Hamm MSC M3 H176 • 3516 - 3520 H177 • 3625 H180 • 3412 - 3414 Technical Manual - PDF DOWNLOAD

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.

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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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

10

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology

# 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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

ENGINE

ENGINE

26

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

Camshaft speed sensor B40.1

Resistance: pin 1 to 2 approx. 3.8kΩ

1 2 3

ENGINE

37

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

Crankshaft speed sensor B40.2

321

Resistance: pin 1 to 2 approx. 1kΩ

ENGINE

38

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

40

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

48

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 Module 3 – Machine technology

# 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

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

69

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

HYDRAULICS

HYDRAULICS

70

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

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

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

128

3412 – 3625 • H176 / H177 / H180 # 2582511

Module 3 – Machine technology

STEERING SYSTEM

STEERING

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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

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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

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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

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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

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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