

To enable a sensitive and exact function of the steering the surge currents of the two control solenoids and both steering valves must be measured. The surge currents are automatically adjusted after entering a code number, so that no electric meter is required.

The surge currents must only be adjusted during initial commissioning in the factory, after a service during which the control on a steering valve or the complete steering valve has been replaced and after the replacement of the ESX-control.

The measuring procedure is identical for both solenoids: Example BW 177 BVC: After entering the respective code numbers the current is increased by the control solenoid in steps of 5 mA, starting from 650 mA.. After each increasing step the system waits for 2 seconds. If a change in drum angle is measured after the waiting time, the surge current is reached. In order to enhance the measuring result this measurement is performed three times. The final surge current is the mean value of these three measurements. This surge current is automatically stored and is valid from the next start of the machine.

For all other machine types the same procedure is used, however, currents and times will vary.

Before the measurement you must strictly make sure that the steering system is „bled“, because an air cushion in the steering cylinders would have a negative effect on the measurement and therefore on the steering performance of the machine. Sufficient bleeding is achieved by performing a few quick steering movements at full engine speed.

The automatic measurement of the steering valve surge currents is performed as follows: • The engine must be operated in ECO mode!

• Enter code number 9 9 9 9 to enter into service mode.

• Travel lever in neutral position (brake must be relieved!)

• Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of surge currents on steering valves"; the display now shows the value 0 0 0 0 with the first zero flashing.

• Now you must enter code number 2 0 0 1 .

• After entering o0ne of the above mentioned code numbers the measurement of the surge current will start immediately.

• The drum is thereby first steered to the right and then to the left.

• During the measurement the actual current is displayed (display value in mA).

• Attention! During the measurement the drum cannot be used for steering ! The steering wheel has no effect.

• During the measurement the machine should not be driven !

• Once the measurement is completed the display value OK will appear for 3 seconds, after this the code number 0000 is displayed again with the first digit flashing and the next measurement can be started.

• The new surge current values are valid from the next start.

Note:

Status: Author:

During the measurement the machine should be parked on level ground.

Before the measurement both drums should be steered to straight ahead position.

19.10.04 Seis/ TE

Functions of the ESX control

Page 13 of 46

Service training WZ-4 from version DH

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

Does not apply for BVC machines with the optional hydraulic steering!

Do prevent the steering from running against the mechanical end stops of the steering cylinder, a clearly defined safety distance to the end stops must be determined.

• Enter code number 9 9 9 9 to enter into service mode.

• Enter code number 2 0 1 0 to activate the mode for "teaching the steering stops".

• Shift the travel lever to neutral position (no brake function, to relieve the machine). The display now shows the standardized steering position (0..1000 → right ... left).

• Now turn the electronic steering wheel clockwise, until the mechanical end stop is reached. The displayed value should be in the range of 100..300. Then shift the travel lever to brake position and enter code number 2 0 1 2 . Upon acceptance the value 2 2 2 2 is displayed for a moment.

In case of a fault the reading is 9 9 9 9 (see below).

• Shift the travel lever to neutral position (no brake function, to relieve the machine). The display now shows the standardized steering position (0..1000 → right ... left).

• Now turn the electronic steering wheel anti-clockwise, until the mechanical end stop is reached.

The displayed value should be in the range of 700..900. Then shift the travel lever to brake position and enter code number 2 0 1 3 . Upon acceptance the value 3 3 3 3 is displayed for a moment. In case of a fault the reading is 9 9 9 9 (see below).

• To exit this mode shut down the machine or enter code 2 0 1 1 .

Causes for faults (code 9 9 9 9 ) : If the standardized values are not within the specified ranges, the steering angle sensor on the articulated joint needs to be adjusted.

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 14 of 46

Service training WZ-4 from version DH

3.9 Driving against the closed brake After entering code number 0 5 0 0 the brake is no longer released. When disengaging the travel lever out of brake lock position and shifting it to one of the travel directions, the travel pumps will be actuated in accordance with the selected travel direction. At the same time a warning (fault code 0 5 0 0 ) appears on the display and the warning buzzer is triggered, in order to keep the operator informed about the condition. The brake control light in the LC-Display remains active.

In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or switch the ignition off. After entering the code number 0 5 0 1 the function is terminated and the confirmation OK appears for 5 seconds. After this a new code number can be entered.

Note:

This function can only be activated / deactivated when the travel lever is in brake lock position. (! ! Input mode)

3.10 Showing stored faults This function sequence is only valid from software version 1.10!

Switch on function „Show stored faults“: • Enter code number 0 7 0 0 . This code number enables the function „Show stored faults“.

The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will appear again. If no faults are stored in the ESX the display will show "- - - - - "

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

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

Note:

This function can only be activated / deactivated when the travel lever is in brake lock position. (! Input mode)

3.11 Deleting all stored faults This function sequence is only valid from software version 1.10!

Execute the function „Delete all stored faults“: • The engine must not be running!

• Enter code number 0 7 1 0 .

• Switch the ignition off and on again.

All stored function are now deleted.

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

Note: This function can only be activated / deactivated when the travel lever is in brake lock position. (! ! Input mode)

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 15 of 46

Service training WZ-4 from version DH

4 How to proceed when replacing components?

Each machine is individually adjusted during initial start-up. This adjustment or teaching process is necessary to make sure that the travel and steering functions are almost identical on all machines.

Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic pump for travel system, proportional valves for steering, steering angle sensors and ESX control.

These tolerances apply for both mechanical as well as electrical functions and are unavoidable for manufacturing reasons.

To enable simple and quick adjustment procedures we have decided to do without expensive tools. All that is needed is this manual and a bit of time. By following the described procedure it is possible to take a machine back into operation after the replacement of one of the components specified above and to re-establish the usual functional quality, with almost any previous knowledge. Even an incorrectly or incompletely conducted teaching procedure can be repeated without problems as often as necessary. At the first glance it seems to be at bit awkward to perform this adjustment on every machine, but this procedure enables the operation of all machines with the same operating software.

At the end of the day this considerably increases the spare parts availability.

4.1 How to proceed when replacing an ESX control?

Since the control stores all teach values of the machine, each teaching procedure must be performed with the new control after a replacement.

Attention:

Before performing one of the following steps you must first adjust the respective machine type (see chapt 3.6 Fehler! Es wurde kein Textmarkenname vergeben.)!

When changing the machine type all previously made adjustments will be lost!

Now you must follow the commissioning instructions.

• • • • • •

Electric pre-adjustment (see commissioning instructions chapter 3) Engine start, heating flange inspection, teaching of travel drive and steering (see commissioning instructions chapter 4) Inspection of display and shut-down functions (see commissioning instructions chapter 5) Inspection of seat contact circuitry (see commissioning instructions chapter 6) Inspection of travel ranges and vibration (see commissioning instructions chapter 7) Inspection of ASC function DH-single drum rollers (see commissioning instructions chapter 8)

4.2 How to proceed when replacing a travel pump / axle drive motor / drum drive motor?

•

Automatic detection of surge currents in the travel system (see chapter 3.6 Fehler! Es wurde kein Textmarkenname vergeben.)

4.3 How to proceed when replacing a steering valve (BVC)?

•

Automatic detection of surge currents of the steering valve (BVC) (see chapter 3.7 Fehler! Es wurde kein Textmarkenname vergeben.)

4.4 How to proceed when replacing a steering angle transducer?

•

Teaching electric end positions of the steering angle sensors (see chapter 3.8)

4.5 How to proceed when replacing an front / rear axle sensor?

•

Teaching the travel direction sensor

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 16 of 46

Service training WZ-4 from version DH

4.6 Which components can be replaced without a subsequent adjustment procedure?

• • • • • • • •

Display Data collector Joystick Electric steering wheel Diesel engine All switches in the dashboard Vibration motor Vibration pump

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

Status: Author:

19.10.04 Seis/ TE

Functions of the ESX control

Page 17 of 46

Service training WZ – 4

Description of signals on the ESX control

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

ESX terminal Signal description X35:1 AGND = Analogue ground: Ground potential for sensors (steering angle sensor, steering unit etc.)

X35:2 Output amplitude changeover Digital output (max. 2.5 A) X35:3 Output warning buzzer Digital output (max. 2.5 A) X35:4 Interface RS 232 RxD, not used for normal operation.

X35:5 Interface RS 232 TxD, not used for normal operation.

X35:6 Not used X35:7 Not used X35:8 Not used X35:9 Not used X35:10 Not used X35:11 Not used X35:12 Input axle speed Frequency input (0....7,5kHz)

X35:13 X35:14

Status: Author:

Not used Not used

19.10.04 Seis/ TE

Nominal values (voltage / current) approx. 0 V measured against ground (terminal 31) active, i.e. high amplitude "approx.12 V inactive, i.e. low amplitude " 0V Warning buzzer active "approx.12 V Warning buzzer inactive " 0V Measurement not possible!

Measurement not possible!

------------Signal changes between approx. 0V and 12V, when machine is driving.

Frequency with travel speed m/min Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz -----

Description of signals on the ESX control

Page 18 of 46

Service training WZ – 4

Description of signals on the ESX control

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

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

X35:20

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

X35:21 X35:22

X35:23

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

X35:29

Status: Author:

Voltage supply for sensors This output supplies steering angle sensor and steering unit.

Without this voltage the control cannot work correctly and will switch to override mode (emergency function).

Output Backup alarm Digital output (max. 2.5 A) Not used Interface CAN-Bus 1 Wire -, is used for communication with the MESX, the data collector, the LC-Display and the BOP. Interface CAN-Bus 1 Wire +, is used for communication with the MESX, the data collector, the LC-Display and the BOP. Input potential terminal 15 Digital input active high This signal must be present, so that the control can work.

Input steering angle sensor Analogue input / voltage input 0..8.5 V 19.10.04 Seis/ TE

Nominal values (voltage / current) Seat occupied " 0V Seat not occupied " ?V --Release brake "approx.12 V Apply brake " 0V Signal changes between approx. 0V and 12V, when steering wheel is turned.

Frequency depends on speed of rotation Signal changes between approx. 0V and 12V, when steering wheel is turned.

