Wacker Neuson EW100 System Manual - PDF DOWNLOAD

Wacker Neuson EW100 System Manual 1000326918, Version 1.2

Content Type

E06-06

Version 1.0

May 2014

Version 1.1

July 2014

Version 1.2

Nov 2014

Content

2

Hydraulics

15

Electrics

179

1000326918_EW100_V_1.1 Reference (apr02)

2

General The system manual describes the function of the EW100 systems and components. It is an WN internal document for trainers and employees.

The system manual is offered additional to the service manual EW100 Additional documentation EN Operator manual

1000309133

Spare parts list

1000315167

Service manual

1000317856

System manual

1000326918

1000326918_EW100_V_1.1 Reference (apr02)

3

General Content

Content Slide General Content

4

Area definition

10

HYDRAULICS Pilot system Pilot oil supply unit

17

Pilot valves

29

Proportional valves

35

Drive Drive pump

39

Drive motor

56

Work Work pump

67

Main valve block

74

1000326915 EW100_V_1.2 Reference (apr02)

5

Content Slide Brake Service brake valve

108

Steering Steering unit

116

Steering mode valve

120

Steering direction valve

125

Swivel Swivel motor

129

Shuttle valve block

140

Stabilize Stabilizer valve

149

Auxiliary system Change over valve

1000326915 EW100_V_1.2 Reference (apr02)

153

6

Content Slide Safety valves Anti hose burst valve

156

Anti load lowering valve

160

Schlauchbruchventil

162

Accumulators

166

Filters

169

Coolers

172

Attachement Quick hitch system

176

ELECTRICS Harness, parts position

182

Controllers

202

Fuses

209

E-Swivel joint

212

1000326915 EW100_V_1.2 Reference (apr02)

7

Content Slide Relays

215

Joysticks

217

Diagnose

220

Safety

222

Power mode pump P3

225

Boom offset

227

Auxiliary circuits

229

Stabilize

233

Undercarriage axle lock

235

Drive

237

Brake

241

Change work-/road travel situation

245

Change gear

249

Steering mode

253

1000326915 EW100_V_1.2 Reference (apr02)

8

Content Slide Steering direction change

256

Hydraulic quick hitch system

258

Engine auto idle

261

Appendix

1000326915 EW100_V_1.2 Reference (apr02)

264

9

General Location

Location The following areas are defined and named: A

Cab Enter via the door

B

Electric compartment Tilt cab, remove cover outside the cab

C

Valve area Tilt cab Reachable areas: chassis floor (C1), cab bottom (C2), side wall area (C3)

D

Engine compartment Open engine hood

E

Counter weight area Remove counter weight cover

F

Undercarriage Bottom side of undercarriage

G

Service cover

1000326918_EW100_V_1.1 Reference (apr02)

11

View from top

Location Valve area

Counter weight area

Engine area

D C B

E

A G

Cab

1000326918_EW100_V_1.1 Reference (apr02)

12

Electric compartment

Service cover

Location

Electric compartment Service cover Counter weight area

B

Front axle T018

G

E

Rear axle T020 <View from side>

1000326918_EW100_V_1.1 Reference (apr02)

13

Undercarriage

Location Front axle T018

Rear axle T020 Gear box T017

F

Drive motor T010

Undercarriage

1000326918_EW100_V_1.1 Reference (apr02)

14

System manual EW100 HYDRAULICS

PILOT SYSTEM

Hydraulics Pilot oil supply unit

Pilot oil supply unit The pilot oil supply unit is located in the valve area (tilt cab)

Variations

Pilot oil supply unit

20 km/h version 40 km/h version (Option)

Functions

X

Park brake Pendulum axle lock Safety function arm rest Pilot signal drive Shift gear box (Option)

Jul-14

Reference (apr02)

18

C006 Pilot oil supply unit

Pilot oil supply unit 20km/h Y008

Function pendulum axles lock

Y013

Function safety switch arm rest

Y043

Function park brake front axle

Y124

Function drive PVM

L018

Accumulator

L018

L018

Jul-14

Reference (apr02)

