A WIRTGEN GROUP COMPANY
MSC M3 H176 • 3516 - 3520 H177 • 3625 H180 • 3412 - 3414 Module 3 • Machine Technology Training Order no.: 2582514 www.hamm.eu/ctt
A WIRTGEN GROUP COMPANY
IMPRESSUM / LEGAL NOTICE Herausgeber / Publisher Hamm AG Hammstraße 1 95643 Tirschenreuth info@hamm.eu www.hamm.eu Fon: +49 9631 80-0 Fax: +49 9631 80-111 Weitergabe sowie Vervielfältigung dieses Dokumentes, Verwertung und Mitteilung seines Inhaltes sind verboten, soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten zu Schadensersatz. Alle Rechte für den Fall der Patent-, Gebrauchsmuster- oder Geschmacksmustereintragung vorbehalten. The disclosure as well as the duplication of this document, the use and the forwarding of its contents, are forbidden as far as not expressively permitted. Violations will cause indemnities. With respect to patent, utility sample or design patent registration all rights reserved. Copyright © HAMM AG 2017
www.hamm.eu/ctt
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
CHAPTER OVERVIEW OVERVIEW
4
OPERATOR´S STAND
11
ENGINE
26
FUEL SYSTEM
41
AIR FILTER SYSTEM
49
EXHAUST SYSTEM
50
COOLING
53
TILT HYDRAULIC HOOD
66
HYDRAULICS
70
ELECTRICS
99
STEERING
129
ROLLER DRUM
133
SPECIAL EQUIPMENT
145
DIAGNOSIS
170
OVERVIEW
CABIN
ENGINE
HYDRAULICS ELECTRICS
DRIVE
STEERING
DRUM
OPTIONS
DIAGNOSIS
3
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
OVERVIEW
OVERVIEW
4
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Type overview and designations
3520E HT P 3520E 3520E 3520E 3520E HT P VIO VC
OVERVIEW
Series 3000 Type/Series Weight in tonnes Extended HAMMTRONIC Padfoot Vibration / oscillation drum Vibration Crusher
5
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Module 3 – Machine technology
Type overview Series
H176
Types Standard
Hammtronic
3516 • 3516 P
3516 HT • 3516 HT P
3518 • 3518 P
3518 HT • 3518 HT P
3520 • 3520 P
3520 HT • 3520 HT P
3520E • 3520E P
3520E HT • 3520E HT P
H177 H180
OVERVIEW
3625 HT • 3625 HT VC • 3625 HT P 3412 • 3412 P • 3412 VIO
3412 HT • 3412 HT P • 3412 HT VIO
3414 • 3414 P • 3414 VIO
3414 HT • 3414 HT P • 3414 HT VIO
6
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Module 3 – Machine technology
Technical data / Example H180 3412 HT Weight Operating weight with cab Axle load front / rear Wheel load per tyre Static linear load, front Machine dimensions Max. Working width Lateral overhang left/right Curb clearance left/right Ground clearance, centre Turning radius, inside/outside Diesel engine Manufacturer Cylinder Power, ISO 14396 Exhaust emission standard Transmission Speed Climbing ability, vibration on / off Permissible longitudinal tilt / lateral inclination Vibration Stage 1 Frequency/ Speed - VPM Stage 1 max. amplitude Stage 2 Frequency/ Speed - VPM Stage 2 max. amplitude OVERVIEW
kg kg kg kg/cm
12200 6705/5495 2747.5 31.3
mm mm mm mm mm
2140 55/55 465/465 375 3690/5830
kw/PS/rpm
Technical data of specific machine types See operating manual / Chapter 5.01 “Technical data”
Deutz 4 100.0 / 136.0 / 2300 EU Stage IIIA / EPA TIER3
km/h/mph % °
0-14.0/0-8.7 58/63 30/30
Hz/rpm mm / inch Hz/rpm mm / inch
30/1800 1.91 / 0,075 40/2400 0.90 / 0,035
7
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Machine – left side 1
9
OVERVIEW
2
8
3
7
4
5
6
1
Drum
2
Operator's cab
3
Air conditioner, tropical / option
4
Engine
5
Engine hood
6
Wheel
7
Fuel filler neck
8
Hydraulic tank [Item 13 hyd.
9
Vibro motor [Item 7 hyd.
diagram] diagram]
8
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Machine – left side
7
OVERVIEW
6
5
4
3
2
1
1
Drum drive motor [Item 5+6
2
Articulated joint
3
Battery compartment, lockable
4
Series number
5
Central electrical system and manual pump, engine hood
6
Axle with drive motor [Item 4
7
Cooling unit
hyd. diagram]
hyd. diagram]
9
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Module 3 – Machine technology
10
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Module 3 – Machine technology
OPERATOR´S STAND
CABIN
11
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Module 3 – Machine technology
Control stand
1
2
1
Beverage holder
2
Rotating beacon H40
3
Circulating air filter
4
Engine speed B2
5
Seat adjustment forward backward
Circuit diagram B2 3 4
CABIN
5
12
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Module 3 – Machine technology
Control stand 1 2 3
1
Armrest adjustment slope
2
Armrest adjustment height
3
Drive lever on both sides with:
4
• •
5 6 7 8 9
CABIN
Vibration pushbutton A6+A7 Dozer blade button A6.1+A7.1 / Option
4
Seat belt
5
EMERGENCY STOP switch S7
6
Seat backrest slope adjustment
7
Seat rotation adjustment
8
Seat adjustment, console leftright
9
Seat adjustment, weight
13
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Control stand - operating elements 1
2
3 CABIN
4
5
1
Display A1
2
Switch preselection, final speed S9
3
Frequency regulation switch S6
4
Amplitude switch S11
5
Switch vibration mode manual-automatic S13 / Option
6
Flashing lights / lighting steering column switch S4
6 14
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Module 3 – Machine technology
Control stand - operating elements 1 2
3 CABIN
4
5
6
7
1
Push-button, parking brake check S14
2
Warning buzzer H2
3
Ignition switch S2
4
Warning flasher switch S5
5
Socket 12 V X4
6
Horn S3
7
Switch, engine management manual - automatic S8
8
Mode system switch S10 Query of diagnostic codes
8 15
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Module 3 – Machine technology
Display - Overview Normal operation Driving mode Vibration drive Signal lamps Error code
CABIN
16
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Module 3 – Machine technology
Display - Normal operation 1
2
1
Hourmeter indicator
2
Fuel level pilot light
3
Engine speedometer
3
2 CABIN
17
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Module 3 – Machine technology
Display - Driving control unit 1
2
3
4
1
Working light pilot light, rear
2
Working light pilot light, front
3
Warning flasher pilot light
4
Flashing indicator pilot light
5
Driving speed indicator
/ Hammtronic or Option
5
CABIN
18
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Module 3 – Machine technology
Display - Vibration control unit 1
2
1
Amplitude pilot light
2
Compaction indicator HMV
3
RMV indicator / jump operation
4
Vibration frequency indicator
Green large amplitude Yellow small amplitude
/ Hammtronic or Option
3 4
Additional instructions Verdana 16 CABIN
Continuous text Verdana 14
19
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Display - Signal lamps control unit 1
2
3
4
CABIN
5
6
1
Coolant level pilot light
2
Pilot light, water sump fuel prefilter
3
Oil pressure pilot light
4
Warning, notice, malfunction pilot light (engine)
5
Air filter pilot light
6
Pilot light, hydraulic oil filter
20
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Display - Signal lamps control unit 1
2
3
CABIN
4
5
6
7
1
Oil temperature pilot light, hydraulic system
2
Engine temperature pilot light
3
Parking brake pilot light
4
Function not exist
5
STOP pilot light
6
Charge current pilot light
7
Cold start assistance pilot light
21
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# 2582511
Control stand - cabin headlining 1
2
4
5
3
6
CABIN
7
8
1