Frequency depends on speed of rotation Steering left active " 0,4..1,2 A Steering left inactive " 0A Steering right active " 0,4..1,2 A Steering right inactive " 0A permissible current range: approx. 0..0,6 A Vibration pump active " 0,0..2,0 A Vibration pump not active " 0A Nominal voltage = 8,5 V Permissible range: approx. 7,65..9,35 V This voltage must be measured against AGND. Backup alarm inactive Backup alarm active ---

" 0V "approx.12 V

MEASUREMENT NOT POSSIBLE! MEASUREMENT NOT POSSIBLE! Control switched on Control switched off

"approx.12 V "approx.2 V

Position steering angle sensor (measured against AGND) right hand stop " 0,50..1,00 V

Description of signals on the ESX control

Page 19 of 46

Service training WZ – 4

Description of signals on the ESX control

ESX terminal Signal description

X35:30

Input longitudinal inclination of machine Analogue input / voltage input 0..8.5 V

X35:31

Input hydraulic pressure travel pump circuit Analogue input (current input 4mA..20mA) from pressure sensor on travel pump Not used Interface CAN-Bus 2 Wire -, is used for communication with travel lever and engine EMR.

X35:32 X35:33 X35:34

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

X35:35

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

X35:36

Input vibration motor sense of rotation (currently not used)

Status: Author:

19.10.04 Seis/ TE

Nominal values (voltage / current) straight ahead / neutral / middle " .. V left hand stop " 6,80..8,70 V Inclination of machine (measured against AGND) -45° axle at top " 0,50..2,49 V Neutral position " 2,50 V maximum down " 2,51..4,50 V 0 bar " approx.4 mA 600 bar " approx.20 mA ---

MEASUREMENT NOT POSSIBLE! Signal changes between approx. 0V and 12V, when machine is driving.

Frequency with travel speed m/min Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz Frequency at vibration frequency in Hz Machine type: Vib. frequency XX Hz "approx.XX Hz Vib. frequency XX Hz "approx.XX Hz Machine type: Vib. frequency XX Hz "approx.XX Hz Vib. frequency XX Hz "approx.XX Hz Machine type: Vib. frequency XX Hz "approx.XX Hz Vib. frequency XX Hz "approx.XX Hz Sense of rotation forward "approx.12 V Sense of rotation reverse "approx.2 V

Description of signals on the ESX control

Page 20 of 46

Service training WZ – 4 ESX terminal Signal description Digital input active high X35:37 Input drum sense of rotation Digital input active high X35:38 Input axle sense of rotation Digital input active high X35:39 Not used X35:40 Input steering sensor (S2/A) Digital input active high

Description of signals on the ESX control Nominal values (voltage / current)

X35:41

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

X35:42

Output emergency steering

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

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

X35:47

Output axle drive motor PWM current output (max. 4 A)

X35:48

Output vibration pump PWM current output (max. 4 A)

X35:49

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

Sense of rotation forward "approx.12 V Sense of rotation reverse "approx.2 V Sense of rotation forward "approx.12 V Sense of rotation reverse "approx.2 V --Signal changes between approx. 0V and 12V, when steering wheel is turned.

Frequency depends on speed of rotation Signal changes between approx. 0V and 12V, when steering wheel is turned.

Frequency depends on speed of rotation Emergency steering active "approx.12 V Emergency steering inactive " 0V ------permissible current range: approx. 0..0,6 A Drum drive motor active " 0,0..2,0 A Drum drive motor not active " 0A permissible current range: approx. 0..0,6 A Axle motor active " 0,0..2,0 A Axle motor not active " 0A permissible current range: approx. 0..0,6 A Axle motor active " 0,0..2,0 A Axle motor not active " 0A Travel forward active " 0,0..2,0 A Travel forward inactive " 0A

Not used Not used Not used

Sauer components with EDC Travel forward active Travel forward inactive -------

X35:50 X35:51 X35:52

Status: Author:

19.10.04 Seis/ TE

Description of signals on the ESX control

" 18..80 mA " 0 mA

Page 21 of 46

Service training WZ – 4

Description of signals on the ESX control

ESX terminal Signal description X35:53 Interface CAN-Bus 2 Wire +, is used for communication with travel lever and engine EMR.

Nominal values (voltage / current)

MEASUREMENT NOT POSSIBLE!

X35:54

Voltage supply for electronics (permanent voltage)

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

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

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

X35:65

Test connection Baby Boards

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

X35:66

Test connection Baby Boards

approx. 0 V

X35:67

Test connection Baby Boards

approx. 0 V

X35:68

Test connection Baby Boards

approx. 0 V

X35:62 X35:63 X35:64

Status: Author:

19.10.04 Seis/ TE

Description of signals on the ESX control

" 18..80 mA " 0 mA

Page 22 of 46

Service training WZ – 4

Description of signals on the data collector

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

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

X27:3 X27:4 Status: Author:

Signal description

Nominal values (voltage / current)

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

Direction indicator right active Direction indicator left active Direction indicator left active Direction indicator left active Engine running Engine not running --Filter clogged Filter OK --Air conditioning on Air conditioning off Filter clogged Filter OK Illumination on Illumination off Coolant level too low Coolant level sufficient --0V (measured against ground)

Not used Voltage supply for monitoring of the water separation (PIN X27:9) 19.10.04 Seis/ TE

"approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V " "

0V ?V

"approx.12 V " 0V " 0V " ?V "approx.12 V " 0V " 0V " ?V

The voltage signals change with the fuel level in the diesel tank Fuel tank empty " ?? V Fuel tank full " ?? V --Voltage supply O.K. "approx.12 V

Description of signals on the data collector

Page 23 of 46

Service training WZ – 4

Description of signals on the data collector

PIN data collector

Signal description

X27:5 X27:6

Ground connection Interface CAN-Bus 1 Wire +, is used for communication with the MESX, the ESX, the LC-Display and the BOP. Interface CAN-Bus 1 Wire -, is used for communication with the MESX, the ESX, the LC-Display and the BOP. Voltage supply (permanent voltage)

X27:7 X27:8 X27:9

Input water separation Current input

X27:10 X27:11 X27:12

Not used Not used Not used

Status: Author:

19.10.04 Seis/ TE

Nominal values (voltage / current) No voltage supply 0V (measured against ground) Measurement not possible!

"

0V

Measurement not possible!

Control running "approx.12 V Control not running " 0V If a sufficient amount of water has been separated a low current flows through the contacts and the water in the separator bowl. This current is evaluated in this input.

No water separated " I= 0A Water separated " I∗ 0,03mA -------

Description of signals on the data collector

Page 24 of 46

Service training WZ – 4

Description of signals on the travel lever

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

PIN Travel lever X23:1 X23:2 X23:3 X23:4 X23:5

X23:6 X23:7 X23:8

X23:9 X23:10 X23:11

X23:12 X24:1 X24:2

Status: Author:

Signal description

Nominal values (voltage / current)

Voltage supply (permanent voltage)

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

Ground connection Output BTS brake Digital output (max. 4 A) Output BTS (not used) Digital output (max. 4 A) Output voltage supply for additional analog evaluations This output supplies the 24-stage travel speed range switch. Without this voltage no additional analogue switches can be connected to the travel lever and evaluated.

Interface CAN-Bus 2 Wire +, is used for communication with the ESX and the engine EMR. Interface CAN-Bus 2 Wire -, is used for communication with the ESX and the engine EMR. AGND = Analogue ground: Ground potential for additional analog evaluation Relation to PIN X23:5 Node address addressing 1 Node address addressing 2 Input travel speed range switch Analog input Not used Not used Input high amplitude

19.10.04 Seis/ TE

"approx.12 V " 0V "approx.12 V " 0V

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

Measurement not possible! approx. 0 V measured against ground (terminal 31)

Connection to machine ground (0V) Connection to machine ground (0V) The voltage signal changes with the adjusted travel range Travel stage min. " ?? V Travel stage max. " ?? V ----High amplitude active "approx.12 V

Description of signals on the travel lever

Page 25 of 46

Service training WZ – 4 PIN Travel lever X24:3 X24:4 X24:5 X24:6 X24:7

X24:8

Status: Author:

Description of signals on the travel lever

Signal description

Nominal values (voltage / current)

Digital input active high Input low amplitude Digital input active high Not used Not used Input left hand armrest (not yet realized) Digital input active high Output voltage supply for additional digital evaluations This output supplies the amplitude pre-selection switch. Without this voltage no additional digital switches can be connected to the travel lever and evaluated.

Output voltage supply ground potential This output in connection with PIN X24:7 enables the control of additional components (relay, displays etc.)

High amplitude inactive Low amplitude active Low amplitude inactive -------

" 0V "approx.12 V " 0V

Voltage supply active Voltage supply inactive

"approx.12 V " 0V

19.10.04 Seis/ TE

0V (measured against ground)

Description of signals on the travel lever

Page 26 of 46

Service training WZ – 4

Description of signals on the LC - Display

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

PIN Display X28:1

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

X28:2 X28:3

Ground connection Interface CAN-Bus 1 Wire +, is used for communication with the MESX, the ESX, the data collector and the BOP. Interface CAN-Bus 1 Wire -, is used for communication with the MESX, the ESX, the data collector and the BOP. Voltage supply (permanent voltage "Battery +" for RTC)

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

X29:8

Status: Author:

Not used Input frequency adjustment lower Digital input active high Input frequency adjustment higher Digital input active high Input engine speed high idle Digital input active high Input engine speed low idle Digital input active high Not used Not used Output voltage supply for additional digital evaluations This output supplies the engine speed switch and the switch for frequency adjustment. Without this voltage no additional digital switches can be connected to the LCD and evaluated.

Not used

19.10.04 Seis/ TE

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

Measurement not possible!

Electronics working Electronics not working " --Adjustment active Adjustment inactive Adjustment active Adjustment inactive High idle active High idle inactive Low idle active Low idle inactive ----Voltage supply active Voltage supply inactive

"approx.12 V 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V

"approx.12 V " 0V

---

Description of signals on the LC - Display

Page 27 of 46

Service training WZ - 4

Description of signals on the DIOS module

9 Description of signals on the DIOS module (only with optional extension plates) DIOS terminal X0:1 X0:2 X0:3 X0:4

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

Interface CAN-Bus 1 Wire -, is used to communicate with the ESXcontrol.

Voltage supply for electronics

X0:9

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

X0:10

Voltage supply for outputs

X0:11 X0:12

Ground connection Input proximity switch plates middle Digital input active high Output plates floating position Digital output (max. 4 A) Output plates priority Digital output (max. 4 A) Not used Not used

X0:5 X0:6 X0:7 X0:8

X0:13 X0:14 X0:15 X0:16

Status: Author:

19.10.04 Seis / TE

Nominal values (voltage / current) Measurement not possible!

Measurement not possible!