19

C006 Pilot oil supply unit

Pilot oil supply unit 40km/h

L018

Jul-14

Reference (apr02)

20

Y008

Function pendulum axle lock

Y013

Function safety switch arm rest

Y038

Function gear 1

Y039

Function gear 2

Y043

Function park brake front axle

Y124

Function drive PVM

L018

Accumulator

Safety switch arm rest Pilot valve

The safety switch S028 activates the solenoid valve Y013 (pilot only supply unit) Hydraulic pilot system activated Distributor tube Arm rest switch S028 Q008

The drive pump (port G) brings oil to the oil supply unit – Y013) and further to the inline filter Q008 to the distributor tube and to all hydraulic pilot valves (port P) If a hydraulic pilot valve is activated, pilot pressure is available (30 bar)

Y013

Hydraulic pilot system deactivated The solenoid valve Y013 blocks the oil supply, if switch S028 will be disconnected

30 bar

C006 Pilot oil supply unit

Jul-14

Reference (apr02)

21

Pendulum axle lock cylinders T018 Front axle

OFF

The drive pump (port G) brings oil to the solenoid valve Y008, passing the swivel joint L017 to both pendulum axle cylinders Z008 at the front axle

Pendulum axle lock - OFF

Foot brake S024

Function

Solenoid valve Y008 is energized and switched, if switch S024 is in OFF position

C013 /OFF B098 L017

12V

Pilot pressure opens the integrated check valves, both cylinders can exchange oil - communicate Same result with open (not pressed) foot brake valve C013 30 bar Charging pressure

Y008 30 bar

C006 Pilot oil supply unit

Jul-14

Reference (apr02)

22

The pilot pressure forces the cylinders to keep contact with the axle loosing contact

Pendulum axle lock cylinder T018 Front axle

Pendulum axle lock - ON Solenoid valve Y008 is not energized (OFF) and the spool in neutral position, if switch S024 is in position ON

ON

S024

Foot brake C013 / ON B098 L017

0V

The pressure line connecting the check valve (inside the lock cylinder) is connected with tank – and closed – pendulum axle lock is active Same result if the foot brake valve C013 is pressed. Brake sensor B098 deactivates solenoid valve Y008

Y008

C006 Pilot oil supply unit

Jul-14

Reference (apr02)

23

Pendulum axle lock cylinder Bleed screw Check valve

Pst

Pendulum axle lock cylinder (Z008) Plunger cylinder with integrated check valve The check valve is a leakage free ball seat valve. which is controlled by the spool

Pst

Z008

The pressure line Pst is connected with both cylinders. The pilot pressure of 30 bar pressurizes both cylinders during oscillation The oil flow between the cylinders is blocked by the check valve

Detail check valve

Attention: In case of high cylinder load, the valve can not open because of high inner cylinder pressure > bleed the cylinders at bleed screw

Pst Jul-14

Reference (apr02)

24

Park brake T018 Front axle

Park brake open (picture) Switch S065 activates solenoid valve Y043 (pilot oil supply unit)

S065 L017

The drive pump (port G) pumps oil to the solenoid valve Y043 through the swivel joint to the park brake cylinder Z009 The negative brake cylinder opens the disc brakes in the front axle (mechanic)

S011

The pressure switch S011 is assembled at port S1 and controls the park brake signal light in display P014 Y043

Park brake closed

30 bar

C006 Pilot oil supply unit

Jul-14

Reference (apr02)

Port A is connected with tank, if solenoid valve Y043 is not energized

25

Pilot system drive PMV R012 Hand throttle

Y (Drive pump)

B054 Drive pedal

Drive signal

N005 Controller

The signal of the drive pedal B054 & hand throttle lever R012 passes to the controller und further on to proportional valve Y124 The drive pump signal PS of the speed sensitive control valve is passing valve Y124 and return to drive pump (port Y)

Y124

Increasing the engine idle increases the control pressure PS at valve Y124 C006 Pilot oil supply unit PS (Drive pump)

