Bomag Single Drum Roller BW 211 213 D-4 BW 216 D-4 Engine Deutz 2012 & 1013EC Service Traning Manual

Service Training

Single Drum Roller BW 211 / 213 D- 4 BW 216 D-4 with Deutz engine 2012 und 1013EC Teile-Nr. 008 099 99

03/2005

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

D1

Service side

D2

Starter side

D3

Lubrication oil circuit

D4

Coolant circuit

D5

Fuel system

D6

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 211 / 213 / 216 D-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

Electric Wiring diagram Hydraulic diagram

BW 211 / 213 / 216 D-4

Service Training Foreword 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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-A2-

Service Training General The new BOMAG single drum rollers D-4 are mainly further developments of their predecessors of series 3.

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

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

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

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

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

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

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

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

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

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

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-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 under a too high engine temperature and too low engine oil pressure.

The machines of series D-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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-A4-

Service Training Novelties The new instrument cluster shows important warnings and control data of the machine.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-A5-

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 211 / 213 / 216 D-4

-B1-

BOMAG Central Service

Seite 1 von 2

BOMAG Central Service - Technical data and adjustment values Status: 2005-03-21

Product type:

BW 211 D Serie 4

Type No.: Serial numbers from:

582 41 101 582 41 1001

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

BF4M2012C 4-stroke-Diesel Water 4 98 kW 2300 1/min 900+/-200 1/min 2430+/-50 1/min 225 g/kWh 0,3 mm 0,5 mm 220 bar 12 V 3,1 kW

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

90R 075 Axial piston-swash plate 75 cm3 /U 172,9 l/min 400 +26 bar 26 bar

Travel motor, rear: Type: System: Max. displacement (stage 1):

51D110 Axial piston-bent axle

Min. displacement (stage 2):

69 cm3 /U 2 l/min 16 l/min 16 bar

Perm. leak oil quantity: Rinsing oil quantity: Rinsing oil pressure limitation:

110 cm 3/U

Drum drive: Type: System: Displacement stage 1:

MSE 18 2CX Radial piston

Displacement stage 2:

1400 cm3 /U 2 l/min

Perm. leak oil quantity:

2800 cm3 /U

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BOMAG Central Service

Seite 2 von 2

Vibration pump: Type: System: Max. displacement:

42R 041 Axial piston-swash plate 41 cm3 /U

Starting pressure: 345+26 bar Operating pressure, soil dependent: ca.100 bar

Vibration motor: Type: System: Displacement:

A10FM 45 Axial piston-swash plate

Frequency: Amplitude: Rinsing oil quantity: Rinsing oil pressure limitation:

30/35 Hz 2 / 1 mm 6 l/min 13 bar

45 cm3 /U

Steering and charge pump: Type: System: Displacement:

HY/ZFS11/16 Gear pump

Max. steering pressure:

175+26 bar

16 cm3 /U

Steering valve: Type: System:

OSPC 500 ON Rotary valve

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

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

Filling capacities: Engine coolant: Engine oil: Hydraulic oil: Vibration bearing housing: Rear axle: Rear axle wheel hubs: AC refrigerant: Compressor oil (filling the system):

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 10 l (SAE 15W-40, API CG-4 (for details see maintenance manual)) 60 l (HVLP 46 VI 150) 2x 0,8 l (SAE 15W-40, API SJ/CF) 11 l (SAE 90 EP, API GL 5) 2,9 l (SAE 90 EP, API GL 5) 1300 g (R 134a) 100 ml (PAG Öl)

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21.03.2005

BOMAG Central Service

Seite 1 von 2

BOMAG Central Service - Technical data and adjustment values Status: 2005-03-21

Product type:

BW 213 D Serie 4

Type No.: Serial numbers from:

582 50 101 582 50 1001

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

BF4M2012C 4-stroke-Diesel Water 4 98 kW 2300 1/min 900+/-200 1/min 2430+/-50 1/min 225 g/kWh 0,3 mm 0,5 mm 220 bar 12 V 3,1 kW

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

90R 075 Axial piston-swash plate 75 cm3 /U 172,9 l/min 400 +26 bar 26 bar

Travel motor, rear: Type: System: Max. displacement (stage 1):

51D110 Axial piston-bent axle

Min. displacement (stage 2):

69 cm3 /U 2 l/min 16 l/min 16 bar

Perm. leak oil quantity: Rinsing oil quantity: Rinsing oil pressure limitation:

110 cm 3/U

Drum drive: Type: System: Displacement stage 1:

MSE 18 2CX Radial piston

Displacement stage 2:

1400 cm3 /U 2 l/min

Perm. leak oil quantity:

2800 cm3 /U

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21.03.2005

BOMAG Central Service

Seite 2 von 2

Vibration pump: Type: System: Max. displacement:

42R 041 Axial piston-swash plate 41 cm3 /U

Starting pressure: 345+26 bar Operating pressure, soil dependent: ca.100 bar

Vibration motor: Type: System: Displacement:

A10FM 45 Axial piston-swash plate

Frequency: Amplitude: Rinsing oil quantity: Rinsing oil pressure limitation:

30/35 Hz 2 / 1 mm 6 l/min 13 bar

45 cm3 /U

Steering and charge pump: Type: System: Displacement:

HY/ZFS11/16 Gear pump

Max. steering pressure:

175+26 bar

16 cm3 /U

Steering valve: Type: System:

OSPC 500 ON Rotary valve

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

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

Filling capacities: Engine coolant: Engine oil: Hydraulic oil: Vibration bearing housing: Rear axle: Rear axle wheel hubs: AC refrigerant: Compressor oil (filling the system):

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 10 l (SAE 15W-40, API CG-4 (for details see maintenance manual)) 60 l (HVLP 46 VI 150) 2x 0,8 l (SAE 15W-40, API SJ/CF) 11 l (SAE 90 EP, API GL 5) 2,9 l (SAE 90 EP, API GL 5) 1300 g (R 134a) 100 ml (PAG Öl)

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21.03.2005

BOMAG Central Service

Seite 1 von 3

BOMAG Central Service - Technical data and adjustment values Status: 2005-03-21

Product type:

BW 216 D Serie 4

Type No.: Serial numbers from:

582 62 101 582 62 1001

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

BF4M1013EC 4-stroke-Diesel Water 4 114 kW 2200 1/min 900+/-200 1/min 2430+/-50 1/min 235 g/kWh 0,3 mm 0,5 mm 275 bar 12 V 3,1 kW

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

90R 075 Axial piston-swash plate 75 cm3 /U 163,65 l/min 400 +26 bar 26 bar

Reduction gear, drum: Type: Transmission ratio:

CR 31 45,6

Travel motor, rear: Type: System: Max. displacement (stage 1):

51D110 Axial piston-bent axle

Min. displacement (stage 2):

69 cm3 /U 2 l/min 16 l/min 16 bar

Perm. leak oil quantity: Rinsing oil quantity: Rinsing oil pressure limitation:

110 cm 3/U

Drum drive: Type: System: Displacement stage 1:

51C 110 Axial piston-swash plate

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21.03.2005

BOMAG Central Service

Seite 2 von 3

110 cm 3/U Displacement stage 2:

55 cm3 /U

Perm. leak oil quantity: Rinsing oil quantity: Rinsing oil pressure limitation:

2 l/min 11 l/min 16 bar

Vibration pump: Type: System: Max. displacement:

42R 041 Axial piston-swash plate 41 cm3 /U

Starting pressure: 345+26 bar Operating pressure, soil dependent: ca.100 bar

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

A10FM 45 Axial piston-swash plate 45 cm3 /U 30/35 Hz 2 / 1 mm 6 l/min 13 bar

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

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

Steering valve: Type: System:

OSPC 500 ON Rotary valve

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

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

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

16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis) 13 l (SAE 15W-40, API CG-4 (for details see maintenance manual)) 60 l (HVLP 46 VI 150) 2x 0,8 l (SAE 15W-40, API SJ/CF) 11 l (SAE 90 EP, API GL 5) 2 l (SAE 90 EP, API GL 5) 1,9 l (SAE 90 EP, API GL 5)

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21.03.2005

BOMAG Central Service

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

Seite 3 von 3

3,2 l (SAE 90 EP, API GL 5) 1400 g (R 134a) 100 ml (PAG Öl)

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21.03.2005

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 211 / 213 / 216 D- 4

-C1-

Service Training Maintenance table

x

BW 211 / 213 / 216 D- 4

-C2-

Service Training

BW 211 / 213 / 216 D- 4

-C3-

Service Training

BW 211 / 213 / 216 D- 4

-C4-

Service Training

BW 211 / 213 / 216 D- 4

-C5-

Service Training Deutz diesel engine Single drum rollers of series BW 211 / 213 D-4 are powered by a Deutz diesel engine of product range BF4M 2012 C. Roller of series BW 216 AD-4 are powered by Deutz diesel engines of series BF4M 1013 EC. 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 211 / 213 D-4 / Deutz 2012C

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BW 216 D-4 / Deutz 1013EC

-D1-

Service Training Service side 3

4

2

5

1

6

14

7

12

13

11

10

9

8

Fig. 1: Service side BFM 1013/2012 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 211 / 213 D-4 / Deutz 2012C

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BW 216 D-4 / Deutz 1013EC

-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 211 / 213 D-4 / Deutz 2012C

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BW 216 D-4 / Deutz 1013EC

-D3-

Service Training Lubrication oil circuit 3

4

2

6

5

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 211 / 213 D-4 / Deutz 2012C

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BW 216 D-4 / Deutz 1013EC

-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 211 / 213 D-4 / Deutz 2012C

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BW 216 D-4 / Deutz 1013EC

-D5-

Service Training FuelFuel system 7

6

4

1a

1b

1c

Fuel tank

1d

Fuel system BW 211 / 213 D-4 / Deutz 2012C

und

BW 216 D-4 / Deutz 1013EC

-D6-

Service Training Legend: 1a

Fuel lift pump

1b

Fuel pre-filter

1c

Water separator

1d)

Water proportion sensor

2

Feed to fuel lift pump

3

Fuel lift pump

4

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

5

Main fuel filter (pressure resistant)

6

Connecting line main filter – supply for injection pump

7

Single injection pump

8

High pressure line

9

Injection nozzle

10

Leakage line

11

Pressure retaining valve - 5 bar

12

Return flow to tank

BW 211 / 213 D-4 / Deutz 2012C

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BW 216 D-4 / Deutz 1013EC

-D7-

Service Training Fuel pre-filter with water separator 1 2

3

4

5

6

Fig. 5: Fuel pre-filter with water separator 1)

Lift pump

2)

Vent valve

3

Filter element

4)

Water and dirt collecting bowl

5

Drain valve

6

Electric connection for water level sensor

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

BW 211 / 213 D-4 / Deutz 2012C

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BW 216 D-4 / Deutz 1013EC

-D8-

Service Training Function:

The fuel lift pump draws the fuel through both filters.

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

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

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

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

• Close the drain valve.

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

Bleed the system by operating the fuel lift pump and then tighten the bleeding screw.

Main fuel filter Attention!

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

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

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

Note:

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

Intake valve = 0.3 mm

Exhaust valve= 0.5 mm

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

Flywheel side

1

2

3

4

Fig. 6: Crankshaft position 1 • Check and adjust the valve clearance by following the black marking in the adjustment schematics.

For control purposes mark the respective rocker arm with chalk.

Flywheel side

1

2

3

4

Fig. 7: 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 211 / 213 D-4 / Deutz 2012C

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BW 216 D-4 / Deutz 1013EC

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

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Service Training plug-in injection pump Deutz diesel engines of product range 2012/1013 are equipped with plug-in injection pumps of series PF 33 from Bosch.

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

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

Stroke

12 mm

•

Diameter

9 mm

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

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

the fuel consumption,

•

the power

•

the exhaust emission

of the engine.

On engines of series 2012/1013 the start of delivery is adjusted without tolerance. The start of delivery is entered in degree of crank angle measured from the top dead centre of the piston and depends on application, power and speed setting of the engine.