Cab lighting E44
2
Air conditioning ventilation nozzles / Option
3
Air conditioning aspiration duct / Option
4
Button, windscreen washer system S45
5
Rotating beacon switch S46
6
Front windscreen wiper switch S40
7
Rear windscreen wiper switch S41
8
Front working lights switch S43
9
Rear working lights switch S44
9
22
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Control stand - cabin headlining 1
2
3
CABIN
4
5
6
7
8
9
1
Illumination for control devices, radio, tachograph / terminal 58
2
Cab lighting, tachograph / terminal 30
3
Working spotlight / terminal 15 / option
4
Windscreen washer system, beacon / terminal 15
5
Windscreen wiper / terminal 15
6
Radio / terminal 30 / option
7
Air conditioner / option
8
Air conditioner / option
9
Fan level air conditioning / option
23
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Module 3 – Machine technology
Control stand - cabin headlining and console 1 2 3 4
1
Slot for radio A40 / tachograph P1 / option
2
Loudspeaker B40+B41 / option
3
Relay slot / option
4
Sun shade
5
Cabin heating control unit S30 or Air conditioning control unit A30 / option a Fan b Temperature regulation
6
Stacker for first aid kit / documents such as instruction manual
7
Windscreen washer tank with pump M42
5 a
b 6 7 CABIN
24
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Module 3 – Machine technology
25
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Module 3 – Machine technology
ENGINE
ENGINE
26
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Module 3 – Machine technology
Drive unit Deutz TCD 2012
Deutz T C D 2012 L 04 / 06 No. of cylinders In-line engine Series Diesel engine Intercooler Exhaust turbocharger
ENGINE
Engine fulfills exhaust emission category: EU Stage IIIA / EPA TIER 3 27
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Engine compartment – left side / maintenance side 1
10
2
9
8
ENGINE
7
6
3
5
4
1
Air filter / pollution sensor S17
2
Coolant compensation tank with sensor B12
3
Cooling unit
4
Alternator G2
5
Engine oil filter and engine oil filler neck
6
Fuel filter
7
Oil level dip stick
8
Steering pump with relief valve (PRV)
9
Fuel prefilter B11
10
SEPAR water trap fuel / option
28
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Module 3 – Machine technology
Engine compartment - right side 1
2
8 ENGINE
3
7
4
6
1
Compressor, air conditioning system Y30
2
Starter M1
3
Ventilation filter fuel tank
4
Fresh air filter, operator's cab
5
Parking chock
6
A/C service unit connections
7
Brake release valve [Item 18
8
Main fuses
hyd. diagram]
5 29
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Module 3 – Machine technology
Lube oil system diagram
ENGINE
1
Lubricating oil pan
2
Lubricating oil pump
3
Relief valve
4
Lubricating oil cooler
5
Non-return valve
6
Bypass valve
7
Bypass valve
30
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Module 3 – Machine technology
Lube oil system diagram
ENGINE
8
Pressure control valve
9
Lubricating oil filter
10
Lubricating oil main channel
11
Piston cooling nozzle
12
Rocker lever
13
Internal exhaust gas recirculation
14
Exhaust turbocharger
31
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Module 3 – Machine technology
Electronic engine control, example Deutz
ENGINE
1
Fuel low-pressure sensor B51 / FCU valve Q19 (w/o illustration)
2
Coolant temperature sensor B43
3
Not installed
4
Sensor, charge air pressure, charge air temperature B48
5
Engine control unit EMR3EDC16 (E box)
6
Central plug for engine control unit A2X1+A2X2
32
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Module 3 – Machine technology
Electronic engine control, example Deutz
ENGINE
7
Crankshaft speed sensor B40.2
8
Fuel pressure sensor rail B49
9
Not installed
10
Engine oil pressure sensor B6
11
Not installed
12
Camshaft speed sensor B40.1
33
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Module 3 – Machine technology
Engine temperature sensor B43 Motor temperature transmitter
Cooling-water temperature [°C]
140
120
100
80
60
40
20
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
-20
-40
2.5 kOhm - 20°C 0.186 kOhm - 100°C
ENGINE
Voltage [mV]
34
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Module 3 – Machine technology
Combination sensor – charge air temperature / pressure B48 Charge air temperature [°C]
120 100 80 60 40 20 0 -20
0
500
1000
1500
1 = ground 2 = temperature voltage 3 = supply voltage 5 V 4 = charge pressure voltage
ENGINE
Charge pressure [bar]
-40
2000
2500
3000
3500
4000
4500
5000
3500
4000
4500
5000
Signal voltage [mV]
4,5 4 3,5 3 2,5 2 1,5 1 0,5 0
0
500
1000
1500
2000
2500
3000
Signal voltage [mV]
35
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Fuel low-pressure sensor B51 Fuel low-pressure sensor
8
Low pressure [bar]
7 6 5 4 3 2 1 0
0
500
1000
1500
2000
2500
3000
Voltage [mV]
3500
4000
4500
5000
Sensor mounting torque Ma = 25 ± 3 Nm
ENGINE
36
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Module 3 – Machine technology
Camshaft speed sensor B40.1
Resistance: pin 1 to 2 approx. 3.8kΩ
1 2 3
ENGINE
37
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Module 3 – Machine technology
Crankshaft speed sensor B40.2
321
Resistance: pin 1 to 2 approx. 1kΩ
ENGINE
38
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Module 3 – Machine technology
Engine oil pressure sensor B6
1
2
1
Pressure sensor measuring range: 0 bar = 0.5 V 10 bar = 4.5 V
2
Tightening torque: Ma = 40 + 5 Nm
3
Sealing ring
Engine oil pressure sensor
3
ENGINE
39
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Module 3 – Machine technology
40
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Module 3 – Machine technology
FUEL SYSTEM
ENGINE
41
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Engine compartment – fuel system 1
5
9
6
2
3 ENGINE
4
7
1
Ventilation filter, ventilation hose, fuel tank
2
Tank suction line – fuel prefilter
3
Fuel prefilter
4
Prefilter suction line – fuel pump
5
Fuel pump
6
Fuel pump pressure line – Fuel filter
7
Fuel filter
8
Filter pressure line - highpressure pump (FCU)
9
Engine return line - tank
8 42
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Engine compartment – Example fuel diagram TCD 2012
ENGINE
1
Fuel tank
2
Fuel prefilter
3
Fuel transfer pump
4
Spin-on fuel filter
5
Fuel line to fuel control unit (FCU)
6
FCU
7
High-pressure pumps
8
Rail
9
Injector
10
Fuel return line to the fuel tank
43
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Engine compartment – fuel prefilter 1
2
3
5
6
4
1
Output / to fuel pump
2
Input / from tank or SEPAR filter
3
Manual pump
4
Vent screw
5
Filter head
6
Filter cartridge
7
Water level sensor B11
8
Drain casing
9
Drain valve
8
7
9 ENGINE
44
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Engine compartment – fuel filter 4 5 2
3
1
Filter cartridge Ma=hand tight + ½ turn
2
Filter head
3
Vent screws Ma=25-5Nm
4
Fuel pump pressure line – fuel filter
5
Filter - engine pressure line
6
Gasket ring
1 6
ENGINE
45
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Engine compartment – SEPAR filter / option
7 6 1
2
1
Input / Fuel tank to SEPAR filter
2
Inspection glass
3
Water sump sensor connection / Order no. 2142353
4
Drain valve
5
Residues of water and dirt
6
Filter insert / Order no.