Jul-14

Reference (apr02)

26

Change gear (Option)

Switch S021 changes between two gears (fast & slow) by activating valve Y038 or Y039 Drive slow (1. Gang) Solenoid valve Y038 (pilot oil supply unit) is active

S021

Y124 Y038

Pilot pressure from the drive pump (port G, 30 bar) is transferred by valve C027 to port G1, to the swivel joint L017 and further on to gear box cylinder (1.G) at gear box T017

30 bar

C006 Pilot oil supply unit

Jul-14

Reference (apr02)

27

Change gear (Option) T017_Gear box

Switch S021 changes between two gears (fast & slow) by activating valve Y038 or Y039 S021

Drive fast (2nd gear) Solenoid valve Y039 is active (pilot oil supply unit)

Y124 Y039

Pilot pressure from the drive pump (port G, 30 bar) is transferred by valve C027 to port G2, to the swivel joint L017 and further on to gear box cylinder (2.G) at gear box T017

30 bar

C006 Pilot oil supply unit

Jul-14

Reference (apr02)

28

Hydraulics Pilot valves

Pilot valves Joystick Left & Right Stabilization cylinder pilot valve Boom extension pilot valve Boom offset cylinder pilot valve AUX I (Auxiliary hydraulics)

Jul-14

Reference (apr02)

30

Pilot system Main valve block C001

Pilot valve Filter

Oil is pumped by the boost pump P2 from tank, passing the boost pump pressure limiting valve to the pilot oil supply unit. The arm rest switch S028 activates Solenoid Y013 and passes the pilot pressure through the pilot filter to the distributor tube to port P (pilot valve) Operating a function, proportional pilot pressure is sent to the main valve block pilot pressure port

Distributor

The spool inside the main valve block will move against the spool spring force

S028

T008 Drive pump

All other, not operated canals are connected to tank C006 Pilot oil supply unit

Jul-14

Reference (apr02)

31

Joystick Drive pump T008 Pilot oil supply unit C027 Distributor tube

Pxx

Jul-14

Reference (apr02)

32

Pxx

Pxx

Pxx

Joystick

Not active

Auto idle

Switch (fixing)

A

Lever

B

Plastic cover

C

Link shaft

D

Link

E

Guidance plate

F

Plunger

P

Pilot pressure

T

Tank

AUX II & AUX III (Power tilt)

Rocker

Breaker

AUX II & Power tilt

Lever left

Not active

Switch

Cruise control

Boom offset cylinder / AUX I

Rocker

Change drive direction

AUX I (ZH)

Forward / Backward

Boom offset cylinder

or Neutral

Lever right

Jul-14

Reference (apr02)

33

Joystick Port Nr.: 1 & 3

Port Nr.: 2 & 4

Move power(theoretical)

Jul-14

Reference (apr02)

Move power (theoretical)

34

Hydraulics Proportional valves

Proportional valve C018 C001

L045

Main valve block

Boom offset cylinder

Function

AUX_I

Similar to the hydraulic pilot system, the proportional valve C018 is supplied by the boost pump P2 with pilot pressure. Passing the pilot oil supply unit C006, inline filter Q008 and distributor tube.

Shuttle valve block bar bar

C018 Proportional

valves mA

N005 N025 S027

Distributor Q008 Filter

C006 Pilot

The proportional valve C018 are controlled by the roller N025 at the right joystick.

The electrical signal (mA) is transferred to a proportional hydraulic signal which moves the spools in the main valve block sections.

oil supply unit

P2

EW100_V_1.2

Reference (apr02)

36

Proportional valve C018 Boom offset cylinder

Coil Resistance R20 = 5,2 Ohm I max = 1500 mA

Boom offset cylinder

Pmax = 50 bar AUX_I

IP65, DC, 12V

AUX_I

EW100_V_1.2

Reference (apr02)