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

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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 2012/1013 are arranged on the camshaft of the engine.

For this reason the conventional adjustment method for the start of delivery cannot be used.

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

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

The permissible manufacturing tolerances for the components •

cylinder crankcase,

•

camshaft,

•

plunger

•

plug-in injection pump

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

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

Crankcase, camshaft and plunger remain unchanged.

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

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

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

1. Remove crankcase ventilation and cylinder head cover.

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Service Training Fig. 8: 2. Remove the engine solenoid

Fig. 9: 3. Insert the pressing device, WILBÄR No. 100 830 carefully into the groove in the governor rod and tighten.

Fig. 10: 4. Turn the knurled fastening screw to press the governor rod to stop position.

Note: Tighten the knurled fastening screw by hand.

Fig. 11:

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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. 12: 6. Remove injection line and injection pump.

Fig. 13: 7. Take the compensation shim carefully out with the rod magnet.

Fig. 14: Determine the thickness of the new compensation shim:

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

295

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

Fig. 15: Injection pump code BFM 2012/1013

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

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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. 16: Injection pump code table BFM 2012

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Service Training

EK (mm)

EP code

EK (mm)

EP code

EK (mm)

EP code

EK (mm)

EP code

145.7

349

146.3

373

146.9

397

145.725

350

146.325

374

146.925

398

145.75

351

146.35

375

146.95

399

145.775

352

146.375

376

146.975

400

145.8

353

146.4

377

147.0

401

145.825

354

146.425

378

147.025

402

145.85

355

146.45

379

147.05

403

145.875

356

146.475

380

147.075

404

145.9

357

146.5

381

147.1

405

145.925

358

146.525

382

147.125

406

145.35

335

145.95

359

146.55

383

147.15

407

145.375

336

145.975

360

146.575

384

147.175

408

145.4

337

146.0

361

146.6

385

147.2

409

145.425

338

146.025

362

146.625

386

147.225

410

145.45

339

146.05

363

146.65

387

147.25

411

145.475

340

146.075

364

146.675

388

147.275

412

145.5

341

146.1

365

146.7

389

147.3

413

145.525

342

146.125

366

146.725

390

147.325

414

145.55

343

146.15

367

146.75

391

147.35

415

145.575

344

146.175

368

146.775

392

147.375

416

145.6

345

146.2

369

146.8

393

147.4

417

145.625

346

146.225

370

146.825

394

147.425

418

145.65

347

146.25

371

146.85

395

147.45

419

145.675

348

146.275

372

146.875

396

Fig. 17: Injection pump code table BFM 1013 Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from table 1.

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

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

64

Fig. 18: Plunger code inscription

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Service Training

A=XXX

Fig. 19: Individual injection pump

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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. 20: Presentation of measurement „A“

• Lo = 117.5 mm - BFM 2012 • Lo = 143 mm - BFM 1013

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Service Training

Ek

Lo+A/100 Z Ts

Fig. 21: Drive in start of delivery position after determination of „Ts“ The plug-in fuel injection pump is now positively connected with the drive, which has been set to start of delivery by inserting a compensation shim "Z" of calibrated thickness..

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

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Service Training Theoretical thickness „Ts“

Compensation shim thickness „Ss“ (mm)

(mm)

Theoretical thickness „Ts“

Compensation shim thickness „Ss“ (mm)

(mm)

0.95 - 1.049

1.0

2.45 - 2.549

2.5

1.05 - 1.149

1.1

2.55 - 2.649

2.6

1.15 - 1.249

1.2

2.65 - 2.749

2.7

1.25 - 1.349

1.3

2.75 - 2.849

2.8

1.35 - 1.449

1.4

2.85 - 2.949

2.9

1.45 - 1.549

1.5

2.95 - 3.049

3.0

1.55 - 1.649

1.6

3.05 - 3.149

3.1

1.65 - 1.749

1.7

3.15 - 3.249

3.2

1.75 - 1.849

1.8

3.25 - 3.349

3.3

1.85 - 1.949

1.9

3.35 - 3.449

3.4

1.95 - 2.049

2.0

3.45 - 3.549

3.5

2.05 - 2.149

2.1

3.55 - 3.649

3.6

2.15 - 2.249

2.2

3.65 - 3.749

3.7

2.25 - 2.349

2.3

3.75 - 3.850

3.8

2.35 - 2.449

2.4

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

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Service Training Exemplary calculation for BFM 2012 EP-code read off engine type plate: 295 • see table 1 corrected injection pump measurement „Ek“: 120,875 mm Lo = 117.5 mm (fixed measurement) Value for A/100 read off new injection pump A/100 = 42 • Ts = Ek - (Lo + A/100) Ts = 120,875 mm - (117.5 +42/100 mm) Ts = 2.955 mm see also table 1 Ts = 3.0 mm

Exemplary calculation for BFM 1013 EP-code read off engine type plate: 397 • see table 1 corrected injection pump measurement „Ek“: 146.9 mm Lo = 143 mm (fixed measurement) Value for A/100 read off new injection pump A/100 = 133 • Ts = Ek - (Lo + A/100) Ts = 146,9 mm - (143 + 133/100 mm) Ts = 2.57 mm • see also table 1 Ts = 2,6 mm

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

Fig. 22: 9. Turn the injection pump control lever to approx. middle position.

Fig. 23: 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. 24:

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Service Training 11. Attach the flange.

Note: The chamfer must face towards the injection pump body

Fig. 25: 12. Slightly oil the screws and tighten them evenly with 5Nm.

Fig. 26: 13. Loosen the screws again for 60°.

Fig. 27:

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

Fig. 28: 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. 29: 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. 30: 19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening torque 9 +/- 1Nm Note: If necessary replace the gasket.

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

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

Fig. 31 • Pressing device for governor rod

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100 830 (Wilbär)

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Service Training Diesel engine, components and test points Starter side

1 2

Pos.

Designation

Pos. in wiring diagram

1

Heating flange module High current relay for heating flange

A 13

2

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Pos. in hydraulic diagram

K 14

BW 216 D-4 / Deutz 1013EC

Measuring values

0/12 V

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Service Training Air intake - blower side

2

1

Pos.

Designation

Pos. in wiring diagram

1

Coolant level sensor Pressure differential switch for air filter

B 55

2

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Pos. in hydraulic diagram

B 03

BW 216 D-4 / Deutz 1013EC

Measuring values

pressureless open, 50 mbar

- D 30 -

Service Training Flywheel end

1 2

4

3

Pos.

Designation

1

Boost fuel valve Coolant temperature switch with warning light Coolant temperature flange for heating flange Throttle lever

2 3 4

BW 211 / 213 D-4 / Deutz 2012C

Pos. in wiring diagram

und

Pos. in hydraulic diagram

Y 01

B 30 B 113

BW 216 D-4 / Deutz 1013EC

Measuring values

0/12 V cold open, approx. 2 Ω at 20°C

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Service Training Auxiliary power take-off side

4

2

3

5

1

6 7 Pos.

Designation

Pos. in wiring diagram

1

Engine oil pressure switch

B 06

2 3 4 5 6

Engine solenoid, speed control Engine shut-down solenoid Fuel pre-filter with hand pump Fuel filter Engine oil filter Water separator sensor, fuel

Y 120 Y 58

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Pos. in hydraulic diagram

Measuring values

pressureless closed,

B 124

BW 216 D-4 / Deutz 1013EC

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Service Training Auxiliary power take-off side ( 1013EC ): BW 216 D-4

1

Pos.

Designation

Pos. in wiring diagram

1

Engine oil pressure switch

B 06

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Pos. in hydraulic diagram

BW 216 D-4 / Deutz 1013EC

Measuring values

pressureless closed,

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Service Training Turbo charger side

2 1

Pos.

Designation

Pos. in wiring diagram

1

Heating flange

R 19

2

Pressure differential switch for air filter

B 03

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Pos. in hydraulic diagram

BW 216 D-4 / Deutz 1013EC

Measuring values

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

- D 34 -

Service Training Diesel engine monitoring: Warning and control lights are integrated in the instrument cluster

Display and shut-down functions Control light

Warning buzzer

Air filter service switch

X

Water separator Fuel filter

X

X

Engine oil pressure

X

X

Coolant temperature

X

X

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Shut down time 10 s

Shut down time 2min

X X

BW 216 D-4 / Deutz 1013EC

X

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Service Training

Minimum coolant filling level

Control light

Warning buzzer

Shut down time 10 s

X

X

X

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Shut down time 2min

- D 36 -

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Travel circuit from brake valve

M4 M5

from speed range valve

ø 0.8 M4

M3

L

2

A

ø 0.81 ø 0.6

6 5

25 bar

1

8

4

ø 0.6

T3

3

9

M2

B

Charge pressure to vibration pump Charge pressure from hydraulic oil filter

Fig. 1: Hydraulic diagram travel system BW 211 / 213 D-4

-E1-

1

Travel pump Sauer 90 R 075

4

Multi function valve

7

Speed range valve

2

Servo control

5

Rear axle

8

Flushing valve

3

Charge pressure relief valve

6

Axle drive motor Sauer 51 D 110

9

Drum drive motor Poclain MSE 18 2CX

Service Training

7

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

M4

M3 A

2

M1

11

6 9

3

12

8

4

T3

T3

25 bar

5

1

M2

B

10

7

1

Travel pump Sauer 90 R 075

5

Rear axle

9

Flushing valve (drum drive motor)

2

Servo control

6

Axle drive motor Sauer 51 D 110

10

Speed range valve (drum drive motor)

3

Charge pressure relief valve

7

Speed range valve

11

Drum drive motor (Sauer 51 C 110)

4

Multi function valve

8

Flushing valve

12

Reduction gear Sauer CR 31

-E2-

Service Training

Fig. 2: Hydraulic diagram travel system BW 216 D-4

Service Training The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of: • travel pump with control and safety elements, • drum drive motor with integrated multi-disc brake (BW 211 and 213 D-4), • drum drive motor with reduction gear (BW 216 D-4), • axle drive motor, • charge pump (also for vibration circuit), • hydraulic oil filter (in charge circuit), • hydraulic oil cooler with thermostat • hydraulic lines.

Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral part of the vibration pump.

The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine.

The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function valves in the pump limit the pressure in the closed circuit to (∆p = 400 bar between low and high pressure sides).

A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain oil quantity out of the closed circuit when the machine is driving (∆p between the two sides of the closed circuit).

Leakage in the individual components of the circuit are replaced by the charge circuit through the boost check valves in the travel pump.

The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is fitted with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven by the auxiliary output of the engine and serves primarily as steering pump.

The charge circuit provides the oil for the charge system and the control functions in the closed circuits for travel and vibration drive, as well as to release the parking brakes and to change the travel speed ranges.

-E3-

Both travel motors are designed with variable displacement. The operator can choose from four different travel speed ranges.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Travel pump

M5

2

25 bar

3

Service Training

Pump drive

4

3

Multi-function valves

Charge pressure relief valve

4

B

-E4-

from/to Travel motor

Travel motor

A from/to

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

M4

1

Charge pressure to vibration pump Charge pressure from hydraulic oil filter

1 Servo control

Fig. 3: Hydraulic diagram of travel pump

2

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Service Training

Cylinder block

4

3

2

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

5

Valve plate

1

Control lever

6

Control piston

7

1 Drive shaft

7

5

2 Swash plate bearing

6

3 Pistons with slipper pads

Fig. 4: Travel pump

4

With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both maximum displacement positions.

When altering the swash plate position through the neutral position, the oil flow will be reversed and the machine will drive to the opposite direction.

-E5-

All valves as well as the safety and control elements needed for operation in a closed circuit, are integrated in the pump.