7
Outflow / SEPAR filter to the fuel
2147028 prefilter
3 5 4 ENGINE
46
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Module 3 – Machine technology
Engine compartment – fuel fill level sensor B1 Display - level indicator +12V power supply Refuelling pump release
Switch point at about 50 mm
GND
Tank full ENGINE
Tank empty 47
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Module 3 – Machine technology
48
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Module 3 – Machine technology
AIR FILTER SYSTEM
ENGINE
49
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Engine compartment – air filter 1
2
1
Air filter
2
Low pressure switch, air filter S17
3
Casing
4
Safety filter cartridge
5
Filter cartridge
6
Dust discharge valve Before maintenance work
Check and clean dust discharge valve
Δ p = 50mbar
6
3
5
4 ENGINE
3 50
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Exhaust system 4
1
Exhaust pipe
2
Insulation
3
Silencer
4
Tailpipe
1 2
3
ENGINE
51
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Module 3 – Machine technology
52
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Module 3 – Machine technology
COOLING
ENGINE
53
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Module 3 – Machine technology
Cooling pack 1
2
3
1
Hydraulic oil cooler
2
Intercooler
3
Water cooler
4
Emergency cooling sheet metal
4
ENGINE
54
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Module 3 – Machine technology
Coolant diagram Deutz TCD 2012 L06
ENGINE
1
Cooler
2
Coolant entry
3
Coolant pump
4
Coolant partial flow to the lubricating oil cooler
5
Lubricating oil cooler
6
Coolant inlet to the engine cooling
7
Cylinder pipe / head cooling
55
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Module 3 – Machine technology
Coolant diagram Deutz TCD 2012 L06
ENGINE
8
Connection option for cabin heating
9
Heat exchanger
10
Return line
11
Coolant return flow to thermostat
12
Coolant outlet
13
Compensation line
14
Vent line
56
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Module 3 – Machine technology
Cooler – engine 3
2
1
1
Coolant engine outlet
2
Cooler delivery
3
Cooler
4
Cooler redelivery
5
Coolant engine inlet
5
Cooler
Test pressure: 4 bar Operating pressure: 3 bar Max. operating temperature: 110 °C
4 ENGINE
57
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Module 3 – Machine technology
Cooler – engine 1
Compensation tank
2
Overpressure line
3
Overpressure line
4
Compensation line
5
Coolant level sensor B12
1 2 5 3 4
ENGINE
58
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Cooler – engine fill level sensor B12 Pin assignment:
1: BN +U 2: BU GND 3: BK SIGN
1
Capacitive proximity switch
2
Mount on the tank without any gap
3
Sensitivity setscrew / factory setting
4
LED lights up at dampened sensor
1
2
3 ENGINE
4 59
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Hydraulic oil cooler
4
1
Connecting block [Item 8 hyd.
2
Infeed hydraulic oil /
3
Cooler delivery
4
Cooler – U-flow
5
Cooler redelivery
3 6
1
2
5
6
ENGINE
diagram]
connecting block M
Return flow hydraulic oil / connecting block D
Cooler
Test pressure: 40 bar Operating pressure: 30 bar Max. operating temperature: 120 °C Inlet and outlet: M26 60
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Connecting block [Item 8 hyd. diagram]
1
1
Cold starting valve
A
Cooler bypass valve 2 bar / M33x2
D
Cooling return flow / M26x1.5
M
Cooling inlet / M26x1.5
O
Hydraulic oil temperature transmitter B8 / M14x1.5
Tightening torques 1: Ma = 60 Nm ENGINE
61
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Module 3 – Machine technology
Connecting block – cold starting valve 1
2
3
4
5
1
O-ring
2
p out
3
Seal ring
4
p in
5
Setting screw
(factory set to 27bar)
Diagram:
ENGINE
62
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Connecting block – Hydraulic oil temperature transmitter B8 connection O
Characteristic resistance curve 2000
Resistance [Ohm]
1800 1600 1400 1200 1000 800 600 400 200 0
0
10
20
30
40
50
60
70
Temperature [°C]
ENGINE
80
90
100
110
Temperature [°C] 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 98 105
Resistance [Ω] 1789 1410 1112 831 622 489 442,7 352,9 303,8 242,2 206,4 172,9 143,0 120,6 103,5 86,4 71,8 59,9 51,6 45,7 41,3 38,8 63
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Intercooler 4 5
1
1
Connection intercooler
2
Hot air hose
3
Intercooler
4
Cold air hose
5
Air intake
2
Cooler
Test pressure: 2.7 bar Operating pressure: 2 bar Max. operating temperature: 170 °C
3 ENGINE
64
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Module 3 – Machine technology
65
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Module 3 – Machine technology
TILT HYDRAULIC HOOD
ENGINE
66
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Module 3 – Machine technology
Tilt hydraulics 1
2
3
7
6
5
4
1
Hydraulic cylinder
2
Hood pressure hose, close
3
Hood pressure hose, open
4
Manual pump
5
Actuating pipe
6
Actuating pipe holder
7
Lubricating nipple, engine hood hinges
Lubricating nipple
Lubricate every 250 operating hours ENGINE
67
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# 2582511
Manual pump 1
1
Lever socket
2
Oil fill and level screw
3
Pressure / non-return valve
4
Suction / non-return valve
4 5
Oil level with closed hood
2 3
6 2
6
Actuating pipe
7
Open / close adjusting lever
8
Pressure hose connection
9
Suction hose connection
Nominal pressure: 250 bar Relief valve: 350+30 bar Oil quantity: 14.8 cm³
9
8
7 ENGINE
5 68
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Module 3 – Machine technology
69
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Module 3 – Machine technology
HYDRAULICS
HYDRAULICS
70
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Module 3 – Machine technology
Variable displacement pump, drive [Item 2.1 hyd. diagram] X1
1
X2
2
3
X1 Pump control port, backwards X2 Pump control port, forwards 5-22 bar / M16x1.5 in front of the orifice plate
4
HYDRAULICS
1
Hydraulic zero position centring
2
Measuring connector Ps = pressure 22bar downstream of the orifice plate / M18x1.5
3
Supply and high-pressure valve with bypass to towing / max. 502bar / forwards
4
Bearing fixing: don´t unscrew!