37

Y122…

Magnet 10.1

Y123…

Magnet 10.2

Y033…

Magnet 10.3

Y034…

Magnet 10.4

DRIVE

Hydraulics Drive pump

Drive pump & Drive pump valves Components Functions Closed circuit DA Pump regulation / valve Boost pump & Boost valve High pressure valve Pressure cut off valve (Max. load control system) Inch valve Drive direction valve Boost pump filter

Jul-14

Reference (apr02)

40

Drive pump

Y004

V Y005

HD

HD

High pressure valve

G

Port Pilot oil supply unit, Test port (MA)

Y004

Solenoid valve Drive backward

Y005

Solenoid valve Drive forward

RV

Speed sensitive control valve

SD

Boost pressure valve

SP

Filter pressure limiting valve

V

Inch valve

DA

Pump control valve V Y004 Y005

SD

HD

Jul-14

Reference (apr02)

SD

41

Drive pump

HD

Y004

1

SP

1

B / HD

High pressure valve

Y004

Solenoid valve Drive backward

5

Boost pump filter

SP

Safety valve boost pump filter

Y004 Y005

SD

HD

Jul-14

Reference (apr02)

42

Closed circuit

9 7

Jul-14

Reference (apr02)

8

8

43

1

Boost pump

2

Load check valves

3

Boost pressure limiting valve

4

Flushing valve

5

Flushing pressure limiting valve

6

High pressure valve

7

Hydraulic pump

8

Hydraulic motor

9

Boost pump filter

Closed circuit

The returning oil from the hydraulic motor is supplied directly to the suction side of the hydraulic pump Resulting, you find a high pressure- (red) and low pressure side (blue) The hydraulic pump retains the hydraulic motor.

Due to the mechanical connection, the hydraulic pump is retained to the diesel engine

Jul-14

Reference (apr02)

44

Boost pump/-valve

The boost pump (1) supplies oil too the boost pump filter (7) and further to the 30 bar boost pressure limiting valve (3)

7

The low pressure side of the closed circuit is loaded with cooled and filtered oil through the load check valves (2) This compensates quantity caused by the flushing valve (4).

Jul-14

Reference (apr02)

45

Flushing system The flushing valve (4) is controlled by the high pressure side of the system The flushing limiting valve (5) controls the leakage quantity from the low pressure side The leakage oil is taken to the cooler and filter, before the boost pump recycles the oil into the closed circuit

Jul-14

Reference (apr02)

46

High pressure valves

The high pressure valves (6) limit the maximum drive system pressure.

The EW100 high pressure valves work in combination with the maximum load control (pressure cut off)

Jul-14

Reference (apr02)

47

Pump control valve (RV) The boost pump (1) delivers oil to the filter (2) and on to the metering orifice (3), the pump control valve (4) and finaly to the boost pump pressure limiting valve (5).

Pst T008

Depending to the engine revolutions, the boost pump quantity builts up a defined back pressure at the orifice

2

The boost pressure valve limits the pressure to 30 bar (red) During engine idle speed the resulting back pressure Pst is not able to move the drive pump swash plate > no direction oil flow, no movement

4 3 5

1

At increased engine idle, the pressure difference at the orifice will control the pump control valve (4) and increase the pump control pressure Pst The higher Pst pressure moves the pump swash plate to higher oil flow and the EW100 will increase drive speed

Jul-14

Reference (apr02)

48

Pump control valve (RV) Pump control valve 4 Metering orifice 3

Pst

Diesel engine Drive pump

Boost pressure limiting valve (30bar)

Boost pump 1

Drive direction valve

Jul-14

Reference (apr02)

49

Pump control piston

Pressure cut off / Maximum load control (DA)

Pumpenregelsignal Pst

T008

B

The shuttle valve connects the actual high pressure side to the pressure cut off valve (1) The DA valve (1) will reduce the Pst pressure signal of the pump control valve (2) if the high pressure side reaches its limit valve The reduced pump control pressure Pst will reduce the hydraulic oil pump flow, maximum down to a vehicle stop

1 DA

A

Jul-14

Reference (apr02)