Note: These machines are equipped with two charge pumps.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

1

2

10

4

Service Training

Swash plate bearing

5

7

Swash plate guide

6

Retainer for swash plate

8

Swash plate

7

1 Sliding block

9

Swashing lever

9

2 Control piston

10

Charge pump (only in vibration pump)

8

3 Servo arm

11

3

Cross-sectional view of travel pump

11

4 Servo valve

Fig. 5: Cross-sectional view of travel pump

5 Feedback device

-E6-

6

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4

View of the rotating group

5

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

3

2 Cylinder block

Pre-tensioning spring

Slipper pad

Working pistons

4 Drive shaft

1

5

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

1

3

Service Training

2

-E7-

2

Description of function

1

5

Service Training

6

Cylinder block

4

5

Multi-function valves

3

Drive shaft

6

Charge pump (only in vibration pump)

7

1 Drive shaft bearing

7

Valve plate

6

2 Swash plate

8

8

3 Pistons with slipper pads

Fig. 7: Function of travel pump

4

The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly connected cylinder block (5).

-E8-

With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper pads of the working pistons abut against the swash plate (3).

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Service Training When moving the swash plate out of neutral position, the working pistons will perform a stroke movement with every rotation of the cylinder block.

The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle by a retaining device.

During a full rotation of the cylinder block each working piston will move through the bottom and top dead centre back to the initial position. During this movement each piston performs a complete stroke.

-E9-

During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the hydraulic circuit and presses it out into the high pressure side.

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32

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Service Training Tandem pump, connections and adjustment points

Thermostat housing

Fig. 8: Connections and adjustment points

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

High pressure port A, high pressure forward

Pressure test port MA, high pressure forward

Charge oil from filter

Pressure test port MB, high pressure reverse

Port L1, leak oil port to travel pump

Port E, charge oil from travel pump

Charge pressure relief valve, vibration pump (blocked)

Multi-function valve 345 bar (charging and pressure limitation), vibration low frequency

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

Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency

Port D, charge pressure to filter

Adjustment screw, high frequency

Port L2

End plate with integrated charge pump (only in vibration pump)

High pressure port B, high frequency

High pressure port A, low frequency

Pressure test port MA, low frequency

Pressure test port MB, high frequency

Port L2, leak oil to tank

Adjustment screw, low frequency

Charge pressure relief valve, 26 bar

High pressure port B, high pressure reverse

Pressure test port, pilot pressure

Travel lever

Port L, leak oil to vibration pump

Adjustment screw, mechanical neutral position

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

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

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

Control solenoid, low frequency (vibration pump)

Control solenoid, high frequency (vibration pump)

Service Training

31

Adjustment screw for mechanical neutral position, vibration

- E 11 -

32

cooler inlet

Thermostat housing: 33, 34, 35, 36 Leak oil port 37

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

servo control

Service Training

The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal of the pump control lever into a position controlling output signal. This position controlling signal determines the swashing angle of the swash plate (the displacement of the pump), as well as the swashing direction (flow direction of the pressure fluid).

Servo arm

Sliding block

Control piston

The flow quantity delivered by the variable displacement pump is proportional to the value of the mechanical input signal. A mechanical feedback device ensures the fixed correlation between the mechanical input signal and the swashing angle of the swash plate (displacement of pump).

Servo cylinder

Fig. 9: Control piston A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any damage to the servo control.

The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel control cable. This requires only very little manual forces and only a slight movement of the lever.

- E 12 -

Since the control is spring centred, the swash plate will automatically return to neutral position under the following conditions, thereby interrupting the oil flow and braking the machine:

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

• when shutting the engine down, • if the external control cable comes loose,

- E 13 -

Service Training

• if the pressure in the charge circuit drops below a certain value.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Multi-function valves High pressure limitation

1

2

Service Training

to the control

7

6

to the control piston

to the control piston

Drive shaft

5

1 Multi-function valve

8

Port A

6

2 Charge pump

A

Port B

3

4

Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override and a pressure relief valve, one after the other.

7

A

B

7

3 Charge pressure relief valve

B

2

4 Pilot pressure relief valve

Fig. 10: Multi-function valves

5

- E 14 -

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

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

2

3

Service Training

4

7

Pressure limitation

Check valve

6

5

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

1

Reducing fitting 8 Spring

7

1 Hydraulic by-pass piston 9

By-pass housing

8

2 Spring plate 10

By-pass sleeve

9

3 Spring 10

10

4 High pressure relief valve

11

5 Valve seat

Fig. 11: Multi-function valve, details

6

Pressure override and high pressure relief valve are both parts of the multi-function valve, which is screwed into the pump.

- E 15 -

With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure override makes sure that the high pressure relief valves will only respond in exceptional cases. This protects the hydraulic circuit against overheating and reduces the load on the diesel engine.

Note: The multi function valves must be tightened with a torque of 89 Nm!

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Charge pressure relief valve

Service Training

The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine (steering and charge pump) and the other pump is integrated in the vibration pump.

The pressures of both pumps are limited by a charge pressure relief valve.

The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted value (26 bar).

The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits and provides the necessary pressure to control the travel and vibration pumps and to operate the multidisc brakes in the travel drives.

Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the pressure in the low pressure side is almost identical with the pressure in the charge circuit.

- E 16 -

When parking the machine on level ground with the engine running, the pressures in both sides of the closed circuit are identical (charge pressure).

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Flushing valve

Fig. 12 Cross-section of flushing valve 1 Flushing spool 2 Flushing pressure relief valve

1

Service Training

2

The flushing valves are integrated in the axle drive motor, or on the BW 216 D-4, also in the drum drive motor. In case of a pressure increase in one of the two sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the low pressure side.

The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).

If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows through a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is immediately replaced by oil entering from the charge circuit through the corresponding boost check valve (part of the multi-function valve).

- E 17 -

In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature household of the hydraulic system is maintained at a permissible level.

Axle drive motor,

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

6

7

Service Training

7

Universal joint

Cylinder block

8

Control piston

8

Output shaft

5

1 Flushing valve

9

Output shaft bearing

11

2 Control

10

Working piston

4

3 Spindle with ball

11

10

9

- E 18 -

The axle drive motor is a swash plate controlled axial piston motor of series 51 D 110 with variable displacement.

1

2

4 Qmin-screw

3

5 Valve plate

Fig. 13: Axle drive motor,

6

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

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

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

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

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

Changing of the displacement is accomplished by pressurizing the corresponding control piston side with pressure oil from the charge circuit via a 4/2-way solenoid valve.

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

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

- E 19 -

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.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Rear axle

- E 20 -

Service Training

Releasing the axle drive brake manually (on both axle drive designs) For manual releasing of the brakes on the rear axle you should proceed as follows:

Fig. 14: Manual releasing of rear axle brakes • Slacken the counter nut (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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

BW 211 / 213 D-4 2 CX

Service Training Front drum drive motor: Radial piston motor MSE 18

On single drum rollers of series BW 211 and 213 D-4 the drum is driven by a hydraulic radial piston motor.

6

5

4

3

2

1

Cam ring

Cylinder block

Multi-disc brake

Brake piston

Oil distributor

Piston with roller

Drive shaft with output flange

7

2

6

3

5

43090070

- E 21 -

4

These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the working pistons and the output shaft.

1

8

7

Bearing plate

Fig. 15: Drum drive motor

8

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

The housing consists of: • bearing section (drive shaft bearings), • torque section (cam race) and • oil distributor.

Service Training

Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure oil presses the working pistons with the rollers against the cam race of the torque section and forces the rollers to roll along the cam race.

This transforms the axial movement of the pistons to a radial movement of the cylinder block. The cylinder block transfers this rotation via a splined connection to the output shaft.

The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc and the rubber elements to the drum.

The function of the radial piston motor is described hereunder. The piston positions described in this explanation can be seen in the related illustration.

5

3

4

- E 22 -

The movement of a piston along the cam race must be examined in several phases during a full rotation:

1

2

Fig. 16: Function of the radial piston motor

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Piston position 1:

Service Training The oil enters into the oil distributor under pressure, flows through the distributor and presses against the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the roller along the cam and causes a rotation of the cylinder block.

Piston position 2: At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The piston continues his travel along the cam race towards the valley between two cams. As the movement continues the opening cross-section for the oil supply decreases.

Piston position 3: Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first piston out of the dead centre.

Piston position 4: Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now connected with the low pressure side and the reverse movement of the piston presses the oil back to the pump.

Piston position 5: The pumping movement of the motor back to the pump comes to an end, the connecting bore between cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre position. This point is the start of a new working cycle.

Reversing the oil flow reverses also the rotation of the motor.

- E 23 -

The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc and the rubber elements to the drum.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

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

Fig. 17: Manual releasing of the brake in the Poclain motor • Remove the plug 1 (Fig. 17).

- E 24 -

• Lay the U-bar (5) across the brake housing (2) and turn the screw (4) into the tapped bore (3) until it bottoms.

• Turn the nut (6) down and tighten it for approx. one turn. The drum must turn freely.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Service Training BW 216 D-4 Front drum drive motor: Bent axle motor 51 C 110 with reduction gear CR 31

2

Travel motor

7

6

Brake discs

Planet carrier

Sun gear

4

1 Tapered roller bearing

8

Mechanical seal

3

2 Spur wheel

9

Brake piston

9

3 Hollow wheel

10

8

5

6

7

The drums on the DH216 D-4 versions are driven by a swash plate operated Sauer bent axle motor 51 C 110. This motor is almost identical with the rear axle motor. Another detailed description at this point is therefore not necessary.

1

10

4 Planet wheel

Fig. 18: Reduction gear CR 31

5

- E 25 -

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

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Brake control

Service Training During operation the closed hydrostatic travel circuit has the function of a service brake. When moving the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill.

However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause creeping of the machine when it is parked on a slope with the engine running, the machine is additionally equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever in neutral position the multi-disc brakes will close and the machine can be parked on slopes with the engine running and without the risk of creeping.

However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is interrupted and the oil from the brake housings flows as leak oil back into the tank.

- E 26 -

If the brake solenoid valve is supplied with current while the engine is running and the brake is open, the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake discs.

Manual releasing of the brake in the drum drive reduction gear

Brake releasing device in operation position

Brake releasing device in position “brake manually released”

Fig. 19 Manual brake releasing device

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

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

- E 27 -

Service Training

• Turn both screws (Fig. 20) for releasing the brake in the drum drive reduction gear evenly in clockwise direction, until the drum can be turned freely.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

8

1

Travel circuit: BW 211 / 213 D-4

3

7

High pressure Low pressure Charge pressure Leak oil (case pressure)

el av

di r

Service Training

1

tio ec

n

4

- E 28 -

1 Travel pump 2 Vibration pump 3 Travel lever 4 Hydraulic oil filter 5 Rear axle 6 Axle drive motor 7 Drum drive motor 8 Hydraulic oil tank

5

Drum drive with radial piston motor

2

6

Tr

Fig. 21: BW 211 / 213 D-4, travel circuit, routing of hoses

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

9

1

av Tr

el

5

e dir

ct i

Service Training

on

2

3

4

1 Travel pump 2 Vibration pump 3 Hydraulic oil filter 4 Rear axle 5 Axle drive motor 6 Reduction gear 7 Drum drive motor 8 Hydraulic oil tank 9 Travel lever

- E 29 -

Travel circuit: BW 216 D-4 Drum drive with travel motor with reduction gear

8

7

6

High pressure Low pressure Charge pressure Leak oil

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

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Brake control: BW 211 / 213 D-4

- E 30 -

Service Training

Brake valve

with radial piston motor

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

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Leak oil

Service Training

Brake valve

- E 31 -

BW 216 D-4 Travel motor with reduction gear

Brake releasing pressure

Charge pressure

Brake circuit Brake control:

Fig. 23: Brake circuit

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Service Training

- E 32 -

Service Training Travel drive, components and test points

Measuring values

2

max. 426 bar

1 Pos. in hydraulic diagram

Pos. in wiring diagram

Designation

10, MD 10, A

- E 33 -

Test port, forward High pressure port, forward

Travel pump: left hand side

Pos.

1 2

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Service Training

2

Measuring values

3

max. 426 bar

1

Pos. in hydraulic diagram

Pos. in wiring diagram

Designation

10, MC 10, B

- E 34 -

Test port, reverse High pressure port, reverse Travel control (travel control cable)

Travel pump: right hand side

Pos.