Ignition ON: Ignition OFF: Plates in middle position Plate outside middle position Lifting active Lifting inactive Lowering active Lowering inactive Offset left active Offset left inactive Offset right active Offset right inactive Ignition ON: Ignition OFF: Ignition ON: Ignition OFF: 0 V measured against ground Plates at top lift point Plates lowered Float position active Lifting inactive Priority active Priority inactive -----

Description of signals on the DIOS module

"approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V

Page 28 of 46

Service training

Fault codes on the ESX control

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

Status: Author:

Fault description General faults / warnings / machine tests Fault in travel system Fault in steering system Fault in remote control Fault of work functions (vibration, rotor, dozer blade, chip spreader) Fault in measuring systems Fault diesel engine Fault hydraulic system Fault anti-theft warning system, locating system, access system, time calculation, etc.

Input of machine codes Input of measuring technology codes Operating hours, load spectrum, etc.

Severe software fault Fault of external I/O-nodes (joystick, data collector, Dios-module, LCD-display, etc.)

19.10.04 Seis / TE

Fault codes on the ESX control

Page 29 of 46

Service training WZ – 4

Description of control input codes

10.2 Description of fault reactions Fault reaction Description of fault reaction 1

Warning.

Fault code is displayed.

2

Warning.

Fault code is displayed.

Audible signal

3

Function affected, the faulty function is replaced by an emergency function.

Fault code is displayed.

Audible signal

4

Partial function faulty, the partial function cannot be overridden by an emergency function.

The machine is stopped if this fault occurs.

The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.

Fault code is displayed.

Audible signal

5

Partial function faulty, the partial function cannot be overridden by an emergency function.

The machine is no longer able to drive, e.g. because parts of the travel system are defective " the diesel engine is shut down.

Fault code is displayed.

Audible signal

6

Fatal fault. The function of the control can no longer be guaranteed.

Control is switched off.

The fault code is displayed, the signal light in the monitoring board is permanently on.

No audible signal!

Note:

Status: Author:

Faults with fault reaction 1 and 2 are only warnings and are NOT stored in the error log!

19.10.04 Seis / TE

Description of control input codes

Page 30 of 46

Service training WZ – 4

Description of control input codes

10.3 Detailed description of fault codes and their possible causes

Fault Code

Fault description

Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

500

Warning "Driving against brake“ The function "Driving against brake“ is activated

A corresponding input code was entered

X

502

Warning "Simulated engine run" The function "sumulated engine run" is active

A corresponding input code was entered

X

504

Warning "Anti-Slip Control (ASC) deactivated" The function "Anti-Slup Control (ASC)" is deactivated

A corresponding input code was entered

X

507

Warning "Drum drive deactivated" The test mode "drum drive deactivated" was activated.

A corresponding input code was entered

X

508

Warning "Axle drive deactivated" The test mode "axle drive deactivated" was activated.

A corresponding input code was entered

X

560

Fault "Overvoltage 8,5V" The voltage level of 8,5V range is exceeded in an unacceptable way (see signal description) Fault "Undervoltage 8,5V" The voltage level of 8,5V range is fallen short of in an unacceptable way (see signal description) Fault "Voltage override relay" The voltage level of the 8,5V range is...

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

X

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

X

Fault brake valve The required control power cannot be transmitted to the control solenoid.

Fault brake valve Signal outside the valid range (see signal description) Fault brake valve Signal outside the valid range (see signal description) Fault BTS brake / travel lever Overheating of the BTS has the effect that the travel lever brake position is not recognized correctly

The connecting line from the output of the control to the control solenoid is interrupted, or the proportional solenoid is defective Cable breakage in ground line, or the connecting cable valve / ground connection has come loose Cable breakage in supply line, or the connecting cable valve / supply has come loose Hardware defect on travel lever

561

562

1001

1002 1003 1004

Status: Author:

19.10.04 Seis / TE

Input code for diagnose

Fault reaction

X

Description of control input codes

X

X

X

X

X

X

X

X

Page 31 of 46

Service training WZ – 4

Description of control input codes

Fault Code

Fault description

1005

Fault BTS brake / plausibility Plausibility conflict when evaluating X- and Y-axes of the travel lever to the brake contact signal

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

1040

Fault travel range switch "ground connection" Signal outside the valid range (see signal description)

1041

Fault travel range switch "supply connection" Signal outside the valid range (see signal description) Fault travel range switch Signal outside the valid range (see signal description)

1042

1070

1071 1072 1073

1074

1080

1081 1082 1083

1084

Assignment BVC-4

Cable breakage in ground line, or the connecting cable switch / ground connection has come loose Cable breakage in supply line, or the connecting cable switch / supply has come loose Increased transition resistance values on contacts may have led to a falsification of the signal.

The switch needs to be replaced

X

X

X

X

X

X

Fault output "travel pump forward" The required control power cannot be transmitted to the proportional solenoid.

Fault of current regulator forward Fault of current regulator forward Fault output "travel pump forward" Supply voltage UB applied at the output to the proportional valve.

Fault when teaching surge current forward

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

X

X

X X X

X X X

Fault output "travel pump reverse" The required control power cannot be transmitted to the proportional solenoid.

Fault of current regulator reverse Fault of current regulator reverse Fault output "travel pump reverse" Supply voltage UB applied at the output to the proportional valve.

Fault when teaching surge current reverse

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

X

X

X X X

X X X

X

X

X

X

X

X

1100

Fault output "front travel motor" The required control power cannot be transmitted to the proportional solenoid.

Fault front travel motor "speed sensor"

19.10.04 Seis / TE

Short circuit in the connecting line (control to prop valve) to supply voltage

X35:17

DH-4

X

Informative message! Surge currents of travel pump NOT YET learned. See 3.6

Status: Author:

Terminal on ESX

X

1088

1105

Possible causes

Input code for diagnose

Fault reaction

Machine is mechanically blocked Bypass valves in travel system are deadjusted

Short circuit in the connecting line (control to prop valve) to supply voltage Machine is mechanically blocked Bypass valves in travel system are deadjusted Function "Learning of pump surge currents" for travel pump not yet executed.

-> New machine/control change The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective Check connecting lines and plugs to the wheel speed sensor or

Description of control input codes

Note

Page 32 of 46

Service training WZ – 4 Fault Code

Fault description

Description of control input codes Possible causes

Faulty or non-existent signal "frequency"

Replace the speed sensor, if necessary

1106

Fault front travel motor "speed sensor" Faulty or non-existent signal "direction"

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

1107

Short circuit in the connecting line (control to prop valve) to Fault output "front travel motor" Supply voltage UB applied at the output to the proportional supply voltage valve.

1110

Fault output "rear travel motor" The required control power cannot be transmitted to the proportional solenoid.

1115

Terminal on ESX

DH-4

Assignment BVC-4

X

X

X

X

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

X

X

Fault rear travel motor "speed sensor" Faulty or non-existent signal "frequency"

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

X

X

1116

Fault rear travel motor "speed sensor" Faulty or non-existent signal "direction"

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

X

X

1117

Short circuit in the connecting line (control to prop valve) to Fault output "rear travel motor" Supply voltage UB applied at the output to the proportional supply voltage valve.

X

X

1140

Fault pressure switch travel system "signal" The current signal is not transmitted (see signal specification) Fault pressure switch travel system "signal range" The current signal is outside the permissible range (see signal specification) Fault pressure switch travel system "no pressure" The current signal indicates that no permanent travel pressure is built up.

The connecting line from the output of the control to the pressure sensor is interrupted, or The pressure sensor is defective The pressure sensor is defective

X

X

X

X

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

X

X

Fault inclination sensor "supply connection" Signal outside the valid range (see signal description) Fault inclination sensor "ground connection" Signal outside the valid range (see signal description)

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

X

X

X

X

Seat contact switch not occupied

Cable breakage in signal line, or

X

X

1141

1142

1145 1146

1300

Status: Author:

19.10.04 Seis / TE

Description of control input codes

Input code for diagnose

Fault reaction

Page 33 of 46

Service training WZ – 4 Fault Code

Fault description

Description of control input codes Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

Input code for diagnose

Fault reaction

driver's seat not occupied (driver not seated!)

1500

Warning "dangerous situation ASC"

2060

Fault output "steering valve right" The required control power cannot be transmitted to the proportional solenoid.

Fault output "steering valve left" The required control power cannot be transmitted to the proportional solenoid.

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

2065

Fault learning the surge current right hand valve

2066

Fault learning the surge current left hand valve

2068

Informative message! Surge currents of steering pump NOT YET learned. See 3.7 (Only machines with electric steering)

Drum was not moved, maximum current reached, steering is blocked (e.g. articulation lock applied) Drum was not moved, maximum current reached, steering is blocked (e.g. articulation lock applied) Function "Learning of pump surge currents" for steering pump not yet executed.

-> New machine/control change

2170 2171

2174 2175 2176

Fault steering wheel "change of direction" Fault steering wheel "impulse coverage" Measuring value of sensor 1 and 2 difference too strong Fault steering wheel "sensor 1 pulse range" The detected steering pulses on steering sensor 1 are outside the valid range (see signal description) Fault steering sensor "sensor 2 pulse range" The detected steering pulses on steering sensor 2 are outside the valid range (see signal description) Fault steering wheel "sensor 1" Fault steering wheel "sensor 2" Fault steering wheel "sensor 1 cable damage"

2177

Fault steering wheel "sensor 2 cable damage"

2190

Fault steering "steering angle sensor... initialization" Fault when initializing the steering angle sensor Fault steering "steering angle sensor—ADC" Fault steering "steering angle sensor—cable damage supply" Fault steering "steering angle sensor—cable damage ground"

2061

2172

2173

2191 2192 2193

Status: Author:

19.10.04 Seis / TE

X

X X

X

(X)

Wiring fault or steering sensor in left hand arm rest defective Steering sensor in left hand arm rest defective.

X X

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

X

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

X

Steering sensor in left hand arm rest defective.

Steering sensor in left hand arm rest defective.

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

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

X X X

Steering angle sensor on articulated joint defective

X

Steering angle sensor on articulated joint defective Voltage supply line to steering angle sensor interrupted or Steering angle sensor on articulated joint defective Ground supply line to steering angle sensor interrupted or Steering angle sensor on articulated joint defective

X X

Description of control input codes

Note

X

X

Page 34 of 46

Service training WZ – 4 Fault Code

Fault description

Description of control input codes Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

2198

Informative message! Steering stops of the electric steering NOT YET learned. See 3.8 (Only machines with electric steering)

Function "Learning of steering stops" for electric steering not yet executed.