50

Brake / Inching The inch valve (1) is controlled by the foot brake valve C013

Foot brake valve C013

1 PS

If the operator slows down the EW100, the brake system pressure is taken to open den inch valve (drive pump). The pump control pressure Pst will be reduced by connecting to tank. That will again bring back the hydraulic pump oil flow and supports the mechanical brake system (axles) to reduce speed of the EW100 During „work“ situation, the foot brake can be fixed. Higher engine idle causes oil flow and power to the drive system and force the EW100 to start driving. The axle brake discs would have to block driving

T008

The whole power is available for the working hydraulic system during full inching The load to the axle brake discs is reduced

Jul-14

Reference (apr02)

51

Drive direction valve (For-/backward)

Drive pump T008

Pst Pilot oil supply unit

V

The direction switch (right joystick) act ivies the solenoid valve Y004 or Y005 at the drive pump

R N

The direction valve (1) passes the pump control pressure Pst to the drive pump control chamber for forward or backward

1

At neutral position of the direction valve, the pump chamber is depressurized to tank Higher control pressure Pst causes higher oil flow of the drive pump

T008

Jul-14

Reference (apr02)

52

Boost pump filter

4 5

The boost pump delivers oil from the hydraulic tank to the boost pump filter (5) The filter pressure limiting valve (4) opens if the maximum back pressure of the filter is reached The boost pump filter has to be changed accordingly the maintenance plan

Boost pump 4

Jul-14

Reference (apr02)

53

High pressure valve

The high pressure valve is equipped with a bypass function (detail A) (see chap towing the EW100 / operator manual)

A Jul-14

Reference (apr02)

1

Housing screw

2

Valve seat

3

Valve rod

4

Spring tension nut

5

Spring (high pressure)

6

Spring (pilot system)

7

Screw

8

Adjustment screw

11

Seal nut

12

Ring with seal 54

Drive pump control system T008 Drive pump

Y124

C006 Pilot oil supply unit

N004 Controller

Jul-14

Reference (apr02)

Pst

Y124

55

Hydraulics Drive motor

Drive motor T010 Variations 20 km/h version (A6VM150) 40 km/h version (A6VM80)

Feature Axial piston motor Closed circuit Engine revolution controlled motor (DA) Directional valve Flushing valve

Jul-14

Reference (apr02)

57

Drive motor A6VM-DA The control pressure (X1,X2) of the drive pump is a result of the diesel engine revolution and controls together with the system high pressure the angle of the swash plate of the hydraulic motor Higher diesel engine revolution give higher control pressure which results in relation to the high pressure to less displacement quantity (lower torque, higher engine revolution) If the high pressure passes the setting point of the controller, the hydraulic motor swash plate changes ist angle to bigger displacement quantity (higher torque, lower engine speed)

Jul-14

Reference (apr02)

58

Drive motor A6VM U

T1

1

G

X2

X3

X1

2 Jul-14

Reference (apr02)

Sa

3 59

1

VG-min screw

2

Pressure limiting valve flush valve

3

Flushing valve

G,U

Plugged

X1

Control pressure, do not remove the joints

X2

Control pressure, do not remove the joints

X3

Plugged

Sa

Tank

T1

Tank

Drive motor A6VM 1

1

Control element

2

Flushing valve element

M1

Measuring port control pressure 1

A B

2

M1 2

Jul-14

Reference (apr02)

60

Drive motor A6VM RB Vg-min

RB… Control start point screw Vg-min… Minimum displacement Jul-14

Reference (apr02)

61

X1

X2

Drive motor Drive pump

The drive motor is assembled at the gear box on the rear axle

Control signal T008

Drive pump T008

The drive motor for the 20 km/h version is different to the 40 km/h version

T010_Drive motor

Jul-14

Reference (apr02)

62

The drive pump T008 moves the oil through the swivel joint L017 to the drive motor T010 (High pressure side) The drive motor moves back the oil through L017 to the drive pump (Low pressure side)

Directional valve Drive forward (picture) Directional valve C is activated by X1 and connects the high pressure side B (directional) with valve D and control piston E

Drive pump

C

D E G F

Drive pump T008

Signal X1

Reference (apr02)

X2… Signal Backward (Y005 active) Drive backward Valve C connects the high pressure side A with valve D & control piston E At the same time valve C brings the signal of the drive pump (X1 or X2) to the control piston D

T010_Drive motor

Jul-14

X1… Signal Forward (Y004 active, pict.)