1 2 3

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

5

3

Service Training

1

Pos. in wiring diagram

4

Pos. in hydraulic diagram

12, L 12, R 12

12 12, 1 12, Y

- E 35 -

Motor Qmax, depressurized Motor Qmin, 26 bar

open, 26 bar pressureless closed

Measuring values

Front travel motor with radial piston motor for BW 211 / 213 D-4

2

Designation

6

Pos.

High pressure port, forward High pressure port, reverse Brake

Cross-flushing of travel pump T1 Cross-flushing outlet to tank Travel speed range selector

1 2 3

4 5 6

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

1 3

5

Flushing valve High pressure port, drum drive motor forward High pressure port, drum drive motor reverse High pressure from travel pump forward High pressure from travel pump reverse Qmin- setscrew

Solenoid for speed range selector valve

Designation

Rear travel motor: Axle motor

Pos.

1

2 3 4 5 6 7

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

2

Service Training

4

Measuring values

6

Pos. in wiring diagram

14

Pos. in hydraulic diagram

7

Y31

Motor Qmax--depressurized, Motor Qmin--26 bar 14 14, A 14, B 14, A 14, B 14

- E 36 -

6

5

Y 30

Pos. in wiring diagram

- E 37 -

Motor Qmax, depressurized Motor Qmin, 26 bar

Measuring values

1

Service Training

7

Pos. in hydraulic diagram

16 - A 16 - B 16 16

16 16 16

4

BW 216 D-4 Travel motor with reduction gear (drum drive motor)

2

Designation

3

Pos.

Pressure travel forward Pressure travel reverse Flushing valve Solenoid for speed range selector valve

Qmin- setscrew Leak oil port Brake port on gearbox

1 2 3 4

5 6 7

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Service Training BW 211 / 213 D-4 Brake and travel speed range selection

Designation

Y 31

Pos. in wiring diagram

08, a1

08, a2

Pos. in hydraulic diagram

Motor Qmax, depressurized Motor Qmin, 26 bar open, 12V closed, de-energized

Measuring values

1

Pos.

Speed range selector valve for front travel motor (Poclain)

Y 04

2

1

Brake valve

- E 38 -

2

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

BW 216 D-4 Brake valve

Pos. in wiring diagram

08,

Pos. in hydraulic diagram

open, 12V closed, de-energized

Measuring values

Service Training

Designation

Y 04

1

Pos.

Brake valve

- E 39 -

1

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

- E 40 -

Service Training Travel lever console with rotary switch for speed range selection

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Designation

B14

Pos. in wiring diagram

Travel lever

Pos.

Initiator for backup alarm

B13

1

1 Initiator for brake

2

2

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

Measuring values

Service Training

Pos. in hydraulic diagram

0 / 12V, normally closed Normally closed, opened in braking position 0/12V

- E 41 -

Trouble shooting

Service Training

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.

3

3

2

3

3 2

2 3 1 3

3

1

1 2

1 2 3 3 3 2 1 2

3 3

2 1 2 3

2

1 2

Machine does not drive (forw. and reverse) Machine drives to one direction only Machine travels with travel lever in 'Neutral' Max. travel speed not reached Hydraulic oil overheating

- E 42 -

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

TROUBLE SHOOTING TRAVEL SYSTEM BW 211 / 213 / 216 D-4

POSSIBLE CAUSES Brake valve (electric/mechanical/hydraulic) Brake in axle/drum drive motor (mechanical/hydraulic) Travel speed range switch position /defective/wiring Charge pump / charge pressure relief valve(s) dirty/defective Pump control (servo control) Pressure override/ travel pump high pressure limitation dirty/out of adjustment/defective Adjustment of travel cable Travel pump mechanical neutral Travel pump(s) defective Axle drive motor control valve (electric / mechanical / hydraulic) Flushing valve axle drive motor seized Travel motor(s) defective Hydraulic oil cooler soiled (internally/externally) Thermostat (hydraulics) soiled/jammed/defective Kupplung Dieselmotor-Pumpe Dieselmotor

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013 EC

SYMPTOMS

Service Training Vibration system The vibration system of the single drum rollers of generation D-4 works with two frequencies and two amplitudes. This enables perfect adaptation of the machine to various types of soil and different applications.

The vibration drive is a closed hydraulic circuit. The circuit consists of: • the vibration pump, • the vibration motor and • the pressure resistant connecting hoses to release the brake

from charge pump via Travel pump D

L2

M3

E

Charge oil Vibration pump

N

Block A

M1 M2 S B

1

2

M4

M5

Fig. 1: Vibration circuit 1 2

Vibration pump Vibration motor

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-F1-

Service Training Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly driven by the diesel engine.

When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to one of the two control piston sides. The swash plate inside the pump will swash to the corresponding side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the vibrator shaft inside the drum.

When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will change its direction and the vibration motor will change its sense of rotation.

Since the end stops for the swash plate are set to different swashing angles to both directions, the angle for the piston stroke is also different to both sides. This angle influences the length of the piston stroke and thereby the actual displacement of the pump.

• Large angle = high displacement = high vibrator shaft speed (frequency) • Small angle = low displacement = slow vibrator shaft speed (frequency) The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights.

This results in the following constellations: • Basic weight + change-over weight = high amplitude • Basic weight - change-over weight = low amplitude In order to achieve effective compaction results the vibration system is designed in such a way, that high amplitude is coupled with low frequency and low amplitude with high frequency.

Fig. 2:

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-F2-

Service Training Vibration pump Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with variable displacement for operation in a closed circuit.

The displacement of the pump is proportional to the engine speed and the chosen displacement.

When actuating the swash plate out of neutral position the flow quantity to the chosen direction will increase from ”0” to the maximum value. When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will change its direction and the vibration motor will change its sense of rotation. All valves and safety elements for operation in a closed circuit are integrated in the pump.

Releasing the brake

from charge pump via Travel pump

Charge oil Vibration pump D

L2

M3

E

1 Vibration pump 2 Charge pump

N

3 High pressure limitation

Block

4 4/3-way solenoid valve A M1 M2

S

B

M4

M5

Fig. 3: Hydraulic diagram vibration pump

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-F3-

Service Training Function

1

2

6

4

5

3

Fig. 4 Cross-section of vibration pump 1

Servo piston

2

Working pistons

3

Charge pump

4

Valve plate

5

Roller bearing

6

Swash plate

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-F4-

Service Training 1 2 5

4

3

Fig. 5 Cross-section of vibration pump 1

Control

2

Servo piston

3

Friction free swash plate bearing

4

Attachment plate

5

Spool valve

The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.

The slipper pads rest against the sliding surface of the swash plate and are at the same time held on the sliding surface by a retaining device.

During each rotation the piston pass through their upper and lower dead centre back to their initial position. Between both dead centres each piston performs a full working stroke. During this stroke movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the length of the working stroke.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-F5-

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

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

Charge pumps These machines are equipped with two charge pumps.

One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine and serves also as steering pump.

The second pump is an internal gear pump and is located in the end cover of the vibration pump.

The oil flow generated by the charge pumps 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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-F6-

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

1 2

3

Fig. 6 Pressure relief valve 1

From the charge pump

2

Closed circuit

3

High pressure relief valve with integrated boost check valve

Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar (pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar).

The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the closed vibration circuit. The function of these valves has already been described in the chapter "travel system".

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-F7-

Service Training Vibration motor The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits.

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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-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 to 345 bar by the corresponding high pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly depends on the condition of the ground (degree of compaction, material etc.).

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

MA

A 2

3

B

1

MB

Fig. 8 Circuit diagram of vibration motor 1

Vibration motor

2

Flushing valve

3

Flushing pressure relief valve

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

- F 10 -

Service Training Drum

4

14

5

9

2

6

13

7 10

3

8

11

12

1 Fig. 10 Cross-section of drum 1

Drum shell

8

Change-over weight

2

Vibration bearing

9

Coupling vibr.-motor – vibrator shaft

3

Basic weight

10

Travel bearing

4

Vibrator housing

11

Travel bearing housing

5

Cooling fan

12

Rubber buffer

6

Vibrator shaft

13

Vibration motor

7

Elastic coupling between shafts

14

Flanged bearing housing

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

- F 11 -

Service Training Vibration system: Components and test ports Vibration pump

1

2

5

Pos.

Designation

1 2

Pressure test port, charge pressure Differential pressure switch, charge pressure High pressure port, low amplitude High pressure port, high amplitude Solenoid valve, low amplitude Solenoid valve, high amplitude

3 4 5 6

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

3 4

6

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

MA 07

26 bar ^p 3.5 bar

MF ME Y08 Y07

12V / 3.33A 12V / 3.33A

- F 12 -

Service Training Vibration pump

1

2

Pos.

Designation

1

Pressure test port, vibration pressure low amplitude Pressure test port, vibration pressure high amplitude

2

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

MF

max. 371 bar

ME

max. 371 bar

- F 13 -

Service Training Vibration motor

1 2

3

Pos.

Designation

1 2 3

High pressure port, high amplitude High pressure port, low amplitude Leak oil and flushing oil port

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

Pos. in wiring diagram

Pos. in hydraulic diagram

16 16 16

Measuring values

approx. 7 l/min, incl. flushing quantity

- F 14 -

Service Training Trouble shooting 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.

No vibration (charge pressure OK) Vibration only with one amplitude Exciter shaft speed too low

TROUBLE SHOOTING VIBRATION BW 211 / 213 / 216 D-4

SYMPTOMS

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

POSSIBLE CAUSES Vibration switch (amplitude pre-selection) Vibration push button (on/off) Electrics defective / wiring Pump control (electrical / hydraulic) Pressure override / high pressure relief valves in vibration pump soiled/out of adjustment/ defective Charge pump / charge pressure relief valve soiled/ defective Vibration pump frequency adjustment Vibration pump defective Coupling between diesel engine and travel pump defective Exciter shaft bearings defective Vibration motor coupling defective Vibration motor defective Diesel engine

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

1 1 1 2 2 1 1 2 2 2

2 2 3

2 2

1 1

- F 15 -

Service Training Steering Single drum rollers of series BW 211 / 213 / 216 D-4 are equipped with a hydrostatically operated articulated steering system.

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

to charge system 1 7

6 5

3 2 4 from steering pump

Fig. 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 operator's platform of the machine. If the steering is not operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel circuits.

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

The steering cylinders retract or extend and steer the machine.

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

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-G1-

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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-G2-

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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-G3-

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 through the distributor valve to the corresponding sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the rotation angle of the steering wheel.

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

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-G4-

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 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-G5-

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

Fig. 5 Articulated joint

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-G6-

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

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

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

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

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

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

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

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

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

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-G7-

Service Training Steering: Components and test ports Steering pump

1

2

Pos.

Designation

1 2

Steering pump (and charge pump) Steering pressure test port

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

Pos. in wiring diagram

Pos. in hydraulic diagram

09 MB

Measuring values

max. 175+26 bar

-G8-

Service Training Vibration and noise damper

The damper is located in the steering/charge circuit directly after the steering and charge pump.

It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.

The damper is mounted to the front plate of the rear frame, between both steering cylinders.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

-G9-

Service Training Steering valve The steering valve is located under the operator's stand

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

- G 10 -

Service Training Trouble shooting 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 numerical values specified in the table indicate the probability of the fault cause and thereby the recommended trouble shooting sequence, based on our latest field experience.

No steering function End stops are not reached Steering hard to move

SYMPTOMS

TROUBLE SHOOTING STEERING SYSTEM BW 211 / 213 / 216 D-4

POSSIBLE CAUSES Steering orbitrol valve Steering/charge pump Steering cylinder Articulated joint

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

2 1 3 3

2 1 3 3

1 2 3 2

- G 11 -

Service Training Electrics:

Single drum rollers of series D-4

This chapter describes the peculiarities in the electric system and the necessary adjustments. These instructions solely describe the electrical test for the D- machines of the single drum rollers of generation 4.