-> New machine/control change

(X)

2300

Fault "driver's seat armrest lifted"

X

2301 2302

Fault "driver's seat armrest" Signal outside the valid range (see signal description) Fault "driver's seat armrest cable damage supply"

2303

Fault "driver's seat armrest cable damage ground"

Arm rest is raised or magnetic switch under left hand arm rest defective Cable breakage in signal line, or magnetic switch under left hand arm rest defective Voltage supply line to magnetic switch interrupted or magnetic switch under left hand arm rest defective Ground supply line to magnet switch interrupted or magnetic switch under left hand arm rest defective

3000

Fault vibration sensor "no signal" The sensor in the vibration motor does not detect any pulses.

Fault vibration pump "valve for low amplitude" The required control power cannot be transmitted to the proportional solenoid.

3001

Note

X X

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

X

X

The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective, or the change-over relay / bridge is missing

X

X

X

X

X

Fault vib. pump valve low amplitude "hysteresis" The...

3003

Fault vib. pump valve low amplitude "current range" The current signal is outside the permissible range (see signal specification)

Fault in connecting line or connection to another potential (e.g.: operating voltage)

X

3004

Fault vibration pump "valve for high amplitude" The required control power cannot be transmitted to the proportional solenoid.

The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective, or the change-over relay / bridge is missing

X

3005

Fault vib. pump valve high amplitude "hysteresis" The...

3006

Fault vib. pump valve high amplitude "current range" The current signal is outside the permissible range (see signal specification)

Fault in connecting line or connection to another potential (e.g.: operating voltage)

X

5024 5025 5026 5027

Fault diesel engine warning "coolant filling level" Fault diesel engine shut-down "coolant filling level" Fault diesel engine warning "air filter" Fault diesel engine shut-down "air filter"

Coolant level too low or sensor defective Coolant level too low or sensor defective Air filter soiled or sensor defective Air filter soiled or sensor defective

X X X X

19.10.04 Seis / TE

Fault reaction

X

3002

Status: Author:

Input code for diagnose

X

Description of control input codes

X X X X

Page 35 of 46

Service training WZ – 4 Fault Code

Fault description

Description of control input codes Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

5028 5029

Warning water separator Shut-down caused by water separator

Water or other dirt in fuel filter Water or other dirt in fuel filter

X X

X X

5100

Fault diesel engine EMR "warning lamp"

X

X

5101

Fault diesel engine EMR "red stop light"

Collective warning " see other fault codes for exact fault diagnose Collective fault engine shut-down " see other fault codes for exact fault diagnose

X

X

5110

Fault diesel engine EMR "nominal speed value"

X

X

5112 5113 5114 5116 5117 5118

Fault diesel engine EMR "oil pressure" Fault diesel engine EMR "charge air pressure" Fault diesel engine EMR "temperature intake pipe" Fault diesel engine EMR "coolant temperature" Fault diesel engine EMR "fuel temperature" Fault diesel engine EMR "engine speed"

X X X X X X

X X X X X X

5122

Fault diesel engine EMR "nominal speed value"

5123 5124 5125

Fault CAN communication Fault CAN communication Fault CAN communication

" CAN connection between ESX and EMR interrupted " CAN connection has short circuit to ground, to +12 V or connection between CAN+ and CAN-. " ESX without voltage supply " Voltage of on-board battery too low " Engine oil pressure too low " Charge air pressure too low " Charge air temperature too high " Coolant temperature too high " Fuel temperature too high " Speed sensor 1 or 2 defective " Connection between EMR and speed sensor 1 or 2 interrupted " CAN connection between ESX and EMR interrupted " CAN connection has short circuit to ground, to +12 V or connection between CAN+ and CAN-. " ESX without voltage supply " Voltage of on-board battery too low " CAN communication between EMR and ESX " CAN communication between EMR and ESX " CAN communication between EMR and ESX

X X X

X X X

5130

Fault diesel engine EMR "oil pressure sensor"

X

X

X

X

X

X

X

X

5131

5132

5133

Status: Author:

" sensor defective " Wire breakage in current path " Current path has short circuit to ground Fault diesel engine EMR "charge air pressure sensor" " sensor defective " Wire breakage in current path " Current path has short circuit to ground " sensor defective Fault diesel engine EMR "charge air temperature" " Wire breakage in current path " Current path has short circuit to ground Fault diesel engine EMR "coolant temperature sensor" " sensor defective " Wire breakage in current path " Current path has short circuit to ground

19.10.04 Seis / TE

Description of control input codes

Input code for diagnose

Fault reaction

Page 36 of 46

Service training WZ – 4 Fault Code

Fault description

Description of control input codes Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

5134

Fault diesel engine EMR "speed sensor"

" Speed sensor 1 or 2 defective

X

X

5140

Fault diesel engine EMR "unknown fault"

Fault diagnose only with DEUTZ diagnose tool (SERDIA)

X

X

5502 5503 5504 5005

Fault warning "hydraulic oil filter" Fault shut down "hydraulic oil filter" Fault warning "oil temperature" Fault shut down "oil temperature"

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

X X X X

X X X X

7011

Fault warning "change of machine type" This warning appears when the machine type has been changed.

Fault "conflict machine type" This fault message is displayed if the set machines do not comply with the basic parameters of the machine.

Only change the machine type after appropriate measures have been applied; e.g. conversion from D to PD (different rolling circumference of drum) The machine type was changed in a way that the type parameters no longer comply with the basic parameters → enter the correct machine code or a basic parameter of the machine was changed (e.g. a different axle)

X

X

X

X

7012

Status: Author:

19.10.04 Seis / TE

Description of control input codes

Input code for diagnose

Fault reaction

Page 37 of 46

Service training WZ – 4

Description of control input codes

11 Input codes for ESX control 11.1 General Input code 0500

Description of display function Activation of function "Driving against closed brake"

0501 0555

Deactivation of function "Driving against closed brake" Display of "software version"

Display values 500 and brake control light stays on when shifting the travel lever out of the neutral gate O K for 3sec. then back to 0000 e.g.: „109" for software version 1.09

0700 0701 0710 0720

Activation of function "Show stored faults" Deactivation of function "Show stored faults" Delete stored faults Display of "machine code"

Fault codes are successively displayed 0000 once the error log is deleted the display will return to 0000 The machine code is displayed (72xx) (see chapter 3.6)

Description of display function Display of output voltage on output of control "brake valve"

Display values Display in V (e.g. 126 corresponds with 12,6V)

11.2 Brake Input code 1001

Status: Author:

19.10.04 Seis / TE

Description of control input codes

Page 38 of 46

Service training WZ – 4

Description of control input codes

11.3 Travel lever / driving Input code 1025

Description of display function Display "travel lever direction"

1026

Display "movement direction"

1027

Display "travel lever enable"

1040 1041

Display "speed range / gear" Display "voltage value for speed range / gear"

1042

Display "voltage value for speed range / gear standardized"

1044

Display "speed range / gear" end value

1070 1071

Display "nominal current travel pump forward“ Display "Actual current travel pump forward“

Status: Author:

19.10.04 Seis / TE

Display values 100 = forward 0 = neutral 1 = reverse 0 = neutral 1 = forward 2 = reverse 1 The display shows the travel range switch position from 1...24 Stages 0...4 = 4 Stages 5...9 = 3 Stages 10...14 = 2 Stages 15...19 = 1 Stages 20...24 = 0 Stage 1 ≈ 956 Stage 2 ≈ 916 Stage 3 ≈ 875 Stage 4 ≈ 835 Stage 5 ≈ 795 Stage 6 ≈ 756 Stage 7 ≈ 716 Stage 8 ≈ 675 Stage 9 ≈ 637 Stage 10 ≈ 597 Stage 11 ≈ 557 Stage 12 ≈ 517 Stage 13 ≈ 478 Stage 14 ≈ 436 Stage 15 ≈ 396 Stage 16 ≈ 357 Stage 17 ≈ 318 Stage 18 ≈ 279 Stage 19 ≈ 238 Stage 20 ≈ 200 Stage 21 ≈ 160 Stage 22 ≈ 120 Stage 23 ≈ 80 Stage 24 ≈ 40 Stage 1 = 417 Stage 2 = 833 Stage 3 = 1'250 Stage 4 = 1'667 Stage 5 = 2'089 Stage 6 = 2'500 Stage 7 = 2'917 Stage 8 = 3'333 Stage 9 = 3'750 Stage 10 = 4'167 Stage 11 = 4'583 Stage 12 = 5'000 Stage 13 = 5'417 Stage 14 = 5'833 Stage 15 = 6'250 Stage 16 = 6'667 Stage 17 = 7'500 Stage 18 = 8'333 Stage 19 = 9'167 Stage 20 = 10'000 Stage 21 = 13'334 Stage 22 = 16'667 Stage 23 = 20'000 Stage 24 = 23'333 0 – 1200 mA Display in mA

Description of control input codes

Page 39 of 46

Service training WZ – 4

Description of control input codes

Input code

Description of display function

Display values

1080 1081

Display "nominal current travel pump reverse“ Display "actual current travel pump reverse“

0 – 1200mA Display in mA

1090

see chapter "Teach travel system surge currents"

1091 1092

Activates Function "detect surge currents in travel system automatically" Function "Determine surge current forward" (only vers.1.07 and 1.08) Function "Determine surge current reverse" (only vers.1.07 and 1.08)

1106 1107

Display "speed sensor travel motor front / pulses" Display "speed sensor travel motor front / direction signal"

1108

Display "sense of rotation front drive"

1116 1117

Display "speed sensor travel motor rear / pulses" Display "speed sensor travel motor rear / direction signal"

1118

display "sense of rotation rear drive"

1140

Display "travel pressure"

Display in bar

1145 1146

Display "inclination sensor" standardized Display "inclination sensor" sensor input voltage

1147 1148

Display "inclination sensor" standardized sensor voltage Display "inclination sensor" initialization

Inclination display as standardized value (65540 → 0%) Display in mV 0% ≅ 2550mV Inclination display in mV 1 corresponds with OK

Status: Author:

19.10.04 Seis / TE

see chapter "Teach travel system surge currents" see chapter "Teach travel system surge currents" Counts the pulses up to 99'999 and then starts at 0 again 2 = forward 1 = standstill and reverse 1 = forward 0 = standstill 2 = reverse Counts the pulses up to 99'999 and then starts at 0 again 2 = forward 1 = standstill and reverse 1 = forward 0 = standstill 2 = reverse

Description of control input codes

Page 40 of 46

Service training WZ – 4

Description of control input codes

11.4 Steering Input code 1300 1301 1302

Description of display function Function status arm rest contact Voltage of arm rest contact Travel operation status by arm rest contact

Display values 1= arm rest up; 2=arm rest down Display in mV 1=travel enabled; 2= travel disabled