63

Control valve drive motor Fast- Drive motor at VG-min

VG-min / Fast Drive pump

The high pressure of B is connected through valve D to the bottom side of control piston E

Signal X1

Drive pump T008

C

D E G F

T010_Drive motor

At the same time pressure is at the bottom side > drive motor goes to VG-min Slow – Drive motor at VG-max An increase of pressure at B (e.g. drive uphill) causes a reduction of bottom side control pressure in valve E The signal is proportional depressurized to tank

VG-max / Slow

Jul-14

Reference (apr02)

> Reduction of speed

64

Flushing valve F… Flushing valve

G F

Fahrpumpe T008

G… Pressure limiting valve flushing valve The high pressure side (pict., side B) pilots flushing valve F. The low pressure side (A) will be connected with flushing valve pressure limiting valve G. A reduced quantity of oil is drained to tank (orifice) The drained oil can be filtered and cooled T010_Fahrmotor

Jul-14

Reference (apr02)

The „lost“ oil quantity is compensated by the boost pump P2

65

WORK

Hydraulics Work pump P3

Work pump P3 The work pump is direct connected to the drive pump unit T008 (P1 & P2) and delivers oil to the main valve block

Jul-14

Reference (apr02)

68

Work pump P3 P3 pumps the oil from the hydraulic tank L042 through the suction filter Q001 to the main valve block C001 The work pump pressure p3 can be measured at test port MA1 (main valve block)

L042_Filter inside the hydraulic tank

L042_Hydraulic tank

Jul-14

Reference (apr02)

69

Work pump P3 DR

FR

Y011

LR

DR…

Pressure controller

FR…

Flow controller

LR…

Power controller

Y011… Solenoid valve pump modes (PM) LS…

Load Sensing Signal DR

B DR

LS

LS S LS Signal

FR Main valve block C001

Jul-14

Reference (apr02)

LS

70

Y011

FR

Work pump controller DR…

The pressure controller keeps the pressure signal invariant. The pump delivers only the oil quantity which is needed by the consumers

DR

FR

FR… PM

LR…

Power controller

LS…

Load Sensing signal main valve block

PM…

Pump power mode HIGH / ECO / LOW

L042_Suction filter

L042_Hydraulic oil tank

Reference (apr02)

Flow controller

The flow quantity at the pump is controlled by the differential pressure at the consumers and realized by the flow controller

LR

Jul-14

Pressure controller

71

Pump power mode HI / ECO / LOW

DR

The pump power mode (HI / ECO / LOW) can be selected with the jog dial controller

FR

Solenoid valve Y011 is located at the working pump controller If the solenoid Y011 is not energized, the pump is in HI mode. The signal will be transmitted

PM

If solenoid Y011 is energized (active), the pump signal is disconnected, the pump is shifted to ECO mode

P3

N016_Controller

Jul-14

Reference (apr02)

The LOW mode is realized by reducing the diesel engine speed

72

Work pump P3 1

Shaft

2

Plate

3

Piston

4

High pressure side

5

Plate

6

Plate

7

Suction side

8

Control piston

9

Control valve

10 Piston 11 cylinder 12 Slide shoes 13 Swash plate

Jul-14

Reference (apr02)

73

Hydraulics Main valve block

Main valve block Components Feature Inlet section Section LUDV Pressure limiting valves Stroke limiter section swing Test port MA1

Jul-14

Reference (apr02)

75

Sections MA1

P3

Inlet section

A1

B1

Boom cylinder

A2

B2

Arm cylinder

A3

B3

Bucket

A4

B4

AUX I (Auxiliary hydraulic)

A5

B5

Swing motor

A6

B6

Boom offset cylinder

A7

B7

A8

B8

A9

B9

Boom extension cylinder Dozer blade cylinder AUX II (3rd hydr. circuit, Option)