For machines of type DH separate Testing and adjustment instructions are available.

Function test: Turn the ignition key to "Ignition ON".

The round gauge runs a 3 second self test.

All control lights are active during this time.

The fuel level gauge shows the actual fuel level.

Brake control light (travel lever in braking position), charge control light (engine stopped) and oil pressure warning light (engine off) are active.

Warning and control lights are integrated in the instrument cluster!

Tabelle 1: Inspection of display and shut-down functions Control light

Warning buzzer

Shut down time 10 s

Shut down time 2min

Air filter service switch

X

Water separator Fuel filter

X

X

X

Hydraulic oil filter

X

X

X

Engine oil pressure

X

X

Coolant temperature

X

X

Minimum coolant filling level

X

X

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

X X X

H1

Service Training Instrument cluster

Electric junction box with module

Module

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

H2

Service Training Seat contact switch Only machines with cabin are equipped with the seat contact circuitry.

This circuit also contains the vibration relay. Machines with ROPS or sun canopy are not equipped with the seat contact circuitry.

The following applies in general: When the seat is not occupied it can be assumed that in the worst case the machine may perform uncontrolled movements. In such an instance the machine must be shut down at the latest after 4 seconds. During these 4 seconds the driver must be warned about this condition by the warning buzzer in the dashboard and the area around the machine by the backup alarm. To start travel movement of the machine the driver's seat must be occupied, as otherwise the diesel engine will be shut down immediately. This prevents the machine from being started from the outside (e.g. through the open window).

1. Starting of the engine should only be possible with the travel lever in position "Brake".

2. Driver standing (seat contact control light does not light up): While the engine is running shift the travel lever to travel operation --- then engine shut be shut down immediately, the seat contact light lights up, warning buzzer and backup alarm sound. If the travel lever is returned to "Brake" position during the shut-down process, the fuel solenoid is switched on again and the engine will automatically start.

Otherwise the engine must be restarted.

3. Driver seated: (seat contact control light does not light up): Normal operation, no warning active.

Driver gets up --- control light comes on and both warning buzzers sound. Driver sits down again within 4 seconds --- machine returns to normal operation. Driver does not sit down again within 4 s --- engine is shut down. If the driver sits down again while the engine is being shut down, the fuel solenoid is switched on again and the engine will automatically start. Otherwise the engine must be restarted.

In addition to the seat monitoring system all monitoring functions are implemented by the

Module UPM2 .

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

H3

Service Training The hardware us available under BOMAG part-number 057 664 81.

Stay-Alive LED Program m ierstec ker

10

11

12

13

14

15

Masseanschluß

Fahrhebel

Öldruck

Generator / D+ Signal

Vibrationstaster

9

Sitzkontaktschalter

8 Bremsventil

7 Anzugswicklung Abstellmagnet

Masseanschluß

5

6

Vibration

Warnsummer

4

3

Haltewicklung Abstellmagnet

1

2

Versorgungsspannung (+UB)

StatusLeuc htdioden

Versorgungsspannung (+UB)

Spannungsversorgung

Fig. 1: Module The complete module (including the specific software) is available under BOMAG part-number 582 701 68.

The following applies when measuring the signal levels: PIN Inputs Output PIN8 Outputs general

Potential with LED on Ground 0V Ground 0V ≈ operating voltage (UB- 0,7V)

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

Potential with LED off Input open Output open Ground 0V (<< 1V)

H4

Service Training Emergency operation If a bridge is inserted between PIN 2 and PIN 3 of the module, the bias coil is permanently supplied with current (as long as the ignition is on) and the vibration is switched on (vibration can be switched on/off with the vibration selector switch).

Inserting a bridge between PIN 10 and the connecting cable to PIN 8 opens the brake (the brake can then be switched on/off e.g. via the parking position of the travel lever). The module is then bridged (only with motors without pickup winding.

D escription of function In addition to m onitoring the seat occupation this m odu le can also be used to control the hydraulic b rake and the function of the vibration relay.

T he following seq uences were used in the U P M 2 softw are to realize the sea t occupation m onitoring system :

S w itching on the ignition -

-

-

-

T he S tay-A live-LE D on the m od ule shows the software version (currently version 3) once by m ea ns of a flashing code (chang es to perm anent lig ht).

W hen the travel lever is in n eutral position (P IN 12 = A ctive-LO W ) the bias coil of the shut-do wn solenoid (P IN 4 = A ctive-H IG H ) is switched on and the pickup wind ing (P IN 7 = A ctive-H IG H ) is energ ized for 2 seconds. In this situa tion the seat contact switch has no effect. T here will be no visual o r audible warning if the driver's seat is not occupied.

If the travel lever is returned to neutral position after the ig nition has been switched on, the bia s coil is autom atically switched on and th e pickup winding is a utom atically energ ized for 2 seconds (startin g is now possible).

A s long as no D + sig nal is detected (starting has not yet been perform ed an d the eng ine is there fore not yet running ), the vibration can be switched on by the vibration control switch.

V ibratio n is switched off.

S tarting the eng ine is only possible with the travel lever in neutral position. S ince the starter does still ro tate despite this fact, e xternal blockag e of the starter is req uired whe n the travel lever is ope rated.

S tarting th e engine -

If runn ing of the eng ine is d etected throug h D +, th e hydraulic brake is a utom atically release d (if it is no long er activa ted by the travel lever in parking position).

If the travel lever is not in neu tral position (irrespective of the seat contact), the bias coil of the shut-down solenoid is sw itched off ag ain.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

H5

Service Training Engine running -

-

Vibration can be switched on with the vibration push button when D+ or oil pressure is applied (OR-linkage).

The bias coil remains switched on.

There will be no visual or audible warning when the driver's seat is unoccupied even though the travel lever is out of neutral position.

If the driver's seat is not occupied and the travel lever is actuated in this condition, the bias coil of the shut-down solenoid is immediately switched off and the engine will stop.

The signalling device (horn) is activated.

W hen D+ is no longer applied (engine not running) the signalling device is switched off and the hydraulic brake closes after 1.5 seconds.

W hen leaving the driver's seat after shifting the travel lever out of neutral, the signalling device will be activated. 4 seconds later the bias coil of the shut-down solenoid will be switched off and the engine will stop.

Engine stops -

-

If the engine stops, but D+ is still applied, the bias coil is switched on again and the pickup winding is energized for 2 seconds, as soon as the driver takes his seat or the travel lever is returned to neutral position.

The signalling device is switched off. The module is then in Engine Running mode and responds as described above.

Engine has stopped The following applies in all cases (irrespective of travel lever and seat contact) if the D+ signal is missing: - If the D+ signal is no longer applied the module will decide that the engine has stopped.

- The bias coil of the shut down solenoid is immediately switched off and the brake closes 1.5 seconds later.

- The machine can be restarted by switching the ignition off and on again (new start).

- However, if the D+ signal (for what ever reason) returns by itself, the bias coil of the shut down solenoid is automatically switched on and the pickup winding is energized for 2 seconds, if the driver has sat down.

- If the driver is not sitting while D+ returns, the reaction will be as described above in Engine Running mode, depending on the history (was the driver's seat left or the travel lever actuated first?).

- If, in addition to the missing D+, there is no oil pressure, the vibration will be shut down.

The vibration is not automatically switched on if one of the signals returns!

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

H6

Service Training New start A new start (after the engine has been shut down) is only possible after switching the ignition on again (see Switching on ignition) or after D+ has returned (see Engine has stopped).

Miscellaneous Due to the design of the Perkins engines restarting of a still turning engine by returning the travel lever to neutral or sitting down on the driver's seat is not possible.

On machines with Perkins engine restarting always requires the ignition, if the bias coil of the shut down solenoid hd been switched off (picking up of the winding only possible after the engine has stopped).

The pickup winding must be triggered by an additional relay, because the module is only able to supply a current of 4 ampere.

The module works from a supply voltage of 7 Volt.

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

H7

Service Training

0

Hardware description

The seat occupation monitoring module consists of the modified UPM2 module.

The inputs are configured to match the following table: Input

Behaviour

Comment

Input PIN11

LOW-active

LED lights when applying ground potential (0V)!

Input PIN12

LOW- active LED lights when applying ground potential (0V)!

Input PIN13

LOW- active LED lights when applying ground potential (0V)!

Input PIN14

LOW- active LED lights when applying ground potential (0V)!

Input PIN15

LOW- active LED lights when applying ground potential (0V)!

0.1

Pin assignment of inputs

Signal name Seat contact switch

Module pin 11

Travel lever

12

Oil pressure

13

Generator / D+ signal

14

Vibration button

15

0.2

Signal at input 0V = driver sits, +U B = driver stands up, 0V = travel lever neutral position +U B = travel lever actuated 0V = oil pressure fault +U B = no oil pressure fault 0V = engine stopped +U B = engine running 0V = Vib. on/off +U B = Vib. off/on

LED on LED off LED on LED off LED on LED off LED on LED off LED on LED off

Pin assignment of outputs

Signal name Bias coil for shut down solenoid Vibration

Module pin 4 5

W arning buzzer/light

6

Pickup winding shut down solenoid Brake valve

7 8

BW 211 / 213 D-4 / Deutz 2012C BW 216 D-4 / Deutz 1013EC

Signal at output +U B = ON 0V = OFF +U B = Vibration should be on 0V = Vibration should be off +U B = W arning buzzer on 0V = W arning buzzer off +U B = ON 0V = OFF +U B = Brake applied 0V = Brake released

LED on LED off LED on LED off LED on LED off LED on LED off LED off LED on

H8

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

BW 177..216 D−4

Zeichnungsnummer drawing − no.

582 700 96 582 700 96 582 700 96 582 700 96 582 700 96 582 700 96 582 700 96 582 700 96 582 700 96 582 700 96

Funktionsgruppe

function unit

Stromlaufplan Versorgung, Starten, Motordrehzahl Motor−Heizflanschst., Signalhorn, Mess−Sensorik Bremse, Rückfahrwarneinr., Anzeige Fahrstufen, Sitzkontaktsch., Vibration ZA Messtechnik ZA Beleuchtung und StvZO ZA Kabine, Beleuchtung, Radio, Tachograph ZA Kabinenheizung, Klimaanlage, Zusatzheizung Bauteilliste

Circuit Diagram supply, starting unit, engine−speed eng. heating−flange contr.,warning horn,sensors measurem. brake, back up alarm, indicator speed−ranges, seat−switch, vibr. option measurement equipm. opt. illumination and StvZO opt. cabin, headlights, radio, tachograph opt. cabin−heater, air conditioning, add. heater component listing

01.03.2004 Seis 01.03.2004 Werner

Stromlaufplan circuit diagram

001

001

582 700 96 001

30 6:1 K30

8:1 15:54

X1:15E

X1:10

17E 1 X1:4

2

20A

X37:A S00

30 K35 2:16

X1

V01

30

R10 82 OHM K61 2:5 2 87

85

nicht bei BW177 D−4 not at BW177 D−4

65

B+ −

D+ MESX

X1

G03 + −

D+

167A

G02

1

R19

31−1

86 B−

W W

23 30 K114 2:14 87a

12

87

24

2

15A

X1:30A

27A

K32:86

8:1

F14:2

5:9

S01:21

X1:151

5:9

21

11

?

?

22

12

?

?