71
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Variable displacement pump, drive [Item 2.1 hyd. diagram]
1
1
Centring / mechanical zero position
2
Leak oil T2 / M26x1.5
3
Measuring connection G = supply pressure max. 22 bar / M18x1,5
4
Supply and high-pressure valve with bypass to towing / max. 502bar / backwards
5
Measuring connection MA = backwards
6
Measuring connection MB = forwards
5+6 max. 502 bar / pressure cutoff max. 450 bar / M12x1,5 7 2 HYDRAULICS
3
4
5
6
7
Supply pressure valve / max. 22bar 72
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Variable displacement pump, drive [Item 2.1 hyd. diagram] 1
2
3
4
5
HYDRAULICS
1
High pressure port / B = forwards SAE 1“
2
Proportional solenoid b= forwards
3
Proportional solenoid a= backwards
4
Ventilation R / M16x1.5
5
High pressure cut-off valve max. 450bar
73
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Variable displacement pump, drive [Item 2.1 hyd. diagram] 1
Leak oil T1 to vibration pump M26x1,5
2
Pressure supply Fa from steering via cooler and filter / M26x1,5
3
Supply pressure measuring connection / M22x1,5
4
High pressure port A = backwards SAE 1“
1 2
4
3 HYDRAULICS
74
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Module 3 – Machine technology
Variable displacement pump, vibration [Item 2.2 hyd. diagram] 1
X1
X2
2
3
X
Pump control port / 5-22bar upstream orifice plate / M12x1.5
X1 Pump control pressure small amplitude X2 Pump control pressure large amplitude
HYDRAULICS
1
Ventilation R / M12x1.5
2
Adjustment high frequency small amplitude
3
Measuring connector Ps =set pressure / 22bar downstream orifice plate / M14x1.5
75
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Variable displacement pump, vibration [Item 2.2 hyd. diagram] M
Measuring connection / max.
423bar / pressure cut-off 420bar / M12x1.5
MB Large amplitude MA Small amplitude
MB
1 2 5
4 HYDRAULICS
1
Supply pressure valve
2
Measuring connection G =
3
Supply / high-pressure valve / large amplitude / max. 420bar
4
Leak oil T2 from drive pump / / M26x1.5
5
Centring, mechanical zero position
Not installed! Pressure control via drive pump supply pressure / max. 22 bar / M18x1.5
3 76
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Variable displacement pump, vibration [Item 2.2 hyd. diagram] 1
2
3
4
HYDRAULICS
5
1
Supply / high-pressure valve / small amplitude / max. 423bar
2
High pressure cut-off valve / max. 420bar
3
Proportional solenoid / b = large amplitude
4
Proportional solenoid / a = small amplitude
5
Adjustment low frequency large amplitude
77
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Variable displacement pump, vibration [Item 2.2 hyd. diagram] 1 Leak oil T1 to oil connecting block / M26x1.5 2 High pressure port A = small amplitude / SAE 1“ 3 Supply pressure measuring connection M22x1.5
5
4 Pressure supply Fa from drive pump connection Fa1 M26x1.5
4
5 High pressure port B = large amplitude / SAE 1“
3
2
1 HYDRAULICS
78
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Connecting block [Item 8 hyd. diagram]
1
1
Cold starting valve 27 bar
A
Cooler bypass valve 2 bar / M33x2
B
Hydraulic filter / M26x1.5
C
Free / M22x1.5
D
Cooling return flow / M26x1.5
E
Leak oil vibro pump / M22x1.5
F
Leak oil hydraulic tank /M33x2
G
Leak oil vibro motor / M22x1.5
Tightening torques
A and 1: Ma = 60 Nm HYDRAULICS
79
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Connecting block[Item 8 hyd. diagram]
1
HYDRAULICS
H
Leak oil drive motor / M22x1.5
I
Not used / M33x2
J
Leak oil variable displacement pump / M22x1.5
K
Leak oil brake release valve/ M22x1.5
L
Leak oil steering pump / M22x1.5
M
Cooling inlet / M26x1.5
N
Steering leak oil / M22x1.5
O
Hydraulic oil temperature transmitter / M14x1.5
80
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Wheel gears – drum drive [Item 5+6 hyd. diagram] 1
Hydraulic variable displacement motor
[Item 6 hyd. diagram]
2
5-planetary reduction gear with integrated parking brake [Item 5 hyd. diagram]
1
2
HYDRAULICS
81
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Wheel gears – drum drive [Item 5+6 hyd. diagram] 1
2
1
5-planetary reduction gear
2
Hydraulic variable displacement motor
3
Parking brake 22 bar / brake operated by moved multiple springs in oil bath
3
HYDRAULICS
82
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Variable displacement motor – drum drive [Item 6 hyd. diagram] 1 2 3
4
5
1
Proportional solenoid
2
Measuring connection G / 80400 bar / M14x1.5
3
Speed sensor connection
4
High pressure port A / SAE 1“
5
High pressure port M1 / M14x1.5
6
Scavenge valve
6
HYDRAULICS
83
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Variable displacement motor – drum drive [Item 6 hyd. diagram] 1
Flow capacity setting screw V/min.
2
Leak oil T / M18x1.5
3
High pressure port B / SAE 1“
4
Flow capacity setting screw V/max.
5
Scavenge valve
1
2 3 4 5 HYDRAULICS
84
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Rear axle 1
2
3
4 5
6
1
HYDRAULICS
7
8
1
Planetary gear
2
Differential casing with selflocking differential
3
Parking brake 22 bar / multidisc brake in oil bath
4
Parking brake connection
5
Parking brake venting
6
Coupling shaft
7
Connecting flange
8
Axle drive variable displacement motor
85
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Variable displacement motor – axle drive [Item 4 hyd. diagram] 1
1
Proportional solenoid
2
2
Measuring connection G / 80400 bar / M14x1.5
3
High pressure port A / SAE 1“
4
Measuring connection M1 / M14x1.5
5
Leak oil T / M26x1.5
6
Flow capacity setting screw V/max.
7
Flow capacity setting screw V/min.
8
Speed sensor connection
9
High pressure port B / SAE 1“
3
4
7 8
9
5 6 HYDRAULICS
86
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Vibration motor [Item 7 hyd. diagram] 2
1
3
4
5
6
7
1
Leak oil T2 / M 18x1.5
2
High pressure B / small amplitude SAE 1“
3
Measuring connection / small amplitude
4
Measuring connection / large amplitude
5
Scavenge system
6
High pressure A / large amplitude SAE 1“
7
Connection T1 / M18x1.5 (closed)
Check the rotation direction after the installation work! HYDRAULICS
87
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Parking brake valve [Item 18+25 hyd. diagram] 1
2
1
3
6
4 5 7
8
9
10 = +U
6
2
1
Shut-off valve
2
Manual pump
3
Brake C
4
Supply pressure P 22bar
5
Tank T
6
Parking brake solenoid Y5
7
Brake pressure sensor S12
8
Relief valve
9
Pressure / non-return valve
10
Suction / non-return valve
= GND
HYDRAULICS
88
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Pressure switch, parking brake S12 1
2
1
Wrench size 27
2
Thread M10
3
Pressure setting Switching point 6 bar
3
HYDRAULICS
89
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Module 3 – Machine technology
Towing Prior to towing 1. 2. 3. 4. 5. 6.