2000 2001 2010 2011 2012 2013

activates Function "teach steering start current" Function "teach steering start current" activates Function "teach steering potentiometer limits" Deactivates Function "teach steering potentiometer limits" Function "teach steering potentiometer right hand limit" Function "teach steering potentiometer left hand limit"

see chapter "Determine steering system surge currents" see chapter "Determine steering system surge currents" see chapter "Determine steering system end stops" 0000 see chapter "Determine steering system end stops" see chapter "Determine steering system end stops"

2060 2061 2062

Activates function „Change steering unit“ Activation of electric steering unit Activation of hydraulic steering unit

see chapter "Changing the steering unit“ see chapter 3.6 see chapter "Changing the steering unit“

2100 2101 2102 2103

Display "Nominal current value steering valve right“ Display "Actual current value steering valve left“ Display "Nominal current value steering valve left“ Display "Actual current value steering valve left“

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

2110 2112 2120

Display of voltage value from steering angle sensor on articulated joint Steering angle actual position Steering angle nominal position

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

2130 2131 2132 2133

Steering wheel sensor 1 track 1 absolute pulses Steering wheel sensor 1 track 2 absolute pulses

Number of total pulses Number of total pulses

Steering wheel sensor 1 direction

2140 2141 2142 2143

Steering wheel sensor 2 track 1 absolute pulses Steering wheel sensor 2 track 1 absolute pulses

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

Steering wheel sensor 2 direction

1=steering wheel steers to the right; 2=steering wheel steers to

Status: Author:

19.10.04 Seis / TE

Description of control input codes

Page 41 of 46

Service training WZ – 4 Input code

Description of display function

Description of control input codes Display values the left

11.5 Vibration Input code 3000

Description of display function Display "switch vibration mode"

3001

Display "Status of vibration relay"

3002

Display "Vibration pump valve current" The actual pump current is displayed.

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

11.6 Engine Input code 5024 5026 5028

Description of display function Display "Status engine coolant level" Display "Status engine air filter" Display "Status water separator"

Display values 0= coolant level OK; 1= coolant level too low 0= air filter OK; 1= air filter soiled 0= water separator OK; 1= water or dirt in fuel filter

11.7 Hydraulics Input code 5002

Description of display function Display "Status hydraulic oil – filter"

Display values 0= hydraulic oil filter OK; 1= hydraulic oil filter soiled

11.8 Changing the machine code Input code 7010

Status: Author:

Description of display function Change "machine code"

19.10.04 Seis / TE

Display values see chapter "Changing the machine code“

Description of control input codes

Page 42 of 46

Service training WZ – 4

12 Terminology in connection with ESX Short circuit A direct, unwanted connection between two different cables or between machine and cables.

Examples: Two lines rub against each other until the insulation has worn off.

A conductive line rubs off the insulation at the vehicle ground.

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

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

Status: Author:

19.10.04 Seis / TE

General terminology

Page 43 of 46

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

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

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

Status: Author:

19.10.04 Seis / TE

General terminology

Page 44 of 46

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

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

This sequence occurs in a closed circuit, the co-called closed loop control circuit.

Marking Operating path:

Closed loop control closed (closed loop control circuit) Measurement and Value to be adjusted is comparison of value to measured and compared. be adjusted: Reaction to faults Counteracts to all faults (generally): targeting the system to be controlled.

Technical expense: Low expense: Measurement of the value to be controlled, comparison of nominal and actual value, power amplification Performance in For unstable systems closed unstable systems loop controls must be used.

Status: Author:

19.10.04 Seis / TE

Control open (control chain) Values to be controlled are not measured and compared.

Does not respond to unknown faults High expense if many faults have to be considered, low expense if not faults occur.

In unstable systems controls cannot be used.

General terminology

Page 45 of 46

Service training WZ – 4 Current and voltage measurement

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

U =R∗I U I= R U R= I

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

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

Status: Author:

19.10.04 Seis / TE

General terminology

Page 46 of 46

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

BW177..226DH−4

Zeichnungsnummer drawing − no.

582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95

Funktionsgruppe

function unit

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

Circuit Diagram supply, starting unit, signal horn engine Deutz EMR II driving system, slope sensor, seat contakt switch data−collector, LC−display steering, vibration joystick, vibration−plates Variocontrol, measurement equipm.

Bomag Compaction Management BCM illumination and StvZO cabin−equipment, headlights, radio, tachograph cabin−heater, air conditioning, add. heater component listing

28.06.2004 Seis 28.06.2004 Werner

Stromlaufplan circuit diagram

001

001

582 700 95 001

30 K11 2:10

15A

X36:B

X1:15A X36:A

1

F05

2

125A

G01

Startschalter starting swwitch

2

G03

+

X1:3

54 58

19 17

K61

NOT−Aus Emerg.−Stop

50a

K32:86

87 D+

5:2

B+

2:11

D+ MESX

8:2

−

87a

X1:1

167A

B+

D+ K09

X1:7

30

86

K11

85

85 31 EMR 3:5

X1:8

86

Taster Hupe push button, horn

X38:A

14

24

X1:97

X1:98

X1:101

X1:102

50 B11

M01

2 B−

23

2:6 B+

G02 2

13 S03

+

S30

87a

30

2:6 85

11:1

X1:155 S01:22 3:1 F05:2 5:8

K05 30 7:3 87

K61

2

1

X1:4

1

86

X1:109

R19

15

X34:P

125mA

V01

1

−

1

X3:3

X1:152

125A

1

1

2

2

V02

1

B11 XS 12V

M −

2

V03

1

1

2

+ −

W X1:110

X1:168

X1:103

X1:123

X1:104

31

31 2:8

Trennschalter Batter break switch battery Heizflansch heating−flange

2

X1:30A

22 12 32 42 52 62

Anzugsw.:50A / Haltew.:10A

F00

15A

21 11 31 41 51 61

X37:B

2

1

F39

2

S01

nur bei Klimaanlage only acc.to air conditioning

F48

15A

X1:28A

X1:151

30

2 x 10qmm

3

1

F23

2

X1:27A

X37:A

Hauptsicherung main fuse

3:19

1

X1:79

Sicherung Heizflansh heating−flange

K14

15A

X1:16A

S00

5

F95

2

X1:30E

X1:28E

4:9

30A

K11:87 5:1 X1:27E

X1:16E 1

F13

87

6:17

X1:15E

X1:10

X1:9

K30 11:1 30 4:1

Batterie battery

Batterie battery

28.06.2004 Seis 28.06.2004 Werner

12:7

2:16

Starter starter

Signalhörer warning horns

3:1 Steckdose socket

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

Generator generator

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

1

1

582 700 95 002

2:17 S01:22

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

2

X1:179

X1:96

B88

B114

B130

Y137

5

3

2

1

2

B115

X33:8

X33:4

X33:1

X33:6

X33:5

X31:7

X31:2

X31:3

X31:1

X31:5

X31:6

X57:6

4

X57:1

AGND

X57:8

X31:8

X31:9 Signal

X57:9

X31:4

X31:25

X31:24

X31:23

X31:16 1

Signal Temperatur

RF REF

1

X57:4

6

+5V

2

X57:25

7

Signal Druck

2

X57:24

X57:19

1

RF−

AGND

X57:18

2

X57:23

X57:17

1

B113

X34:N

X1:182 X1:186

2:4

X31:19

X57:15

3

X57:16

X57:14

2

RF MESS

STG+

X57:11

X31:18

STG−

X57:10

X31:17

X31:15

AGND

Signal

X57:13

X31:14

X31:11

AGND

Signal

X57:12

X31:10

X31:13

+5V

X57:22

X31:12

X31:22

X31:21

X31:20 Signal

X57:21

X30:2 AGND

X57:20 1

EMR Stellglied EMR commander

X32:B

X32:G

X32:H

X32:K

X30:1 CAN2− 4:11 CAN2+ 4:11

ESX Fahrst.

Ubat −

X1:181

X30:13 CAN low

X30:12

X30:11 CAN high

X1:180

X30:10

X30:14

A48 Motorsteuerung EMR2 engine−controller EMR2

X1:184

L

K

X1:183 X32:L

X32:A 31

X33:3

8−polig PNEUTRON

Diagnosestecker EMR diagnosis interface EMR

2:20

X33:2

max 7A

X33:7

X1:185 Steckerschnittstelle Deutz connector interface Deutz

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

28.06.2004 Seis 28.06.2004 Werner

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

Motor Deutz EMR II engine Deutz EMR II

1

1

582 700 95 003

2:14

30

30 5:1 F24:2 5:3

X1:2

3:4 EMR Deutz 3:4

X1:145

CAN2+

CAN2+ 7:6

CAN2−

CAN2− 7:6 CAN1+ 5:8

Fahrhebel

CAN1− 5:8

LC−Display, OPUS 21

X1:42 31 X1:119

X1:120

X1:146 32

1

F84 10A

X34:G

X34:H

X34:C

X1:174 3:20 31

Sensor Achse sender axle

X35:55

X35:65

X35:66

X35:67

X35:68

X1:124

X1:142

X1:142

X1:143

X1:143

Gehäuse housing

X35:47

X35:26

CAN1−

X1:50

X1:49

X1:48 X35:27 X35:46

Achsmotor

+

X16:1 1

X15:1 1

H14 −

Y17

Y16

X14:A

X9:2

X16:2

X1:149

X1:117

X1:123

S06

sw

S X1:55

−

X1:46 8:2

6:4

+

2

X15:2

400 ... 1.200mA

X9:1

X14:B

400 ... 1.200mA

2,5V

−

1

1

Y30 2

Y31 2

X1:123

X1:144

2

X1:144

PITCH MESX

Neigungssensor slope sensor

31 5:1

Sitzkontaktschalter switch, seat contact

Prop.−Pumpe Vorw. prop.−pump forwards

Rückfahrwarnsummer back up alarm buzzer 28.06.2004 Seis 28.06.2004 Werner

X1:47

Bandagenmotor

X1:141

4V

Sensor Bandage sender drum

CAN1+

Fahrpumpe rückw.

X1:143

1V

−

X1:178

X1:54

X35:53 X35:49 Fahrpumpe vorw.

X1:122

X1:82

8:2 SPEED MESX

X35:33

CAN2+

RxD

X35:4 Rückfahrwarnsum.

X35:24

X35:15 Sitzkontakt

X1:121

400 ... 1.200mA

B57

dir.