S01 K35 K05/87

K09

X1:152 X1:60

30

K22 87

2x2.5qmm

X38:A 30

X1 81

50 86

Y01 1

86 M01

K114

M 2

85

85

54 1 Y58

70A/1A

85

−

87a

X1 AW + HW

Y120 −

2 X1

2 X1:55

2

X1 X1 58 59

4:9

K11 85

NOT−AUS Emerg.−Stop

85

X1 X1 7 8

B+ 2:5

86

K36

3:2

V47 2 1

G01 +

11

87a

87a

6:2 1

1 F39

2

86

1

X1

30

S120

1

X1 80

3.9A

F00 2

125mA

86

K05 4:3 87

1

nur bei Klimaanlage only acc.to air conditioning

1

K11:86

1

50A / 10A

125mA

K61

125A

125A

2

X37:B

X1:4 3:2

K61/85

S30

X1

AUX

Hauptsicherung main fuse

heating−flange

Sicherung Heizflansch

X1:3

4:13

1

50a

79

87(4) F48

19 17 54 58 15:54 2:13

X1:30E

ohne Kabine/ROPS without cab./ROPS

15

87

15A

27E

4:5

87a

F14

4qmm

2:11 Startschalter starting swwitch

2

X1

17A

30

Schalter Motordrehzl switch engine speed

X36:A

X36:B

X1

B+

3:5

K11/87 3:1

2

X1:15A

K14

87a

1

F105

30A

30(3)

2:10 87

X1:56

55

X1 X1 3.8A

X1:9

X1 F13

30

K11

2:10

62 63 X1:168

31

31 2:8

Trennschalter Batter break switch battery Batterie Heizflansch heating−flange battery

Batterie battery

01.03.2004 Seis 01.03.2004 Werner

Generator generator

4:4

9:7

2:18

2:16

Starter starter

Startmehrmenge start boost fuel

Versorgung, Starten, Motordrehzahl supply, starting unit, engine−speed

3:1

2:13

Hubmagnet Drehzahl sol. engine speed

Kraftstoffabschaltug fuel shut off

1

1

582 700 96 002

2:20

K11/87

K11/87 4:1 F24:2

4:10

4:19 2:10

K11:86

2:13

K05/87

GLÜH

X1

X1:42

52 X1 78 X1

X1 28E

X1 53

75

1

F23 10A

2

X1 28A

1

_t

A13 3

4

6

14

24

X1 97 98 X1 X1 101 102

2

V22

2

V21

K14

X1:171 2

+ B60

1

1

Anbau im Motorbereich assembled in engine−area

1

Relais Heizflansch relais heating−flange

23

X1

1 B113

13 S03

4.2A

7

Taster Signalhorn push but. warning horn

2

4.2A

5

Anbau im Motorbereich assembled in engine−area

Modul Heizflanschsteuerung modul heating−flange−control

X1:155

speed

B11 1

B11 1

dir. X1:173

− 2

DIR MESX 6:2 SPEED MESX 6:2

X1:172 SPEED TAC

8:6

2

2

X1

X1 57

2:20

X1 64

X1 99

100

X1:174

31

31 4:1 2:2 Kühlmitteltemperatur collant temperature

Signalhorn warning horn

Nicht bei BW177 D−4 Not at BW177 D−4

01.03.2004 Seis 01.03.2004 Seis

Signalhorn warning horn nur bei CE−Konformität only at CE−conformable

TS021

Sensor Achse sender axle nur bei ZA Messtechnik only at opt. measurement−equ.

Motor−Heizflanschst., Signalhorn, Mess−Sensorik engine heating−flange cont., warning horn, sensors measurem.

1

1

582 700 96 003

K11/87

K11/87 5:1 X1:31E

2

X5:1−20

30 K36 2:7 87a

87

X12 3 X12 2

4:13

X1:147 11

S01 2:18

12

8

4

10

3 2

14

X1

11

13

X1

69

5:9

X1:150

76

86

Y04

6:2 BRAKE MESX

1

K26

2

85 125mA

109

X9

X10

85

H14+ − X9

1

K22

89

86

R03

2

X10 X1

129

X1:117

X1:74

X1

X1 111 112

X1

X1 107 108

X8

1 X8

X1:72 X1

82

K48:87A 4:3 B21

3

P bl

P

X1 X1:117

2 or

+ 85

67

X1

2:6

105

90

X1 86

X1:77

5:9

73

X1:68

X1

X1 114

71

7:17

5

X1

106 5:9

16

X1

X1 K26/87A

17

87

110

X1 X1:153

15

X1

SITZWARN. 5:9

2.5A

K05

85 125mA

Bel.

X1

X1:113

X1:149

A68/3

87

7:17

X1:61

K48:87A

X1:148

86

12 Sitz

X13 3 X13 2

K48/87

K48

1

30

7:16

Wasserabscheider

BL/BU SW/BK

OUT1

Kühlmittelfüllstand

87

BL−R BL−L

BEL

K26 4:6 87a

19 Blinker rechts

3:5

HOURS

5:9

B14

BL−W

18 Blinker links

GND

K48 4:2 87a

1

GLÜH

7 Warnbl.

9

H07

BL/BU SW/BK

BR/BN

30

5:2

6 Vorglühen

OUT2

7:5

300mA

B13

1

Initiator Vorw. und Null proximity switch forwards and "0"−position

BR/BN

X13

125mA

X12

Initiator Farhebel"0 proximity switch travel lever "0"−position

Position (Bremse ein)

geöffnet in 0

F25:2

FUEL

B06:1

86

20

Motoröldruck

X1:156

15/54

Öltemperatur

X1

3

B03

Sensor

F24:2

Luftfilter

29A

Hydraulikölfilter

X1:31A

5 4 3 2 1

201918 1716151413 121110

Sammelanzeige monitoring module A15 3:15

Bremse

X1

5:9

10A

2

9 8 7 6

1

K61/85

10A

F24

D+

29E 1

F25

D+

X1

Zentralstecker Sammelanzeige (Ansicht von hinten) mainplug monitoring module (view from backside)

Tankanzeige

3:20

3

3

_t

P 4

4

B30

2

X21:1 B06

1

4

B124

B55

+

Q

P

−

2

X1 X1:117

X21:2

57

X1:117 31 5:1

3:20 31 4:3

2:11

4:8

2:18 nicht bei BW177 D−4 not at BW177 D−4

Magnetventil Bremse solenoid valve brake

Rückfahrwarnsummer buzzer back up alarm

Warnsummer Störung buzzer failure

Tankgeber sender fuel

Resist. buzzer

01.03.2004 Seis 01.03.2004 Werner

Bremse, Rückfahrwarneinr., Anzeige brake, back up alarm, indicator

Luftfilter Sensor Wasserabschei Motoröldruck air cleaner engine oil pressure sens. water separator Hydraulikölfilter Kühlmittelstand Öltemperatur hydraulik oil cleaner oil temperature coolant stock level

1

1

582 700 96 004

4:20

K11/87

K11/87 7:1 X1:32E

2

4:3

K48/87

2:20

F14:2

Standard D−Maschinen Standard D−maschines

1

12

13

14

30

56

4:8 K04

31

S 4

13

S42

1234

6

9

11

X1:158

X1:157

56b

5

S42

X11 B

88

23

X14

1

2

2

2

X1:124

X1:124

X1:124

X1:116 X6

31

1

X11 A

X1:115 X7

2

Y07

3.33A

1.23A

1.23A

Y31

6:2

KA MESX 6:2

1 Y08

8:6

1

GA MESX

GA

Y30

1

X1:141

14 X1:160

8:7

1.23A

X1:142

24 X1:161

KA

Y31

V03 1 2

X1:149

X1:141

1

V05

X7

X6 2

2

X1:118

V02 2

4 1

2

SITZWARN. 4:10

Sitzkontaktschalter switch seat−contact

X1:143

X1:162

X1:154

X1:144

13

S35 13

3

S58

4:19

Taster Vibration pushbutton vibration

A68/3

X1:143

X1:159

1 14

S13

X1:149

X1

3.33A

X14

1

S01:21 2:20 K26/87A 4:8

1 5 7 3 Fahrstufensch. switch speed ranges

X1:149

14

V09

4:20

15

2

2

Schalter Fahrstufen switch speed ranges

Sitzschalter/Vibration A68 Modul module seatswitch/vibration

Modul Vibration modul vibration nur bei Maschinen ohne Kabine/ROPS only maschines with cabin/ROPS

nur BW177D−4 only BW177D−4

1

X1:32A

D+

F25:2

F03 15A

B06:1

Öldruck

4:17

D+

Fahren

4:13

31 6:1

Schalter Vibration klein/groß switch vibration small/big ampl.

Stufenumsch. hinten switching axle

Vibration vorne groß vibration big ampl.

Vibration vorne klein vibration small ampl.

Stufenumschaltung hinten switching axle Stufenumschaltung vorn switching drum

01.03.2004 Seis 01.03.2004 Seis

TS021

Fahrstufen, Sitzkontaktsch., Vibration speed−ranges, seat−switch, vibr.

1

1

582 700 96 005

Beschleunigungssensoren acc. sensor front

Beschleunigungssensoren acc. sensor rear

Drucker printer

Display Messtechnik BOP display measurem. BOP

X1:34A 2:20

GND

30

30 7:1

Pot 30

X2:57 X48:3

X48:4

X49:3

X49:4

X2:54

X2:55

X2:58

X2:59

CAN−

P11 1

1 R20 2

2

3:16 3:16 3:18 4:5 2:6 7:4 5:20

X44:33

X44:53

X44:3 X1:85

X44:26

CAN1−

2

CAN1+

R21

X44:27

X44:5

X44:4 X44:68

X44:67

X44:66

X44:65

X44:55

1

TxD

RxD

AGND MESX

X44:1

Aufn. hinten 20g

X44:7

Aufn. hinten 15g

X44:30

Aufn. vorne 20g

X44:31 X44:41

X44:37

X44:36

X44:32

X44:38

X44:29

Elektronik

X44:60 X44:35

X44:14

X44:59

X44:54

X44:58

X44:15

X44:57

X2:51

X2:65

EVIB

KA MESX SPEED MESX DIR MESX

X2:64

GND

GA MESX

5:17

X44:38

Leistung

X44:56

Pot. 15

X44:28 5:17

Aufn. vorne 15g

X2:50

A83 Messtechnik−Rechner measurement calc. unit

CAN3+

1 R242

CAN3−

X2:61

1 R252

X2:62

+

X2:60

PITCH MESX

P07 E VIB

BRAKE MESX D+ MESX

− X2:63

X2:66

P15

X1:82

BEL MESX 31

X2:63

01.03.2004 Seis 01.03.2004 Werner

TS021

ZA Messtechnik option measurement equipm.

X2:49

P33

nur beit BTM+/BTM prof only at BTM+/BTM prof

CAN+

F2

X42:3

F1

X42:8

4 X2:70

5 X2:66

15g/bl

20g/br

15g/bl

3 X2:71

B62 −/gg

nur bei BTM prof only at BTM prof

B62 −/gg

+/sw

P16

X42:5

X49:1

X42:2

X2:57

X49:2

X42:7

X2:60

X48:1

X42:6

X2:53

X42:1

X2:56 X48:2

2

X1:35A

X1:32A

− nur bei BEM only at BEM

15A

2

20g/br

10A

+ 1

F146

+/sw

F148

1

X42:4

X1:35E

X1:32E

X2:47

Pot 15

X2:48

7:20

K11/87

EVIB−Meter EVIB−meter

BCM 05 BCM 05

nur bei BEM only at BEM

nur bei BCM only at BCM

1

1

31 7:1

582 700 96 006

K11/87 6:19 30 X1:18E

K11/87 6:2 30

5:20

10A

X1:18A

X1:2

K06 7:4

X1:26A X1:83

87

Schalter StvZO switch, StvZO 31

012

11

S15

X1:25A X1:305

13

X1:22E 5

F22

X1:23E

X1:24E

F09

F10

15A

15A

4

F19

15A

15A

X1:21A E

X1:22A

X3:4

X3:5

23 Schalter Blinker switch indicator

L0R

S37

Anschluß Arbeitsscheinwerfer D bei Kabine Connection head lights with cabin STV1 8:17 STV2 8:17

30

14

24

49L

49R

L

R

A02 31 82

X1:24A

4:11

2

2

14

24 BL−W 4:19

X61:1 X1:322

2

Warnblinkschalter switch, hazard light

E08 1

E09 1

E10 1

E11 1

2

2

2

2

X1:314

2

23

X59:2

E25 1

13 01

X60:1 X1:321

E23 1

01 S14

X1:313

Arbeitsscheinwerfer vorne rechts working head lights, front rh.