Drive lever in 0 position. Diesel engine off. Secure machine against rolling away. Interrupt frictional connection of the hydrostatic drive. Release parking brakes. Towing with towing bar.
Towing 1. 2. 3.
In case of the failure of a diesel engine steering is difficult / Emergency steering Towing speed: Max. 1 km/h Towing distance: Max. 500 meters.
After towing 1. 2. 3. 4.
Secure machine against rolling away. Engage the frictional connection of the hydrostatic drive. Make parking brake operational. Remove towing bar. Notice ! When the maximum values are exceeded: Hydraulic system empties in case of lacking supply, therefore the risk of running dry and overheating of the components. HYDRAULICS
90
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Towing High-pressure valves with bypass
1
2
Interrupt frictional connection of the hydrostatic drive. To do so loosen counternut [2] , screw in screw [1] at the high-pressure valves, until it is flush with counternut [2]. Engage the frictional connection of the hydrostatic drive. Unscrew screw [1] to the stop, then tighten counternut [2] HYDRAULICS
91
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Towing 1
2
3
Disengaging the parking brake 1. 2. 3.
Loosen counternut [2] Screw in screw [1] to stop. Vent spring-operated brakes using pumps at lever [3].
Engaging the parking brake 1.
Screw out screw [1] by two turns.
2.
Tighten counternut [2]. Notice! Screw out screw [1] not more than by two turns. Otherwise, hydraulic oil escapes.
HYDRAULICS
92
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Hydraulic oil filter [Item 7 hyd. diagram] 1
2
3
Contamination indicator without H176: SN 2489-9999 H177: SN 0187-9999 H180: SN 3371-9999
HYDRAULICS
4
5
mounted: with SN 0001-2488 SN 0001-0186 SN 0001-3370
1
Drive pump charge pressure filter
2
Filter head
3
Gasket set
4
Filter insert
5
Contamination indicator S16
6
Bypass valve / Δp=7.0 bar
Fa
Drive pump connection
B
Connecting block port
6
1 93
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Steering hydraulic oil filter [Item 7 hyd. diagram] 1
2
3
1
Filter cartridge Operating pressure = 250 bar
2
Bypass valve Δp=7.0 bar
3
Observe the flow direction!
4
Filter insert Filter: 10 µm Order no. 2031492
G ¾“ 4
SW 30 HYDRAULICS
94
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Power take-off – steering pump [Item 7 hyd. diagram] 1
2
3 4
HYDRAULICS
5
1
Suction hose of hydraulic tank
2
Gear pump [hyd. diagram,
3
Valve block [Item 20.1 hyd.
4
Steering pressure line via high-
5
Relief valve Δp=250bar
6
Leak oil line to connecting block L
[hyd. diagram, item 13] via suction filter [hyd. diagram, item 27] item 20]
diagram]
pressure filter [Item 23 hyd. diagram] to steering unit [Item 22 hyd. diagram]
6
95
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Power take-off – dozer blade pump (option) H176 2
H180 1
5
4
H176 1
Tandem pump
2
Suction hose from tank
3
Pressure hose to valve
H177 – without H180
3
6
HYDRAULICS
4
Gear pump [Item 7 hyd. diagram]
5
Suction hose from tank
6
Pressure hose to valve
96
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Hydraulic oil tank [Item 7 hyd. diagram] 2 1
1
4
2
5
3
6
7
4
HYDRAULICS
5
8
1
Ventilation filter
2
Return flow from connecting
3
Connecting block [Item 8 hyd.
4
Oil level indicator
5
Oil filler
6
Suction hose, steering pump
7
Suction hose dozer blade / option
8
Oil outlet
9
Suction filter
block F
diagram]
9
97
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
98
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
ELECTRICAL SYSTEM
ELECTRICS
99
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Battery 2
1
1
Battery G1 Option: gel-type battery
2
Battery compartment, lockable
3
Battery isolation switch S1
3 ELECTRICS
100
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Main fuse box 1
2 3 4
5
6
ELECTRICS
7
8
1
Main fuse box
2
Pre-heating relay K17
3
Start relay K16
4
Battery plus cable to starter
5
Power supply / 100A F01 to
6
Alternator G2 / 100A F02
7
Cold starting device / 150A F03 to high-current relay K17
8
Air conditioning system / 80A F04
high-current relay K15
101
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
High-current relay – Power supply K15 / Pre-heater system K17 1
5
Normally open relay 1+2 Control circuit connection 3+5 Normally open contact Operating circuit (Kl. 30 + Kl. 87) Coil resistance: 37 Ω
1 2 5
2
3
ELECTRICS
3
102
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Central electrical system Hammtronic 1
2
5
6
4
1
Circuit board
2
Smooth or padfoot drum setting
3
Deutz diagnostic connector and error diode
4
WIDIAG interface
5
CDS / old system, no longer
6
Signal converter T1
available
H180: from SN 2610 / RC28 H177: from SN 0083 H176: from SN 1934
3 ELECTRICS
103
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Drum type setting Plug X14 Pin Colour 1 BK 5V Tilt sensor 2 BN GND 3 BU Signal 4 released 5 BN GND Rotary switch 6 WH Signal
1
2
3 2
1
Rotary switch S15
2
Wire harness / Tilt sensor
3
Plug X14
4
Rotary switch connector
5
Tilt sensor B13
A-C: Smooth drum A-B: Padfoot drum position
4
5 Note mounting position! Rotary switch Pin Colour A BN B GND
Read tilt sensor! RC28: Setup Routine MC6: BODAS
GND Signal ELECTRICS
104
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Central electrical system Hammtronic – connector 1
1
Wire harness slots
2
Jumper with 7.5A fuse
3
Power supply terminals
4
Diagnostic connector
2 3
J1: Selection km/h – mph J2: Fuel filter heating J3: CAN bus connection Resistor
XD1: ITT-Canon 12-pole for SERDIA XD2: ICS-Power-Con 9-pole XD3: Sub-D 9-pole / BODAS MC6 XD4: Bush 1-pole 4mm banana plug / MC6
4.1 WIDIAG interface RC28 4.1 4
ELECTRICS
105
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Central electrical system Hammtronic – fuses
ELECTRICS
106
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Central electrical system Hammtronic – fuses
ELECTRICS
107
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Central electrical system Hammtronic – relays K1
Control relay, engine control unit
K2
Fuel filter heating
K3
Flashing light relay
K4
Refuelling pump
K5
Driving light
K6
Brake
K7
Back-Up
K8
Dozer blade
K9
Dozer blade
K10 Start release K11 Preheat COM-2 K15 Power relay
ELECTRICS
108
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Central electrical system HT – computer 1
1
Central board
2
computer
2.1 MC6 A2.1 H180: SN 0001 - 2609 H176: SN 0001 - 1934 H177: SN 0001 - 0082
2