T3

End plate

P3

Jul-14

Reference (apr02)

76

Valves 11

AP

12

1

LS Pressure limiting valve (AP)

2

Inlet pressure compensator

3

PLV Boom cylinder rod side

4

PLV Boom cylinder bottom side

5

PLV Arm cylinder rod side

6

PLV Arm cylinder bottom side

7

PLV Bucket cylinder rod side

8

PLV Bucket cylinder bottom side

9

PLV AUX I

10 PLV AUX I 11 Plug (AUX II) 12 Flow control valve 11

Jul-14

Reference (apr02)

77

PLV…

Pressure limiting valve

LS…

Load Sensing Signal

AP…

Adjustment point

EW100_V_1.2

Reference (apr02)

78

AUX_II

Dozer blade

Triple boom

Boom offset

Swing motor

AUX_I

Bucket

Arm

Boom

Inlet section

Schematic

Inlet section valves

C001

6

8

Jul-14

Reference (apr02)

7

79

6

Flow regulation valve

7

LS-Pressure limiting valve

8

Inlet pressure compensator

Inlet section valves P M P2

T2

Ls

T

T1

1

Inlet pressure compensator

2

LS- pressure limiting valve

3

Flow regulator

M

Measurement port MA1

B067

Pressure sensor auto idle

Ls2

B067

Jul-14

Reference (apr02)

80

Ports T1

M

Inlet pressure compensator

T

P

Inlet section

A1

B1

Boom cylinder Z001

A2

B2

Arm cylinder Z002

A3

B3

Bucket cylinder Z003

A4

B4

AUX_I

A5

B5

Swivel motor T015

A6

B6

Boom offset cylinder Z005

A7

B7

A8

B8

A9

B9

Boom extension Z004 Dozer blade cylinder Z006 AUX_II

T3

End plate

P3

Jul-14

Reference (apr02)

81

Pilot ports

Inlet section Pa1

Pb1

Boom cylinder Z001

Pa2

Pb2

Arm cylinder Z002

Pa3

Pb3

Bucket cylinder Z003

Pa4

Pb4

AUX_I

Pa5

Pb5

Swivel motor T015

Pa6

Pb6

Boom offset cylinder Z005

Pa7

Pb7

Boom extension cylinder Z004

Pa8

Pb8

Dozer blade cylinder Z006

Pa9

Pb9

AUX_II End plate

Jul-14

Reference (apr02)

82

Inlet section ports P

T

P2

T2

Ls Ls2

Jul-14

Reference (apr02)

Measurement port MA1

LS..

Load sensing port

LS2.. Pressure sensor auto idle B067

T1

M

M…

83

P…

Supply working pump P3

P2..

closed

T…

Return line Tank T2

T1..

Return line Tank 20

T2..

Closed

1

Housing

6

Flow regulator

7

LS-Pressure limiting valve

8

Inlet pressure compensator

Inlet section A… Inlet pressure compensator C001

The working pump P3 transports the oil from the hydraulic tank to the main valve block – port P The inlet pressure compensator (A) limits the maximal pressure in the P-canal (pump pressure) The spring force of the inlet pressure compensator defines the standby pressure.

A

Jul-14

Reference (apr02)

If the LS-canal (yellow) pressure increases, the spring force of the inlet pressure compensator (A) increases and following the maximum pressure in the P-canal increases (spring force + LS pressure) •

Pump pressure (P3) increases

•

No adjustment of valve A

84

Inlet section C… Load Sensing (LS) pressure limiting valve

LS

The LS-pressure limiting valve (C) controls the maximum pump pressure P3!