E28 1

BL−R

X1:308

Arbeitsscheinwerfer vorne links working head lights, front lh.

E27 1

X1:91

BL−L

X1:96

X1:304

Arbeitsscheinwerfer hinten rechts working head lights, rear rh.

E13 1 E12 1 E14 1 E15 1

Arbeitsscheinwerfer hinten links working head lights, rear lh.

X1:303 0,125A

X1:312 X59:3

X61:3 X1:320

X1:311

6:2 BEL MESX

0,125A

X59:5

X1:84

X58:3

S53 14

E16 1 E17 1

4:19 4:19

BEL

X1:319

13

X58:2

X1:23A

X60:3

X1:310

87a

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

Schalter Arbeitsbele switch, working head lights

7:9

X58:5 X1:309

15A

X1:19A

87a

X1:21E

24

K16 30 87

F08

15A

L0R

X1:302

12

X1:25E

F07

Anschluß Arbeitsschein− werfer ohne StvZO

23

connection working head lights without StvZO 32

30

X1:19E

X1:306

15A

X1:301

F18

X1:307

X1:26E

F11

X61:2

X59:6

−

X60:2

H06 X58:6

4,6A

86

4,6A

K16

4,6A

2

31 7:10

Schlußleuchte links tail light, LH Parkleuchte links parking light, LH Parkleuchte rechts parking light, RH

Scheinwerfer links head light LH Scheinwerfer rechts head light RH

7:2

Connection head lights acc.to ROPS/SD

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 01.03.2004 Seis 01.03.2004 Werner

8:1

31

Bel. Warnbinkschalter illumination, switch hazard light Anschluß Arbeitsscheinwerfer bei ROPS/SD Aufbau

1,75A

X1:324

1,75A

X1:316

1,75A

X1:323

X3:1

1,75A

X1:315

85 0,42A

X1:324 X61:4

X1:316 X59:6

2

0,42A

X1:315 X58:6

2

0,42A

85

2

0,42A

86 X1:323 X60:4

X1:316 X59:6

K06

4,6A

X1:315 X58:6

4,6A

6:20

2

4,6A

+ 2

ZA Beleuchtung und StvZO opt. illumination and StvZO

1

1

582 700 96 007

X3:6

2:11 K30

2:11

K32:87

9:2

E

F

X3:7 K32

X3:8

30 7:13 7:13

8:1 87 F143 15A

G

10A

STV1

87a

H

F42

7

STV2

A

F43 15A

8

B

F44 15A

1

C

F130 10A

2

F42 9:8 F130 8:14

F41 10A

3

F130

8:9

F144 15A

6

5 F130 9:7

0,83A

S163 5 1

4,6A

4,6A

1 E28

1 E23

1 E25

1

2

2

2

2

XS 12V

+ −

Steckdose socket

E27

4,6A

C4

1

4,6A

3

5

2

3,8A

Nachtleuchte night illumination

X3:18 5

S38

4

X56:1

B4

A5+A6 1

3

3 5

+ M

M05

M

+ M04

M − M06

X56:2

15

E32

K141

M

− M07

X55:2

I

S158

4

31

+

5A

4 A51 2

5:17

5

X56:3

2

X55:1

7,8,9

P09

1 E72

3 min

− 85

S20

3,8A

B3

X55:3

1

X3:16

K32

1

E70

Abfallverzögert

+

4

2,9A

S86

−

A1

5:16

TK

A2+A3 6

X55:4

X3:17 4 3:16 SPEED TAC A16 Schalter Innenleuche switches interior lights

S45

5

Tachographenmodul module, tachograph

A01

2

2 S21

Radio radio

+

01W 7 01

− − 31

Innenleuchte inside light, cabin

Heizung Heckscheibe heating rear screen

2

Kontrolleuchte indicator

E71 1

2

4,7A

− −

2

2

X3:3

01W 7 01

D−Typ

87a

R80

86

15 + + B51

E29

2:20 1

30

X56:4

B51 + +

1

X3:15 KA

8:16 87

K32:86

30

GA

K141

1,75A

A12

− ZA option 9:18 KABINE 31

Frequenzmodul module, frequency

Schalter Nachtleuchte switch, night illumination

Tachograph tachograph

7:20

X3:2

Türkontaktschalter door switch

X3:1

Relais Kabine relais cabin

Schalterbel. switch illum.

31

31 9:1

8:6

Wascher hinten washer rear Wischer hinten windscreen wiper, rear

01.03.2004 Seis 01.03.2004 Werner

Wascher vorn washer front Wischer vorne windscreen wiper, rear

ZA Kabine, Beleuchtung, Radio, Tachograph opt. cabin, headlights, radio, tachograph

Arbeitsscheinwerfer vorn working head lights, front

8:2

Arbeitsscheinwerfer hinten working head lights, rear

1

Rundumkennleuchte rotary beacon

1

582 700 96 008

8:17 F130 F42 Potential 15 aus Kabine 8:9

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

X54:12

K09

5 1

0123

Regel aus = 0,4A

X54:1

E30 Zusatzheizung add. heater

ge

rt

M04

M br

X18:1

X1:169 X19:1

B131

B103

1

S28

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

6 2 1 3

2

X19:2 X20:1

or

X20:2 Y15

1

Kabinenlüfter cab ventilator

01.03.2004 Seis 01.03.2004 Werner

6

8

7

4

15

2

X18:2

Y138 1

1

8:19

Y14

V06 2

KABINE 31 2

2 X1:168

V04 3,5A

5

1

_t

HP

10 9

1A

_t

X17:4 X1:164

X1:167

Thermofühler Heizung temperature sensor heating unit

87a

X20:4

or

br

31

2

X3:14

87

X1:170

8:20

12 11 13 14 16

30

X20:3 Überwachung Kühlmitt monitoring coolant pressure

Thermofühler Klimaan temperature sensor air conditioning

X53:H X3:12

X3:11

M

1

2:8

B104 P LP 3

M09

3

Power Stufe = 2,8A

4

rt

2

A

Anlaufstrom beim Start = 8,3A

X17:3 X1:166

X17:2 X1:165

X17:1 X1:163

X3:9

X3:10

X53:L

X53:M

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

8:19 K32:87 Potential 15 aus Kabine

2

1 31

Klimakompressor air conditioning compr.

Magnetventil Heizung solenoid valve, heating unit

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

Kraftstoffpumpe fuel pump heating unit

1

1

582 700 96 009

Name

01.03.2004 Seis 01.03.2004 Werner

Bauteilliste component listing 1 6 101

582 700 96

Bl. 007 008 003 004 008 008 005 009 006

Pf. 17 5 3 16 6 6 10 11 6

Benennung

title

A02 A12 A13 A15 A16 A51 A68 A72 A83

Blinkrelais Radio Steuergeraet Heizung Platine Ueberwachungsmodul Elektronik Tachograph Platine Frequenzanzeige Modul Sitzkontakt Steuergeraet Klimaanlage, Heizung Elektronik Messtechnik

indicator relay Radio Control unit, heating Printed circuit board, monitoring module Electronic system, tachograph Circuit board,frequenzy meter Modul seat contact Control unit,air conditioning,heating electronic measurement−equipment

TYP

B03 B06 B11 B11 B13 B14 B21 B30 B51 B51 B55 B57 B60 B61 B62 B62 B103 B104 B113 B124 B131

004 004 003 003 004 004 004 004 008 008 004 003 003 006 006 006 009 009 003 004 009

15 17 9 11 2 6 14 16 4 6 17 15 14 12 8 10 7 7 3 19 10

Unterdruckschalter Luftfilter Druckschalter Motoroel Signalhorn Signalhorn Naeherungsinitiator Fahrhebel links Naeherungsinitiator Fahrhebel rechts Differenzdruckschalter Hydr.−Oelfilter Temperaturschalter Motoroel Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Neigungssensor Stufenumschaltung Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Temperaturschalter Klimaanlage Druckschalter Klimaanlage EMR Temperaturgeber Kuehlmittel Geber Wasserstandsabscheider Diesel Temperaturschalter Heizung

Vacuum switch, air cleaner Pressure switch, engine oil Warning horn Warning horn Proximity switch, travel lever, lh.

Proximity switch, travel lever, rh.

Pressure diff. switch, hydr. oil filter Temperature switch, engine oil Speaker radio Speaker radio Coolant charge expansion tank Slope sensor, speed range selection Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Temperature switch, air conditioning Pressure switch, air conditioning EMR Temperature switch, collant Sender, water separator fuel Temperature switch, heating

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

007 007 007 007 007 007 007 007 007 007 007 008 007 008 007 008 007 008 008 009 008 008 008 008

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 F03 F07 F08 F09 F10 F11 F13 F14 F15 F18 F19 F22 F23 F24 F25 F31 F39 F40 F41 F42 F43 F44 F48 FM4 F105 F130 F143 F144 F146 F148

002 005 007 007 007 007 007 002 002 009 007 007 007 003 004 004 009 002 009 008 008 008 008 002 006 002 008 008 008 006 006

4 18 15 18 6 8 2 10 18 18 5 12 10 9 10 2 3 19 13 19 3 10 13 3 11 16 15 2 20 4 2

Hauptsicherung Batterie Sicherung Vibration Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw.

Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Hubmagnet Motor Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li.

Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Magnetv. Fahren u. Bremse Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Platinensicherung Sicherung Motordrehzahl Sicherung Nachtleuchte Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15)

Fuse, main, battery Fuse, vibration 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, shut off solenoid, engine 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, sol. valve, travel and brake 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 Multifuse Fuse, motor speed Fuse, night lamp fuse rear screen heating unit Fuse cabin−socket Fuse Controller (Pot. 30) Fuse Controller (Pot. 15)

125A MAX. 1,23A 15A 15A 10A 10A 15A 30A 15A

G01 G02 G03

002 3 002 5 002 4

Batterie Generator Batterie

Battery Generator Battery

103A

H06 H07 H14

007 15 004 10 004 8

Meldeleuchte Warnblinker Warnsummer Betriebsstoerung Warnsummer Rueckwaertsfahrt

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

MAX. 0,12A MAX. 0,12A

K04 K05

005 18 004 3

Schrittrelais Vibration Relais Startstrom

Toggle relay, vibration Relay, starting current

MAX. 1,23A BOSCHW

MAX. 0,12A

MAX.5A MAX.5A

5A 0,83A 1,75A

30A 30A 30A 10A 10A 10A 15A

125A 20A

103A

Name

01.03.2004 Seis 01.03.2004 Werner

Bauteilliste component listing 2 6 102

582 700 96

Bl. 007 002 002 003 007 004 004 008 002 002 004 002 002 008

Pf. 4 8 10 5 9 9 6 1 16 7 2 5 14 16

Benennung

title

TYP

K06 K09 K11 K14 K16 K22 K26 K32 K35 K36 K48 K61 K114 K141

Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Vorgluehen Relais Scheinwerfer vorne Relais Hubmagnet Motor Relais Rueckfahrwarneinrichtung Relais Kabine Relais Selbsthaltung Relais Bremskontrolle Relais Fahrhebel 0−Stellung Relais Ladekontrolle Relais Motordrehzahl Relais Heckscheibenheizung

Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, glow plug system Relay, head lights, front Relay, shut off solenoid, engine Relay, back up alarm Relay, cabin Relay, holding contact Relay, brake control Relay, travel lever 0−position Relay, charge control Relay, engine rpm relay, heating rear screen

BOSCHW BOSCHW BOSCHW BOSCHL BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW

M01 M04 M04 M05 M06 M07 M09

002 008 009 008 008 008 009

11 12 4 10 13 11 3

Starter Scheibenwischermotor vorne Scheibenwischermotor vorne Scheibenwischermotor hinten Scheibenwaschermotor vorne Scheibenwaschermotor hinten Kabinenluefter

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

2.3 KW 4,7A

P07 P09 P11 P15 P16 P33

006 008 006 006 006 006

15 8 14 17 16 18

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

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

R03 R10 R19 R20 R21 R24 R25 R80

004 002 002 006 006 006 006 008

12 6 2 17 17 17 17 2

Geber Tankanzeige Parallelwiderstand Heizflansch Widerstand Widerstand Widerstand Widerstand Heizung Heckscheibe

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

S00 S01 S03 S13 S14 S15 S20 S21 S28 S30 S35 S37 S38 S42 S42 S44 S45 S53 S58 S86 S120 S158 S163

002 002 003 005 007 007 008 008 009 002 005 007 008 005 005 009 008 007 005 008 002 008 008

10 18 9 13 15 4 13 10 18 3 15 18 19 3 6 3 3 4 13 3 14 15 16

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

Starter switch Switch, emergency off Push button, warning horn Switch, vibration, travel lever, rh.