2.2 RC28 K200 with signal converter T1 / Hammtronic only H180: SN 2610 - 9999 H176: SN 1935 - 9999 H177: SN 0083 - 9999
3
3 3
2.1
Control unit EMR3 – EDC16 D1
2.2
ELECTRICS
109
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Central electrical system Hammtronic – Signal converter T1
ELECTRICS
PIN
Function
1+2
Power supply +12V
3+4
Power supply 0V GND
5+6
Input and output signal 1 Drum speed sensor
7+8
Input and output signal 2 Axle speed sensor
9+10
Input and output signal 3 Vibration sensor
11+12
200Ω Resistor for oil temp. evaluation
110
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Standard central electrical system – fuses
ELECTRICS
111
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Standard central electrical system – fuses
ELECTRICS
112
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Standard central electrical system – relays K1
Control relay, engine control unit
K2
Fuel filter heating
K3
Flashing light relay
K4
Refuelling pump
K5
Driving light
K6
Brake
K7
Back-Up
K8
Dozer blade
K9
Dozer blade
K10 Start release K11 Preheat COM-2 K14 Vibration control unit K15 Power relay, terminal 15 ELECTRICS
113
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Change-over relay 12 V with diode #1263986 Rated voltage:
12V
Coil resistance (20°C)
96Ω±10%
Contact resistance
max. 50mΩ
(20°C) Rated current
20A Normally closed contact / 25A Normally open contact
Casing
water-protected
Relay coil
Pin 85+86
Relay contacts
Pin 30+87+87a
ELECTRICS
114
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Ignition switch S2 S
S
Ignition switch
Terminal:
17
15/54 50a
19
30
Battery - steady plus
15/54
Switched to plus
17
Connection unused (direct start)
19
Pre-heater system
50a
Starter
30
S
ELECTRICS
115
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Display 1
1
Machine type setting
2
Connector A1X2
3
Connector A1X1
LED switching points for standard variantes without EMR3: Yellow Red LED Red LED, LED, Type Signal (flashing), temp. high temp. temp. too high too low Engine temp., 0, 1, 8, 9 >4.030V <0.495V <0.265V X2:2 Engine temp., 3, 4, 5 >4.371V <1.109V <0.902V X2:2 Engine temp., A, B >4.455V <0.987V <0.880V X2:2 Hydraulics 0-5, 8, 9, >4.03V <1.00V <0.807V temp., A, B X2:1 Switching points for HAMMTRONIC machines and maschines with E Yellow Red LED Red LED, LED, Type Signal (flashing), temp. high temp. temp. too high too low Engine temp., H159 <15°C >120°C >130°C via C AN H160-H162, Engine temp., <15°C >105°C >115°C H169 via C AN H188-H189
3
2
H176-H177, H179-H180 all
ELECTRICS
Engine temp., via C AN Engine temp., via C AN Hydraulics temp., via C AN
<15°C
>110°C
>115°C
<15°C
>112°C
>115°C
<15°C
>90°C
>100°C
116
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Switch #1262955
7+8
1
Output 1
2
Supply voltage
3
Output 2
7+8
LED
9+10 LED
9+10
e.g.
ELECTRICS
S8
Engine management
S13
Vibro-automatic switch
117
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Switch #1269461
7+8
9+10
1
Output 1
2
Supply voltage
3
Output 2
4
Output 3
5
Supply voltage
6
Output 4
7+8
LED
9+10 LED e.g. S11 Switch amplitude small / large
ELECTRICS
118
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Switch #1269488
7+8
1
Output 1
2
Supply voltage
3
Output 2
7+8
LED
9+10 LED
9+10
e.g. S6 Vibro frequency button S9 Speed preselection button
ELECTRICS
119
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Emergency flasher switch S5 13+3
Supply voltage
11+4
Output to flashers relay
5
Flashing signal input
17+18 Left and right flashing lights 10
ELECTRICS
Flashing pilot light
120
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Flasher unit K3 #282618 49
Input flasher unit [12V]
49a
Output flasher unit
31
Battery minus / ground
Flash frequency: 1.5 Hz ± 0.5 Hz (= 90 light appearances per minute ± 30)
ELECTRICS
121
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Module 3 – Machine technology
Vibration sensor / option for standard machines 1
Vibration sensor connection box A4
2
Vibration frequency sensor HB3
1
2
Sensor gap setting not needed. Notice! Two O-rings mounted ELECTRICS
122
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
ABS sensor connection box A4 Sensor
hyd. diagram
PIN = KABEL 1 = Shield Pin1Nr.=1cable1 = Nr. shield PIN = KABEL 2 = Sensor Pin2Nr.=2cable2 = Nr. sensor PIN = KABEL 3 = Sensor Pin3Nr.=3cable3 = Nr. sensor
1 2 3 1 2 3
Control unit
PIN = Kabel=Nr 1= +12V Pin1Nr= 1cable1 +12V PIN = Kabel 2= GND (Masse) Pin2Nr. = 2cable2 = Nr GND (ground ) PIN = Kabel 3= SIGNAL Pin3Nr. = 3cable3 = Nr signal
Shield 11Shield Sensor 22Sensor 33Sensor Sensor 11+U 2 GND +U 32SignalGND 3
SIGN
Green LED = supply voltage +12V
LED-GRÜN = Versorgungsspannung +12V LED-ROT = Rechteck-Signal (pulsierend) Red LED = square wave signal (pulsating) ELECTRICS
123
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
Alarm devices 1 2 3
1
Back-up alarm H3
2
Relay K7
3
Blade-type fuse 7.5A F15
4
Horn H1 with diode V6
5
Proximity switch B7
For standard machines / HT machines – according potentiometer position
4 5
ELECTRICS
124
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Module 3 – Machine technology
Light installation 1
3
2
4
ELECTRICS
1
Front drive light, parking light, direction light Left E1 Right E2
2
Tail light left E5 right E6 Flasher left E10 right E12
3
Warning beacon H40
4
Working spotlight front left E40 front right E41 rear left E42 rear right E43 Option: LED
125
3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology
# 2582511
Drive lever potentiometer R20 1
1
Potentiometer
2
Potentiometer complete with holder and adjustment lever Order no. 856606
3
Terminal resistance connected in parallel / 2x5kΩ±20% Potentiometer must be read in. RC28 MC6
Setup routine BODAS
3 Pin Colour 1 BN 5V 2 WH Signal 1 3 WH Signal 2 4 GN Ground
2 ELECTRICS
126
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Module 3 – Machine technology
Proximity switch 1
2
3
1
Sensor adjustment 3-4mm
2
LED
3
Nuts / sensor gap setting
B9 Parking position B7 Back-up alarm / standard machines only
ELECTRICS
127
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Module 3 – Machine technology
128
3412 – 3625 • H176 / H177 / H180 # 2582511
Module 3 – Machine technology
STEERING SYSTEM
STEERING
129
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Module 3 – Machine technology
3-point articulated joint 1
1
Ball joints
2
Grease nipples
3
Safety strut
4
Steering cylinder with 2x lubricating points each [Item 24 hyd. diagram]
Lubricate grease nipples every 250 operating hours!