11:6 SPEED TAC

R21

X1:114

speed 8:2 DIR MESX

R23

X1:158

0,46A

br

+

B59

120 OHM 1 2

−45_G=0,5V

bl

X1:172

sw

−

dir.

speed

ws

br

+ B60

Diagnosestecker Fahrzeug diagnosis interface equipment

X34:B

120 OHM 1 2

400 ... 1.200mA

X1:175

X35:5

TxD

Elektronik Neigung

X35:30

X35:54

X35:60

X35:59

X35:57

X35:58

X35:34 speed

X1:176 bl

X35:37 Richtung

X1:177 ws

X35:12

X35:56

X35:31

X35:28 X35:38 speed

X1:44

X1:45 Richtung

+45_G=4,5V

X1:173

X1:171

Leistung

Drucksensor

8:2

+

X34:A

2

X1:34A X1:34A

A34

X34:D

X35:64

2

X1:17A

Fahr−Steuerung driving controller

R20

X1:53

1

15A

Drucksensor Fahrpumpe pressure sensor drive pump

R22 X1:34E

F67

B112

120 OHM 1 2

CAN2−

X1:17E

120 OHM 1 2

X1:52

sw

X1:51

rt

X52:2

X52:1

S01 2:16

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

Prop.−Ventil Bandagenmotor prop.−Valve drum motor

Prop.−Pumpe Rückw. prop−pump backwards

Prop.−Ventil Achsmotor prop.−Valve axle motor

1

1 1

582 700 95 004

4:20 2:20

30

30 8:1 K11:87 7:14

K11:87 F24:2

4:3

F24:2 6:15 2:17 F05:2 4:17 CAN1+ 4:17 CAN1−

X1:29E 1

F24 15A

ESX Fahrsteuerung

2

F05:2 2:17 CAN1+ 7:14 CAN1− 7:14

DIOS Platten

X1:29A

X1:80

X1:86

X1:41

X1:40

X1:39

X1:87 X1:88

not connected

X29:8

Ub out

not connected

X28:6

Ub "15"

Ub "30"

CAN1 low

CAN1 high

CAN1 low

VCC

CAN1 high

X34:R

D+

P

X1:117

X1:94

28.06.2004 Seis 28.06.2004 Werner

X28:1

X29:7

X29:6 DIN6

X29:4 DIN4

X29:5

X29:3 DIN3

DIN5

X29:1 DIN1

X28:4 X29:2

X28:2 GND

DIN2

X26:12

GND/UIN3

GND

X27:3

AIN1

X27:5

X27:1

AIN2

GND

X27:12

X28:3

X27:7 X27:11 UIN2

X26:6 DIN6

X27:10

X26:2 DIN2

UIN3

X26:1 DIN1

X26:11

X26:9 DIN9

DIN11

X26:7 DIN7

X26:4

X27:2

DIN4

ECO Low High

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

Füllstand Diesel fuel−level

Q

X1:94

A81 LC−Display LC−display

23

down

13

up

23

13

S120 24

14

S139

24

14

X10:2

2 X8:2

UIN1

Sepa2

X27:9

Sepa1

Wasserabscheider water−seperator X8:1

B124

1 B55

X21:2 31

X1:105

R03 P 2

4:20

X1:108

X10:3 X1:117

0 .. 67 OHM

2:6

1 B03

X27:4

X26:10 X21:1

B21

X1:107

Kühlmittelvorrat coolant stock level

X1:112

Luftfilter air cleaner

Hydraulikölfilter hydraulic oil filter

X1:111

DIN10

X26:8

X26:5 DIN5

connector−colour: X26−grey; X27−black

DIN8

X26:3 DIN3

X1:106

X27:6

Steckerfarbe: X26−grau; X27−schwarz

A80 Datensammler data−collector

X28:5

X27:8

Schalter Motordrehzahl switch engine−rpm mode X1:154

X1:149

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

switch frequency−control Schalter Frequenzverstellung

X1:82

31 6:1

1

1

582 700 95 005

S01:22

S01:22

X1:148

Lenkwinkelsensor steering angle sensor

7:1

F24:2 X1:41 X1:187

Lenkeinheit steering unit

S1 A

X39:3

X35:18

A34 Fahr−Steuerung driving controller

X35:23

X35:29

X35:1

X1:42

8,5V

X1:207

X1:55

4:6

VIB

11:6

BTS BREMSE 7:2

X35:35

1

X22:3

X22:4 X1:189

0V

sw ws

BTS Bremse

A

X41:6

0V

X35:19

X39:4

bl

B16

X41:8

X41:2

X40:3

S2

− X22:2

X1:206

X1:162

2

B

X40:2

X35:41

X41:4 X40:4

X39:2

X41:7

X1:159

S1 B

X1:208

X41:3 X40:1 VCC

X35:40

X41:1 X39:1 VCC

X41:5

1

X1:161 X1:160

+

br

X1:205

1

2

X1:56 FM1 X1:57

2

X1:58 FM2 X1:59

X1:60 FM5 X1:61

X1:203

AGND

X34:J nur BVC only BVC

Sig.

−

X1:195

Y112 1

1 Y93

2 X1:149

2

X1:200

X1:197

X35:3 Warnsummer

KA MESX

X1:38 7:14

GA MESX

8:2

K56

1

86

K57

86

K43

2

85

86

85

85

X6:1 Y08

1

X1:197

6:4

Bremse

2:16 12

X7:1 Y07 1

+

X1:150 X1:113

H07

8:2 BRAKE MESX

Y04 1

2

6:3

6:14

−

2

X7:2 X1:82

Anbau 177DH: h.r.

Anbau 177DH: h.l.

Anbau 213DH: oben

Anbau 213DH: unten

X1:117

X1:190 31

7:1

Magnetventil Bremse solenoid valve brake

Prop.−Ventil Vibration klein prop. valve vibration small Prop−Ventil Vibration groß prop. valve vibration big

Prop. Ventil lenken links prop. valve steering left

28.06.2004 Seis 28.06.2004 TS022 Werner

S01

X1:115

2 X6:2 X1:118

31

Notlenkung rechts emrg. valve steering right

11

8:2

X1:37 X1:116

5:20

Notlenkung links emerg. valve steering left

X35:61

X35:48 Prop. out

X35:2 X35:22

7:2 87a

Y92 2

X1:200

6:2

X35:16

X1:89

6:12 87a

150mA

X1:196

K43 87

30 K48 87 X1:147

max.1.8A

Y113 1

X1:198

30

400 ... 1.200mA

6:9

X1:199

400 ... 1.200mA

X35:16

400 ... 1.200mA

X1:154

Umsch. Amplitude

87a

X35:22

6:8 87

Pumpe Vib.−Platten

6:9 87

X35:16

K56 30

Armlehne

K57 30

87a

X35:25

X35:20

X51:2

X51:3

X43:1 X35:21

Schalter Armlehne armrest−switch

B132

−

Aufnehmer Vibrationsmotor sensor vibration motor

X22:1

Lenkwink.

X1:55 X1:202

S

X35:17

A45

X1:188

X1:201 B65 +

X51:1

X43:2

F24:2

Vib.− Frequenz

X23:1

5:20

Vib.− Richtung

3:20

Warnsummer Störung warning buzzer, failure

Prop. Ventil lenken rechts prop. valve steering right

Lenkung, Vibration steering, vibration

1

1

582 700 95 006

CAN2+

5:14 5:14

LC−Display

CAN2−

5:20

CAN1+

CAN1+ 8:16

CAN1− K11:87

CAN1− 8:16 BTM K11:87 8:1

Taster 1 = Platten rechts push button 1 = plates right

X1:31E

Taster 2 = Platten heben push button 2 = lift plates

Taster 4 = Platten links push button 4 = plates left

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

BTS BREMSE 3

2

Näherungssch. Platten Mitte sensor plates centered

X1:156

X1:157

Taster 5 = platten senken push button 5 = lower plates

6:18

1 F145

Näherungssch. Platten oben sensor plates up

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

15A

X1:31A X1:209

B135 + −

B134 + −

S

S

X1:214

4:17 4:17

ESX Fahrst.

X1:213

6:2 X23:1

2

Fahrstufenschalter speed range selector

7

1

4

8

5

X35:22

X62:1

X62:2

X62:14

0V (Ref PIN5)

6:11

+5V out

X62:13

8

CAN+

X62:9 X62:10

2

Add1

CAN−

X62:8

0V in

7 6 5

X62:3

BTS zus.

S55 Fahrhebel travel lever

X62:7

X1:153

1 3 4

X62:12 A54 Platten Steuerung plate−controller

X62:6

BTS Bremse

X62:11

Bremse auf = Ub

X25:3

Ub in

Bremse zu = 0V

X25:4 X25:2

+ − S

X62:5

X62:4

S42

AK Ext1

9 Add2 10

11 AK Ext2 12 Stecker X23

400 .. 1.200 mA

X50:1

X50:2

X50:3

Ub out

8 OV out

7 DK Ext6

DK Ext5

DK Ext3

DK Ext4

DK Ext1

2 DK Ext2

1

Stecker X24 3 4 5 6

X1:210 S − + S35 K0G K48

86

K05

13

23

S09

13

S64

13 S36

13

S139

86

Y123 1 2 Y98

14

14

14

6:20 6:17

85

2

2

1

Y122 1

Y142 1

Y144 1

2

2

2

2

X72:2

X1:149

31

Y145 1

14

24 85

Y143 1

X72:1

X1:211

X1:212 8:1 31

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

28.06.2004 Seis 28.06.2004 TS022 Werner

Nur bei BVC Only at BVC

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

Schalter Vibration Ein/Aus switch vibration on/off

Schalter Betriebsart Platten modesw. plates

Fahrhebel, Vibrationsplatten joystick, vibration−plates

Prop−Pumpe Platten prop.−valve plates

MV Platten heben MV Platten rechts plates up plates right MV Platten senken MV Platten Schwimmst plates down plates float−pos.

MV Platten links MV Platten Priorität plates left plates priority

1

1

582 700 95 007

Beschleunigungssensoren acc. sensor front

Drucker printer

Aufnehmer Verstellmotor sens. adjust. motor

Display Messtechnik BOP display measurem. BOP

Bedieneinheit BEM control−unit BEM

GND

30 10:1 X2:48 + X2:66

X48:2

X48:1

X49:2

X49:1

X2:78

B62

X2:67

X2:68

X47:A

X47:B

AGND MESX

CAN−

X42:4

X74:4

CAN+

X4:E

X74:5

DIOS Platten

X4:C

X4:D

X74:3 X74:1

X74:2

X4:A

X4:B

X2:64

X2:65

120 OHM R21 1 2 120 OHM

10:4

2 X2:76

0..6VDC

CAN3−

X1:85

1

9:15 +

CAN3−

P07 E VIB

CAN3+

X2:60

9:15

−

2 X2:74

X2:63

8:19

CAN1−

X2:66

31.1

v.l.