Switch, hazard light Switch, lighting StVZO Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, cabin heating Switch, battery disconnect Switch, vibration low/high Switch, indicator Switch, warning light Speed range selector, fast−slow Speed range selector, fast−slow Switch, cabin ventilator Switch, cabin inside light Switch, working lights Push button, ether starting unit Switch door, lh.

Switch, engine speed Switch, cabin night lamp switch rear screen heating unit

V01 V02 V03 V04 V05 V06 V09 V21 V22 V47

002 005 005 009 005 009 005 003 003 002

6 6 7 8 10 9 10 10 11 15

Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode (A7)

Diode Diode Diode Diode Diode Diode Diode Diode Diode Diode (A7)

X1:1 X1:2 X1:3 X1:4 X1:4 X1:7 X1:8 X1:9 X1:10 X1:42 X1:52 X1:53 X1:54 X1:55 X1:55 X1:56 X1:57 X1:57 X1:58 X1:59 X1:60 X1:61 X1:62 X1:63 X1:64

002 007 002 002 002 002 002 002 002 003 003 003 002 002 002 002 003 004 002 002 002 004 002 002 003

5 10 9 10 13 11 11 4 4 14 2 3 18 10 18 15 3 15 16 16 16 15 16 16 3

WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten

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

2,9A MAX. 3,8A MAX. 3,8A

82 OHM 167A 120OHM 120OHM 120OHM 120OHM

4UF004 MAX. 1,23A MAX. 1,23A FE5B MAX. 0,12A MAX. 0,12A

FE5B

Name

01.03.2004 Seis 01.03.2004 Werner

Bauteilliste component listing 3 6 103

582 700 96

X1:65 X1:67 X1:68 X1:69 X1:71 X1:72 X1:73 X1:74 X1:75 X1:76 X1:77 X1:78 X1:79 X1:80 X1:81 X1:82 X1:82 X1:83 X1:84 X1:85 X1:86 X1:87 X1:88 X1:89 X1:90 X1:91 X1:96 X1:97 X1:98 X1:99 X1:100 X1:101 X1:102 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 X1:124 X1:124 X1:124 X1:129 X1:141 X1:141 X1:142 X1:143 X1:143 X1:144 X1:147 X1:148 X1:149 X1:149 X1:149 X1:149 X1:150 X1:151 X1:152 X1:153 X1:154 X1:155 X1:156 X1:157 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 X1:170 X1:171 X1:172 X1:173 X1:174 X1:178 X1:17A X1:17E X1:18A X1:18E

Bl. 002 004 004 004 004 004 004 004 003 004 004 003 002 002 002 004 006 007 007 006 004 004 005 004 004 007 007 003 003 003 003 003 003 004 004 004 004 004 004 004 004 004 004 005 005 004 004 004 004 005 005 005 005 004 005 005 005 005 005 005 004 004 004 005 005 005 004 002 002 004 005 003 004 005 005 005 002 002 005 005 005 009 009 009 009 009 002 009 009 009 003 003 003 003 003 002 002 007 007

Pf. 5 15 17 13 15 17 17 16 4 17 16 4 10 14 14 11 15 5 4 15 10 13 11 10 9 17 17 9 10 10 11 9 10 12 14 19 20 12 14 19 20 5 8 16 14 5 8 12 14 14 3 5 7 6 3 7 5 3 7 5 5 2 1 12 13 19 5 18 18 6 13 9 2 13 13 16 10 10 16 14 6 3 5 3 4 10 8 10 7 7 14 15 15 14 18 16 16 2 2

Benennung

title

WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−KASTEN WAGO,E−KASTEN WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten 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

01.03.2004 Seis 01.03.2004 Werner

Bauteilliste component listing 4 6 104

582 700 96

X1:19A X1:19E 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 X1:308 X1:309 X1:30A X1:30E X1:310 X1:311 X1:312 X1:313 X1:314 X1:315 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 X1:32A X1:32E X1:32E 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 X2:71 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

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

Pf. 15 15 10 10 12 12 6 6 8 8 18 18 5 5 18 18 9 9 2 2 5 5 9 15 18 18 18 15 2 19 19 2 7 7 17 19 2 7 17 2 7 19 6 10 10 8 18 19 6 18 8 19 18 2 18 2 4 4 18 18 19 17 18 8 7 8 7 3 10 9 10 9 13 17 18 13 18 14 14 14 14 11 12 12 15 14 11 11 10 10 11 11 11 10 10 1 10 12 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,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO,E−Kasten WAGO 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−Kasten WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO,E−Kasten WAGO ZENTRALELEKTRIK WAGO,E−Kasten 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 STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER ROPS/SD STECKER ROPS/SD STECKER KABINE/ROPS

WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO,E−BOX WAGO,E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO 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. conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. ROPS/SR conn. ROPS/SR conn. cabin/ROPS

TYP

Name

01.03.2004 Seis 01.03.2004 Werner

Bauteilliste component listing 5 6 105

582 700 96

X3:7 X3:8 X3:9 X3:10 X3:11 X3:12 X3:13 X3:14 X3:15 X3:16 X3:17 X3:18 X6:1 X6:2 X7:1 X7:2 X8:1 X8:2 X9:1 X9:2 XS X10:2 X10:3 X11:1 X11:2 X12:1 X12:2 X12:3 X13:1 X13:2 X13:3 X14:A X14:B 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 X36:A X36:B X37:A X37:B X38:A X42:1 X42:2 X42:3 X42:4 X42:5 X42:6 X42:7 X42:8 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 X44:38 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

Bl. 008 008 009 009 009 009 009 009 008 008 008 008 005 005 005 005 004 004 004 004 008 004 004 005 005 004 004 004 004 004 004 005 005 009 009 009 009 009 009 009 009 009 009 009 009 004 004 002 002 002 002 002 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006

Pf. 2 2 3 3 4 4 7 10 7 6 6 6 14 14 16 16 19 20 8 8 20 12 12 13 13 2 2 1 6 6 6 13 13 3 3 4 5 10 10 7 7 7 7 7 7 17 17 4 4 10 11 11 18 18 19 18 19 18 19 19 13 15 14 14 10 12 5 5 11 18 17 3 7 9 8 6 18 5 6 7 4 7 7 11 10 17 5 13 4 4 4 5 5 13 13 14 14 11 12

Benennung

title

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 STECKER KABINE/ROPS DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH Steckdose AMP SUPERSEAL AMP SUPERSEAL DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH DEUTSCH 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 EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOß E−KAST ST. ZÜNDSCHLOSS E−KAS ST.STARTER E−KASTEN STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 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 MESX STECKER STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER

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 conn. cabin/ROPS DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector Socket AMP connector AMP connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector DEUTSCH connector 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 supply e−box supply e−box connector ignition switch connector ignition switch, e−box connector starter e−box conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21 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 MESX Stecker conn. sender PLEIGER conn. sender PLEIGER

TYP

Name

01.03.2004 Seis 01.03.2004 Werner

Bauteilliste component listing

Bl. 006 006 006 006 006 006 006 006 006 009 009 009 009 009 009 009 009 009 009 009 009 008 008 008 008 008 008 008 008 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007

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

Benennung

title

X47:C X48:1 X48:2 X48:3 X48:4 X49:1 X49:2 X49:3 X49:4 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 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

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 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 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

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. 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 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

Y01 Y04 Y07 Y08 Y14 Y15 Y30 Y31 Y31 Y58 Y120 Y138 Y140 Y141

002 004 005 005 009 009 005 005 005 002 002 009 006 006

12 5 14 16 14 7 5 3 7 18 16 10 10 11

Magnetventil Startmehrmenge Magnetventil Bremse Magnetventil Vibration vorne gross Magnetventil Vibration vorne klein Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Stufenumschaltung hinten Magnetventil Kraftstoffabschaltung Magnetventil Motordrehzahl hoch Magnetveentil Heizung Magnetventil Erreger auf Magnetventil Erreger ab

Solenoid valve, start boost fuel Solenoid valve, brake Solenoid valve, vibration, front, high Solenoid valve, vibration, front, low Fuel pump, heating unit Magnetic clutch, air conditioning compr.

Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, speed range sel., rear Solenoid valve, fuel switch off Solenoid valve, rpm engine high Solenoid valve, heating unit solenoid valve exciter up solenoid valve exciter down

TYP

MAX. 3.9A MAX. 1,8A MAX. 2,5A MAX. 2,5A 3,5A MAX. 1,67A MAX. 1,23A MAX. 1,23A MAX. 3.8A 3,5A

6 6 106

582 700 96

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume D 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.

02.03.2004 11:33:11

Seite 5

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume D 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.

02.03.2004 11:33:11

Seite 6

WAGO smart DESIGNER 4.0 1

249-116

2

280-315

3

4 x 280-833 "L" + 793-501

7

282-328

8

4 x 282-901 "L" + 793-501

9

282-422

12

282-422

14

282-422

15

19 x 282-696 "R" + 793-501

16

282-422

18

282-422

20

282-422

22

282-422

25

282-422

28

282-422

31

282-422

33

282-422

35

282-422

37

282-422

39

282-422

41

282-422

43

282-422

45

282-422

48

282-333

49

249-116

Optional1 :

Projektgruppe :

Walzenzüge-4 Klemmenleisten

Optional2 :

Projekt : Zeichnung : Plan : Ort : Betriebsmittel :

Zeichnungsnummer : Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft :

Absicherung D-4 Version

Lieferadresse: :

Optional3 : Optional4 : Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten.

01.03.2004 17:18:16

Seite 1

X36

X37

X38

X1:51 … X1:178

X1:1 … X1:34

Nur bei StvzO only acc. To StvZO illumination

R10

A02

K11

K05

K16

K06

K36

K22

K09

K26 K35 K48

A68

K61 K114

Gez.: 01.03.2004 Name: Seis Gepr.: 01.03.2004 Name: Werner

Übersicht Schaltkasten BW 177...216 D-4

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von: 2

page: 1

from: 2

overview e-box BW 177...216 D-4

Ers. f.:

Blatt Nr.: 201

Replaces:

Sheet No.: 201

582 700 96

X2:47 … X2:78

LCD + Datensammler + OPUS 21

CAN 1 A83 Messtechnik Steuerung

CAN 3

Gez.: 01.03.2004 Name: Seis Gepr.: 01.03.2004 Name: Werner

BCM

Übersicht Schaltkasten-Tür BW 177...216 D-4

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von: 2

page: 2

from: 2

overview e-box door BW 177...216 D-4

Ers. f.:

Blatt Nr.: 201

Replaces:

Sheet No.: 201

582 700 96

X55

X56

X53 X54

X5

X21

X11 X12 X13

X59 X42

X58

X20

X14

X18 X19

X17

X6 X7

X4 X3

X48 X49

X8 X10

X36 X37 X1

X60 X61

X38 X2

X9

X44 X34

X61 X9 X21 X59

X8 X10

X42 X11 X12 X55 X5

X13 X53 X18 X19

X20 X14

X17

X56

X6 X7

X54

X58

X4 X3 X36

X1

X37 X44 X2 X38

X34

X60

X48 X49

Gez.: 01.03.2004 Name: Seis Gepr.: 01.03.2004 Name: Werner

Steckerübersicht BW 177...226 DH/BVC-4

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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 96