2 3
4
STEERING
130
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Module 3 – Machine technology
Steering unit [Item 22 hyd. diagram] R
P
L
T
T
Return flow G ½“
P
Pressure port G ½“
R
Steering cylinder G ½“
L
Steering cylinder G ½“
1
Geared hub profile 16/32
1
If not steered, the connection P to T is open – Open Center (OC)
STEERING
131
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Module 3 – Machine technology
132
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Module 3 – Machine technology
ROLLER DRUM
DRUM
133
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Module 3 – Machine technology
Drum suspension / Example H180 3414-3414 VIO 1
3 4 5 6
6
5
2
4
1
Drum drive variable displacement motor
2
Planetary gear box
3
Vibration motor
4
Driver with rubber buffers
5
Suspension
6
Spacers / frame assembly allowance compensation Hydraulic system • Variable displacement motor • Planetary gear box • Vibration motor See chapter Hydraulics
DRUM
134
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Module 3 – Machine technology
Overview of drums Mat. no. 873128 2058532 2141540 2141540 2345690 2427640 2058533 2141542 2141542
BR H180 H176 H180 H176 H177 H177 H176 H176 H180
Vibration drum
Type 3412 VIO - 3414 VIO 3518 - 3520 3412 - 3414 3516 3625 HT VC 3625 HT VC 3518 P - 3520 P 3516 P 3412 P - 3414 P
Roller drum VIO-drum V drum V drum V drum P drum P drum P drum P drum P drum
Padfoot drum
SN 1-9999 1-9999 1-9999 1-9999 1-268 269-9999 1-9999 1-9999 1-9999
Vibration oscillation drum
DRUM
135
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Module 3 – Machine technology
Basic Principle of Drums Vibration padfoot drum 1
VIO-drum 2
3
1
Centre shaft with 2 x likely sensed unbalances
2
Centre shaft
3
Flexible unbalance
4
Fixed unbalance Hydraulic system • Drive pump • Vibration pump • Drive motor • Vibration motor See chapter hydraulics
4 DRUM
136
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# 2582511
VIO-drum – Example H180 – 3412-3414 VIO
1 4
4
2 1
Shaft unbalance flexible
2
Centre shaft
3
Shaft unbalance fixed
4
Belt tensioner
3
DRUM
137
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Vibration drum – Example H180 H180 – 3412-3414 / 3412P-3414P H177 – 3625 VC
1
H176 – 3516 / 3516P H176 – 3518-3520 / 3518P-3520P
4
1
Assembly right unbalance
2
Assembly left unbalance
3
Vibro-motor assembly
4
Smooth drum / padfoot drum
3 2
DRUM
138
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Module 3 – Machine technology
Padfoot shells / option – H series as example Smooth drum
Padfoot shells
DRUM
139
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Module 3 – Machine technology
Scrapers 1
1
Smooth drum scraper
2
Padfoot drum scraper
2
DRUM
140
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Module 3 – Machine technology
Drum 3625 VC – H176 1
2
4
1
5
4
1
Vibrator
2
Drum
3
Vibration motor [Item 7 hyd.
4
Cylindrical roller bearings
5
Unbalance fixed
Series no. H1770269 diagram] / See chapter Hydraulics
3 DRUM
141
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Module 3 – Machine technology
Picks 3625 VC – H177 SN: 1-268
1
2
4 3
SN: 269-999
1
Picks
2
Padfoot
3
Picks / padfoot holder
4
Locking tappet
5
Tool set with extractor and hammer
1
4 5 DRUM
142
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Module 3 – Machine technology
Scraper and travel ring 3625 VC – H176
1
2
1
Scraper
2
Travel ring
DRUM
143
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Module 3 – Machine technology
144
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Module 3 – Machine technology
SPECIAL EQUIPMENT
OPTIONS
145
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Module 3 – Machine technology
Dozer blade 1
3
2
4
1
Dozer blade
2
Hydraulic cylinder
3
Holding plates
4
Wear plate
5
Lubricating nipple
[Item 32 hyd. diagram]
5 OPTIONS
146
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Module 3 – Machine technology
Dozer blade control block [Item 31 hyd. diagram] 5
1 6 7 2
8 3
9
1
Solenoid valve Y13 - floating operation
2
Connection B
3
Connection P
4
Solenoid valve Y12 – lower blade
5
Solenoid valve Y11 - floating operation
6
Connection A
7
Relief valve Δp=120bar
8
Solenoid valve Y10 – lift blade
9
Connection T
4 OPTIONS
147
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Module 3 – Machine technology
Dozer blade – circuit diagram Y10
Lift blade
Y12
Lower blade
Y11/13
Operate blade floatingly
Y10-13
Solenoid valve blade
Function
Y10 Y11 Y12 Y13
Lift Lower
X X
Floating operation
X X
OPTIONS
X X
148
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Module 3 – Machine technology
Dozer blade - electrical system 1
2
3
4
5
1 2 3 4 5 6
Stecker X12 Reserve 0.75 ws Y10 0.75 ws Y13 Reserve 0.75 ws Y11 0.75 ws Y12
1
Dozer blade wire harness
2
Ground bar connection M6 31.9
3
Socket X12 on central board
4
Relay 12V 20A/25A diode / slots ZE K8+K9
5
Connecting plug dozer blade control block Electrical system dozer blade drive lever: see Chapter: "Electrical system“
OPTIONS
149
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Module 3 – Machine technology
Vibratory plate 1
5
2
3
4
6
7
8
1
Hydraulic and electrical connections
2
Transverse adjustment
3
Vibrator
4
Quick coupling
5
Hydraulic filter
6
Frequency regulation
7
Switch vibration and transverse adjustment
8
LED pilot lights Green: Vibration Yellow: Transverse adjustement Red: Multi-coupling Operation and servicing / Supplementary sheet Operating instruction OPTIONS
150
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Bypass filter 1
2
3
1
Bypass filter / filter cartridge 1µm Order no. 2027327
2
Screw SW19 / Ma=50Nm.