BEL MESX

X2:51

X44:27 X44:3

X44:53

X44:5

X44:4 X44:68

X44:67

X44:66

CAN1+

v.r.

Y141

X42:3

1 R20 2

TxD

EVIB

400 .. 1.200mA

1

X2:73

X42:5

CAN1+

X2:50

GND

Y140

BRAKE MESX D+ MESX

Prop.

PITCH MESX

400 .. 1.200mA

X2:75

7:20

CAN1−

7:20

RxD

X44:46

X44:23 X44:47

6:15

Prop.

KA MESX GA MESX SPEED MESX DIR MESX

2:6

X2:69

P33

CAN3+

6:15

6:17

nur bei BTM prof only at BTM prof

−/sw

+/sw 20g/br

X44:41

X44:37

X44:31

X44:29

Elektronik

X44:60

X47:C

7:20

P11

X44:1

X2:59

X44:65

X2:58

X44:55

X2:55

S/ws

X44:9

X2:54

+/rt

8.5V

X49:4

B61

X44:7

X49:3 Aufn. vorne 20g

X48:4 Aufn. vorne 15g

X48:3

X44:54 X44:36

X44:59

X44:14

X44:32

X44:57

X44:58

X44:35

Leistung

X44:56 X44:15

X44:38

Pot. 15

X44:28

15g/bl

20g/br

15g/bl

−/gg

Aufn. hinten 20g

B62

9:15

X2:57

4:3 4:3 4:8

F2

X2:71

2

−/gg

A83 Messtechnik−Rechner measurement calc. unit

F1

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

FM4

X42:8

X2:57

8:20

X2:60

X44:26

X2:53

X44:33

X2:56 2

X1:35A F148:2

P16 1

Erregerpos.

15A

2

X1:32A

X2:70

X2:77 1

Aufn. hinten 15g

10A

F146

X44:30

F148

+/sw

1

X2:49

− nur bei BEM only at BEM

X1:35E

X1:32E

31.1

Pot 15

X2:47

Pot 30

K11:87 10:1

X42:7

7:20

K11:87

X42:1

30

X42:2

5:20

X42:6

4:9

Beschleunigungssensoren acc. sensor rear

X1:34A

X1:82

31

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

EVIB−Meter EVIB−meter

Prop−Ventil Erreger ab solenoid valve exciter down

28.06.2004 Seis 28.06.2004 TS022 Werner

Variocontrol, Messtechnik Variocontrol, measurement equipm.

1

1

582 700 95 008

8:4

8:18

F148:2

CAN3−

8:18 CAN3+

1 R242

CAN3+

CAN3−

120 OHM X2:61

X2:62 R25 1 2 120 OHM

X4:N

X4:M

X75:7

X75:2

A87 USB−CAN Schnittst.

USB−CAN Interface BCM X2:70 X76:1 P15

X4:G

X76:2 X4:F X2:63

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

31

31 10:1

28.06.2004 Seis 28.06.2004 TS022 Werner

Bomag Compaction Management BCM Bomag Compaction Management BCM

1

1

582 700 95 009

K11:87 30

K06

X1:26A X1:83

87

23

12

X1:21E

F10

15A

15A

X1:22A

X3:4

X3:5

30

14

24

49L

49R

L

R

A02

10:10

85

X61:1

E09 1

E10 1

E11 1

2

2

2

2

+

− X3:1

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

11:1 31

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

Blinkleuchte HR indicator rear, RH

Blinkleuchte VR indicator front, RH

Schlußleuchte rechts tail light, RH 28.06.2004 Seis 28.06.2004 Werner

X1:314 X59:2

E08 1

1,75A

24

X1:321

14

X60:1

Warnblinkschalter switch, hazard light

X1:323 X60:2

23

X1:313

2

13 01

X58:2

2

01 S14

1,75A

2

BR

X1:304

Arbeitsscheinwerfer vorne rechts working head lights, front rh.

2

4,6A

Arbeitsscheinwerfer vorne links working head lights, front lh.

E25 1

4,6A

Arbeitsscheinwerfer hinten rechts working head lights, rear rh.

E23 1

BL

H06

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

Scheinwerfer rechts head light RH

86

E28 1

4,6A

K16

Arbeitsscheinwerfer hinten links working head lights, rear lh.

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

2

0,42A

X1:316 X59:6

2

0,42A

2

E27 1

4,6A

X1:312 X59:3

X1:303

X1:311 X58:3 2

0,42A

85

0,125A

X1:319

86

X1:315 X58:6

4,6A

K06

E13 1 E12 1 E14 1 E15 1

X1:323 X60:4

X1:43

X60:3

8:7

X1:316 X59:6

5:9 5:9

0,42A

X1:84

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

S16 14

BEL MESX

31 Scheinwerfer links head light LH

X1:24A

13

0,125A

X1:310 X59:5

X1:23A BEL 5:9

2

4,6A

2 X1:315 X58:6

F09

X1:21A E

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

X1:315 X58:6

Schalter Arbeitsbele switch, working head lights

X1:309 X58:5

87a

E16 1 E17 1

9:20

X1:24E

15A

Schalter Blinker switch indicator

31 82

10:9 87

X1:23E

4

F19

15A

23

L0R

S37

X1:22E 5

F22

24

K16 30

13

L0R

X1:302

32

87a

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

S15

X1:25A X1:305

X1:322

11

15A

X1:19A

1,75A

31

F08

15A

10:4

Schalter StvZO switch, StvZO 012

X1:25E

F07

X1:324 X61:2

X1:18A

30

X1:19E

1,75A

10A

X1:2

X1:316 X59:6

15A

X1:301

F18

X1:307

X1:26E

F11

X1:306

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

Beleuchtung und StvZO illumination and StvZO

1

1

582 700 95 010

X3:6

K30

2:14

K32:87

12:2

E

F

X3:7 K32

X3:8

30

STV2 10:13 10:13 STV1

11:1 87 G

F143 15A

10A

7

87a

H

F42

A

F43 15A

8

B

F44 15A

1

C

F130 10A

2

F42 12:8 F130 11:14

F41 10A

3

6

5

11:9 F130

F144 15A

F130 12:7

1

2

B4

VIB X3:18 5

3

C3

E27

1 E28

1 E23

1 E25

1

2

2

2

2

XS 12V

+ −

Steckdose socket

7,8,9

P09

1

2

4,6A

B3

0,83A

X56:1

1

X56:3

A1

X56:4

A2+A3 6

5

4

4,6A

5

4,6A

S20

4,6A

4

6:18

+

K32 M

M05

M 2,9A

− 85

+ M04

M − M06

X56:2

I

15

E32

K141

M

− M07

X55:2

3 S158

4

31

+

5A

3,8A

A5+A6

−

3 min

+

5

S38

1 E72

4,7A

S86

S163 5

Abfallverzögert

Innenleuchte inside light, cabin

X3:17 4 4:3 SPEED TAC A16

−

1

E70

Tachographenmodul module, tachograph

A01

TK

2

2 S21

Radio radio

+

S45

01W 7 01

− − 31

Schalter Innenleuche switches interior lights

max. 13A

2

Kontrolleuchte indicator

E71 1

2

Nachtleuchte night illumination

− −

2

2 Heizung Heckscheibe heating rear screen

01W 7 01

3,8A

87a

R80

86

15 + + B51

E29

2:19 1

30

X55:1

11:16 87

K32:86

B51 + +

1

X55:3

30

X55:4

K141

1,75A

A12

ZA option 12:18 KABINE 31

Schalter Nachtleuchte switch, night illumination

Tachograph tachograph X3:2

Türkontaktschalter door switch

X3:1

Relais Kabine relais cabin

Schalterbel. switch illum.

10:20 31

31 12:1 Wascher hinten washer rear

11:6

Wischer hinten windscreen wiper, rear

28.06.2004 Seis 28.06.2004 Werner

Wascher vorn washer front Wischer vorne windscreen wiper, rear

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

Arbeitsscheinwerfer vorn working head lights, front

11:2

Arbeitsscheinwerfer hinten working head lights, rear

1

Rundumkennleuchte rotary beacon

1

582 700 95 011

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

D

F31 20A

Potential 30 aus Kabine

F40 20A

4

Bedienteil Kabinenheizung/Klimaanlage X53:B

X54:4

0123

X54:3

3 A72 Steuergerät control unit 6 11 12

Schalter Kabinenlüfter switch blower cabin

X54:11

X54:6

K09

X54:12

5 1 X54:1

E30 Zusatzheizung add. heater

S28

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

6 2 1 3

X3:14

X18:1

X1:169 X19:1

B131

B103

1 2

X19:2 X20:1

ge

rt

M09

M

or 5:9

br

br

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

X20:2 Y15

Stufe 3: 11.5A pro Lüfter

8

7

4

15

1

11:19

Y14 2

KABINE 31 2

2

2

X1:168 1 31

Klimakompressor air conditioning compr.

Kabinenlüfter cab ventilator

Y138 1 V06

V04 3,5A

X1:164

6

2

X18:2

1

X17:4

5

1

_t

HP

10 9

1A

_t

X20:4

or

X1:167

Thermofühler Heizung temperature sensor heating unit

87a

KLIMA

11:20 31

0123

Regel aus = 0,4A

30

87

X1:170 Stromaufnahme Lüfter / current blower

12 11 13 14 16

2:8

X20:3 Überwachung Kühlmitt monitoring coolant pressure

Thermofühler Klimaan temperature sensor air conditioning

X17:3 X1:166

X17:2 X1:165

X3:12

X3:11

X53:H

X53:M X3:10

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

M

1

Anlaufstrom beim Start = 8,3A

B104 P LP 3

M09

3

Power Stufe = 2,8A

4

rt

2

A

2

X3:13

ge

5A

X54:2

4

S44

F15

8

1

control−unit cab−heater /air conditioning

X53:C

H

Schalter Kabinenzusatzheizung switch, cab add.−heater

11:19 K32:87 Potential 15 aus Kabine

Magnetventil Heizung solenoid valve, heating unit

Kraftstoffpumpe fuel pump heating unit

Kabinenlüfter cab ventilator

28.06.2004 Seis 28.06.2004 Werner

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

1

1

582 700 95 012

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 1 9 101

582 700 95

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

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

Benennung

title

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

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

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

TYP

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

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

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

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

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

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

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

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

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

Indicator, front, lh.