3
Max. flow rate 2L/min
4
Connecting block
5
Pressure gauge
6
Inlet M12 P from connecting block M
7
Outlet M18 T to connecting block L
4 5 6
M
L
7 OPTIONS
151
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Module 3 – Machine technology
Additional safety devices 1
4
2
1
Ram protection
2
Lamp protection
3
Lamp protection
4
Hose protection
3
OPTIONS
152
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Module 3 – Machine technology
Seat contact switch 2
1
1
Seat contact switch • contactless • switch closed, when seat occupied
2
Switch plate
3
Rotating points
3
3
1
OPTIONS
153
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Module 3 – Machine technology
Camera system 1
2
1
Monitor
2
Camera
OPTIONS
154
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Module 3 – Machine technology
Speedometer 1
3
2
Pin 1 2 3 4
Colour BN BU BK WH
1
Indicator speed
2
Sensor B4 axle B5 drum
3
Wire harness to connector X5
Function +U GND Frequency 1 Frequency 2 (rotation direction)
OPTIONS
155
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# 2582511
Compaction meter HCM-3 1
2
1
Accelerometer B10
2
HMV Meter
3
Calculator HCM-3 #2024246
3
OPTIONS
156
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Calculator HCM 3 – I-SENSOR I-Sensor / Speedometer 2 1
3 4
PIN
Designation
1
+U (+12V/+24V)
2
GND (0V)
3
I-Signal Roller drives
4
Free
+U 0V
OPTIONS
157
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Calculator HCM 3 – A-SENSOR A-Sensor / Acceleration sensor 3
4
2 1
8
5
PIN
Designation
6
1
Temp. 1
7
2
+9V
3
Temp. 2
4
GND (0V)
5
Free
6
A-Signal 1
7
A-Signal 2
8
Free
A-Signal:
AC: 100 mV/g
DC: 4.5V
Vibration active
0V
OPTIONS
158
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Module 3 – Machine technology
Calculator HCM 3 – INSTRUMENTS Instruments 2 1
3
4 5
PIN
Designation
1
Speedometer (0…0.3V DC)
2
HMV Instruments (0…0.3V DC)
3
GND (0V)
4
RMV Instruments 0…5V DC, FM overlap, 0…500Hz, depends from the amplitude
5
Free
OPTIONS
159
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Module 3 – Machine technology
Calculator HCM 3 – POWER Power 3 2
4
1
5
6
PIN
Designation
1+2 +U (12V/24V) 3+6 Free 4+5 GND (0V)
OPTIONS
160
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Module 3 – Machine technology
Calculator HCM 3 – CDS CDS
2 1
3
7 6
PIN
Designation
1
HMV-Value (DC: 5V = 150 HMV)
2
+12V max. 0.8V
3
I-Signal
4
Large amplitude <0.8V Small amplitude >4V
5
Vibration frequency (DC: 5V = 75Hz
6
RMV-Value (DC: 5V = 50 RMV)
7
GND
4 5
OPTIONS
+U 0V
161
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Module 3 – Machine technology
Calculator HCM 3 – DIGITAL Digital Connector
G
F
PIN
Designation
A
GND
B
CAN-High
D
C
CAN-Low
C
D
RES-In
E
CAN-GND
F
TP200
G
USB-
H
USB+
J
RxD
K
USB-GND
L
Boot-In
M
TxD
E M
H J L K
A
B
OPTIONS
162
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Module 3 – Machine technology
WIFMS – Printed-circuit board and diagnostic interface WIDIAG 1
3
1
Diagnostic socket XD5
2
Connector X22s on central board X23
3
Board #2261462
2
OPTIONS
163
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Module 3 – Machine technology
WIFMS – Gateway and connector overview 1
2
3
1
Gateway WIFMS K400
2
Wire harness #2254940
3
Wire harness #2255841 Electrical system See WIDOS electric diagram: WIFMS Gateway
OPTIONS
164
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Module 3 – Machine technology
Auxiliary heater 2
1
3 4
5
6 4 7
5
10
9
1
Fuel inlet Ø5mm
2
Temperature sensor
3
Type plate
4
Temperature limiter
5
Coolant inlet Ø20mm
6
Coolant outlet Ø20mm
7
Wire harness sockets
8
Combustion air inlet Ø30mm
9
Exhaust air outlet Ø38mm
10
Circulating pump
8 OPTIONS
165
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Module 3 – Machine technology
Auxiliary heater 2
1
3
4
5
1
Timer P80
2
From plug P80.X1/Pin1 (timer) via connector X87 to plug S2X2/Pin6 (ignition lock Kl.15)
3
Plug P80.X1 to timer
4
Fuel tank fuel line via fuel pump to heater
5
Fuel transfer pump M80 with plug M80.X1s
6
Fresh-air hose with sound absorber
6
OPTIONS
166
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Module 3 – Machine technology
Auxiliary heater 1
2
3
1
4
5 2
Connector X84p+X84s Ground X31
3
Relay K82
4
Fuses:
5
Steady plus F01
6
W05 20A W06 5A W07 20A
7 6
Auxiliary heater E80 with
7
Exhaust pipe with sound absorber
plug: E80.X1s+E80.X3s
Electrical system Auxiliary heating electric diagram S3000 / Order no. 2245025 OPTIONS
167
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# 2582511
Auxiliary heater 5
4
3
2
7
1
Layout of hoses standard:
2
Layout of hoses auxiliary heater
3
Motor – cab blower unit
Motor – auxiliary heater inlet
3
Layout of hoses auxiliary heater
Auxiliary heater outlet – blower unit inlet
2 4
Cabin heating wire harness / plug X41: Pin1: jumper to X85/Pin1 Pin4: tripped by X85/Pin2
5
4
5
Plug X85:
6
Blower unit
7
Auxiliary heater
Pin1: jumper X41/Pin1 Pin2: to S30X1:B
1 OPTIONS
168
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Module 3 – Machine technology
169
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Module 3 – Machine technology
DIAGNOSIS
DIAGNOSIS
170
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Module 3 – Machine technology
MC6 Error code list – S3000 HT TIER3 Till version 1.88 / without pressure sensor Note: The partly very abridged texts in column “error message” are identical to the stored error texts which can be read out via PC and the BODEM software. Error 1 – 51: These errors are generated by the micro controller MC6 (behind right ascent). Error 50 – 51: These errors are stored under error 49 in the MC and are shown in the display. Error 90 – 93: These errors are exclusively generated by the dashboard display (steering wheel).
DIAGNOSIS
171
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Module 3 – Machine technology
DIAGNOSIS
172
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Module 3 – Machine technology
DIAGNOSIS
173
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Module 3 – Machine technology
DIAGNOSIS
174
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Module 3 – Machine technology
DIAGNOSIS
175
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Module 3 – Machine technology
DIAGNOSIS
176
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Module 3 – Machine technology
DIAGNOSIS
177
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Module 3 – Machine technology
DIAGNOSIS
178
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Module 3 – Machine technology
RC28 Error code list – Error codes 205-338 Error code 205 208 209 231 233 235 238 242 254 262 266 271 272 273 274 280 301 302 303 305 337 338
Location Alternator charge control Braking position signal contact with active traction lever Seat control no contact with active traction lever Traction lever invalid zero point signal Temperature sensor hydraulics Level sensor engine fuel tank Tilt sensor Emergency stop activated Pressure sensor MHV Temperature sensor charge air Vibration frequency sensor front Speed sensor front axle track 1 Speed sensor front axle track 2 Speed sensor rear axle track 1 Speed sensor rear axle track 2 ASC Off due to speed sensor Traction pump forward Traction pump backward Drum engine Axle engine Current monitoring traction engine Current monitoring traction pump
DIAGNOSIS
179
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Module 3 – Machine technology
RC28 Error code list – Error codes 401-999 Error code 401 402 405 406 407 408 409 410 411 431 480 481 482 486 487 488 489 490 491 492 493 494 495 999
Location CAN A BUS OFF CAN B BUS OFF Traction lever no messages CAN A Traction lever no messages CAN B Traction lever invalid signal track 1 Traction lever invalid signal track 2 Traction lever invalid difference track 1 - track 2 Diesel-engine no rpm Display disconnected Setup missing Start routine - system voltage supply too low Start routine - No voltage supply for sensors Start routine - hardware monitor 1 Start routine - hardware monitor 2 Start routine - start condition not fulfilled Start routine - cable break safety outputs Start routine - short circuit safety outputs Start routine - voltage supply 1 Start routine - no voltage supply 1 Start routine - voltage supply 2 Start routine - no voltage supply 2 Start routine - emergency stop active Start routine - shutdown safety outputs No clearance for start DIAGNOSIS
180
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Module 3 – Machine technology
181