Indicator, rear, lh.

Indicator, front, rh.

Indicator, rear, rh.

Parking light, lh.

Tail light, lh.

Parking light, rh.

Tail light, rh.

Head light, lh.

Head light, rh.

Working head light, front, lh.

Working head light, front, lh.

Working head light, front, rh.

Working head light, front, rh.

Working head light, rear, lh.

Working head light, rear, lh.

Working head light, rear, rh.

Working head light, rear, rh.

Inside light, cabin Heating unit Warning light Night lamp indicator light switch rear screen illum. Switches

MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 4,6A MAX. 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A 1,75A

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

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

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

Hauptsicherung Batterie Sicherung Steckdose Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw.

Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li.

Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Steuerung (Potential 30) Sicherung Steuerung (Klemme 54) Sicherung Motormanagement intern Platinensicherung Platinensicherung Platinensicherung Platinensicherung Sicherung Nachtleuchte

Fuse, main, battery Fuse, socket Fuse, hazard light Fuse, indicators a. work. head light Fuse, parking and tail light, lh.

Fuse, parking and tail light, rh.

Fuse, head light, lh.

Fuse, starter switch Fuse, heating unit Primary fuse, work. head light, fr.

Fuse, working head light, front, lh.

Fuse, working head lights, rear Fuse, warning horn Fuse, monitoring module Fuse, cabin ventilator Main fuse, cab Fuse, heating unit cab Fuse, rotary beacon Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, controller (pot.30) Fuse, controller (Pin 54) Fuse, engine controller (internal) Multifuse Multifuse Multifuse Multifuse Fuse, night lamp

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

5A 0,83A 1,75A

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 2 9 102

582 700 95

Benennung

title

TYP

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

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

15A 15A 15A 15A 10A

002 3 002 5 002 4

Batterie Generator Batterie

Battery Generator Battery

103A

H06 H07 H14

010 15 006 16 004 11

Meldeleuchte Warnblinker Warnsummer Betriebsstoerung Warnsummer Rueckwaertsfahrt

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

LED ROT 0.15A MAX O,46A

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

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

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

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

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

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

M01 M04 M05 M06 M07 M09 M09

002 011 011 011 011 012 012

11 12 10 13 11 3 4

Starter Scheibenwischermotor vorne Scheibenwischermotor hinten Scheibenwaschermotor vorne Scheibenwaschermotor hinten Kabinenluefter Kabinenluefter

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

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

P07 P09 P11 P15 P16 P33

008 011 008 009 008 008

15 8 14 16 16 18

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

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

R03 R19 R20 R20 R21 R21 R22 R23 R24 R25 R80

005 002 004 008 004 008 004 004 009 009 011

6 2 15 17 15 17 12 12 15 15 2

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

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

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

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

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

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

Starter switch Switch, emergency off Push button, warning horn Switch, seat contact, lh.

Switch, vibration, front Switch, hazard light Switch, lighting StVZO Switch, working head lights, front Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, cabin heating Switch, battery disconnect Switch, vibration low/high Switch, vibration Switch, indicator Switch, warning light Speed range selector, fast−slow Switch, cabin ventilator Switch, cabin inside light Switch, travel control lever Switch, float position Switch door, lh.

Switch, engine speed Switch, frequency control Switch, frequency control Switch, cabin night lamp switch rear screen heating unit

V01 V02 V03 V04 V06

002 002 002 012 012

7 17 18 8 9

Diode Diode Diode Diode Diode

Diode Diode Diode Diode Diode

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

002 004 010 002 002 002 002 002 002 006

6 9 10 10 10 12 12 5 5 15

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

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

F143 F144 F145 F146 F148

Bl. 011 011 007 008 008

G01 G02 G03

Pf. 2 20 18 5 2

103A

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

NOTAUSH

FE5B FE5B FE5B FE5B

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 3 9 103

582 700 95

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

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

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

Benennung

title

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

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

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 4 9 104

582 700 95

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

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

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

Benennung

title

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

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

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 5 9 105

582 700 95

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

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

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

Benennung

title

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

WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

Wago−measurement equip.

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

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 6 9 106

582 700 95

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

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

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

Benennung

title

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

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

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 7 9 107

582 700 95

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

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

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

Benennung

title

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

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

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 8 9 108

582 700 95

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

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

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

Benennung

title

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

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

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing

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

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

Benennung

title

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

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

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

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

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

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

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

Solenoid valve, brake Solenoid valve, vibration, front, high Solenoid valve, vibration, front, low Fuel pump, heating unit Magnetic clutch, air conditioning compr.

Solenoid valve, travel direction forw.

Solenoid valve, travel direction backw.

Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, steering, front rh.

Solenoid valve, steering, front lh.

Solenoid valve, vibrat.freq.,rear Solenoid valve, steering (Y1) Solenoid valve, steering (Y2) Solenoid valve, lift plates Solenoid valve, let down plates EMR adjustment Solenoid valve, heating unit solenoid valve exciter up solenoid valve exciter down solenoid valve, plate displace left solenoid−valve, plate displace right solenoid−valve, plate swimming−position solenoid−valve, plate (priority)

TYP

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

9 9 109

582 700 95

X36 X37

X38 X1:301…

X1:324 X1:79 … X1:214

A80

X1:1 … X1:61

Nur bei StvzO only acc. To StvZO illumination

A02

K11

K05

K16

K06

K09

K43 K48 K61

B57

K57 K56

X32:1-12

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

X34:1-19

Übersicht Schaltkasten BW 177...226 DH/BVC-4

Seite: 1

von: 2

page: 1

from: 2

overview e-box BW 177...226 DH/BVC-4

Ers. f.:

Blatt Nr.: 201

Replaces:

Sheet No.: 201

582 700 95

X2:47 … X2:78

CAN 1 A34 Fahrsteuerung

CAN 2

EMR + Fahrhebel

CAN 1

LCD + Datensammler + OPUS 21

A83 Messtechnik Steuerung

CAN 3

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

BCM

Übersicht Schaltkasten-Tür BW 177...226 DH-4/BVC

Seite: 2

von: 2

page: 2

from: 2

overview e-box door BW 177...266 DH-4

Ers. f.:

Blatt Nr.: 201

Replaces:

Sheet No.: 201

582 700 95

WAGO smart DESIGNER 4.0 1

05756417

2

3 x 05756540 "R" + 793-501

5

05756539 "R" + 793-501

6

05756537

7

3 x 05756540 "R" + 793-501

10

05756537

11

05756540 "R" + 793-501

12

05756535 "R" + 793-501

13

05756537

14

2 x 05756538 "R" + 793-501

16

2 x 05756539 "R" + 793-501

18 19

05756537 4 x 05756540 "R" + 793-501

23

05756537

24

4 x 05756540 "R" + 793-501

28

2 x 05756539 "R" + 793-501

30 31

05756537 05756540 "R" + 793-501

32

05756539 "R" + 793-501

33

05756537

34

4 x 05756540 "R" + 793-501

38

05756539 "R" + 793-501

39

05756537

40

4 x 05756540 "R" + 793-501

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume DH-4 VErsion

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:04:26

Seite 1

WAGO smart DESIGNER 4.0

44

05756537

45

05756540 "R" + 793-501

46

05756535 "R" + 793-501

47 48

05756537 05756540 "R" + 793-501

49

05756535 "R" + 793-501

50

05756537

51

05756538 "R" + 793-501

52

2 x 05756540 "R" + 793-501

54

05756539 "R" + 793-501

55

05756537

56

3 x 05756540 "R" + 793-501

59

05756538 "R" + 793-501

60

05756537

61

3 x 05756540 "R" + 793-501

64

05756535 "R" + 793-501

65

05756537

66

2 x 05756540 "R" + 793-501

68

05756539 "R" + 793-501

69

05756537

70

3 x 05756540 "R" + 793-501

73

05756535 "R" + 793-501

74 75

05756537 2 x 05756540 "R" + 793-501

77

05756539 "R" + 793-501

78 79

05756537 05756417

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume DH-4 VErsion

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:04:26

Seite 2

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume DH-4 VErsion

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:16:28

Seite 6

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume DH-4 VErsion

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:16:28

Seite 7

WAGO smart DESIGNER 4.0 1

05756417

2

4 x 05756540 "R" + 793-501

6 7

05756537 2 x 05756540 "R" + 793-501

9

4 x 05756538 "R" + 793-501

13

2 x 05756539 "R" + 793-501

15

05756537

16

05756417

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Optionen Beleuchtung

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:19:48

Seite 1

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Optionen Beleuchtung

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:22:27

Seite 2

WAGO smart DESIGNER 4.0 1

05756417

2

2 x 05756540 "R" + 793-501

4

05756539 "R" + 793-501

5

05756537

6

05756538 "R" + 793-501

7

2 x 05756540 "R" + 793-501

9

05756539 "R" + 793-501

10

05756537

11

2 x 05756540 "R" + 793-501

13

05756539 "R" + 793-501

14

05756537

15

05756540 "R" + 793-501

16

05756538 "R" + 793-501

17

05756540 "R" + 793-501

18

05756537

19

05756540 "R" + 793-501

20

05756539 "R" + 793-501

21 22

05756537 2 x 05756438 "R" + 793-501

24 25

05756421 05756417

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Klemmenleiste X2 /

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:27:03

Seite 1

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Klemmenleiste X2 /

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:29:27

Seite 2

X74 X75 X55 X76

X56

X53 X54

X29 X28

X21

X39 X23 X24 X50

X59

X40 X25 X41

X58

X42

X51 X43

X18 X45 X46

X47 X48 X49

X19

X22

X17

X52

X30 X31

X48 X49

(BVC) (BVC)

X57

X20

X14

X72

X33

X4 X3

X36

X26

X37 X1

X27

X6 X7 X8 X10

X15 X16 X60 X61 X62

X38 X2

X9

X44 X35 X32 X34

X61 X9 X21 X59

X74 X75

X72

X76 X55

X42 X23 X24 X50

X57

X25 X41 X51 X53

X29 X18 X28 X19

X20 X14

X17

X56

X54

X45 X46

X47 X48 X49 (BVC) (BVC)

X52

X30 X31

X6 X7 X15 X16

X39 X40 X58

X62 X8 X10

X43

X33

X4 X3

X36 X35 X1

X26

X37 X44 X2

X27

X38 X32 X34

X60

X48 X49 X22

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

Steckerübersicht BW 177...226 DH/BVC-4

Seite: 1

von: 1

page: 1

from: 1

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

Ers. f.:

Blatt Nr.: 301

Replaces:

Sheet No.: 301

582 700 95