The LS-pressure limiting valve limits the maximum LS-pressure in canal LS (Load signal yellow)

A

C

Due to the connection with the inlet pressure compensator (A), the setting of the LS-pressure limiting valve (C) influence the max. pressure P3 Test port for P3 is MA1

C001

Jul-14

Reference (apr02)

•

Pressure test (LS-PLV + MA1)

•

Setting values (> Technical data, service manual)

85

Inlet section

C001

B… Flow regulator The LS-canal is permanent leaking to tank at the flow regulator The leakage depressurizes the LScanal if the load signal is off (no function)

D B

The LS-signal controls the working pump and the section pressure compensators (D) The leakage quantity is insignificant during working

Jul-14

Reference (apr02)

86

Section Pb

Pa P1

C001

LS

LS P1

1

Housing

2

Spool

3

Check valve / Load holding valve

4

Section pressure compensator

5

Pressure limiting valve (Secondary)

6

Plug

7

Bore / Screw

3

LS Load Sensing canal P1 Pump canal

2

5

Pa Pilot control canal

4

Pb Pilot control canal

Jul-14

Reference (apr02)

87

Section parts

5

Gasket

20 Housing 21 Spool 22 Pressure limiting valve (250 – 330 bar, 10 bar Stufen) 23 Plug 25 Check valve 26 Section pressure compensator

Jul-14

Reference (apr02)

88

Section parts

26 Pressure compensator

Pressure limiting valve

25

23

Check valve

Jul-14

Reference (apr02)

89

22

Plug

Spool function

Example: Boom up (1/2) The spool 1 can be moved by the pilot pressure.

P3

If the pressure at pilot port (Pa1) is higher than the spring force, the spool will move proportional (grey).

1

2

The spool (1) is moved by the pilot pressure at port Pa1 The pump pressure P3 will be passed through the spool throttle to the pressure compensator (2).

In case only one function is activated, no relevant pressure is at the LS-side of the pressure compensator (leakage by the flow regulator) C001

Jul-14

Reference (apr02)

The pressure compensator (2) will be pushed to its end position and connect LS- & pump canal (grey)

90

Spool function

Example: Boom up (2/2) Prosecution:

P3 LS 1

2

If the pressure compensator (2) moves to its end position the maximum oil quantity passes to the main spool (1) and following to the boom cylinder At the same time, the LS-canal will be pressurized with the same pressure (throttle).

The LS-signal is necessary to „close“ the inlet section pressure compensator and to control the work pump

Jul-14

Reference (apr02)

91

Secondary pressure limiting valve 330 bar

Situation

C001

Main Spool (1) not activated, Cylinder external load with 330 bar The secondary pressure limiting valve opens to tank, if the setting value of the valve is reached.

P3 LS 1

2

Features SPLV 22… SPLV is not adjustable Pressure setting is labeled 250 – 330 bar / 10 bar steps

22 S-DBV Jul-14

Reference (apr02)

92

LUDV – Load independent flow distribution 200 bar

150 bar

Situation: Several functions activated All functions are supported by P3 All section pressure compensators are connected with the LS-canal, all have the same pressure level (yellow)

P3 200 bar

LS 1

A

2

B

The pressure compensator A - Function 1 – with the high load signal (200bar) will stay in end position The load signal (150bar) of function 2 restricts the flow quantity by moving the pressure compensator B to restricted position. The connection to LS-canal will be disconnected.

T

C001

The flow quantity to the spool depends to the pressure difference LS – Load signal (P*) The available quantity at spool 2 will be reduced, speed compensation

Jul-14

Reference (apr02)

93

Z001

Section Boom cylinder Pa1

Pb1

P3

1

A1

B1

C001 Mobilsteuerblock

LS

1... Pressure limiting valve secondary bottom side

2 2

1

Pb1

Pa1 Jul-14

Reference (apr02)

94

2… Pressure limiting valve secondary rod side

Section Boom cylinder Z001

Pb1

P3

Detail – Preliminary tension

LS

An orifice in the boom cylinder spool throttles the oil coming back from the bottom side of the cylinder. This will be recirculated to the rod side canal if necessary Resulting, a boom swing movement will be damped > preliminary tension between bottom and rod side 2

1

Pa1

Jul-14

Reference (apr02)

95

Z002

Section arm cylinder Pa2

Pb2

P3

1

A2

B2

C001 Mobilsteuerblock

LS

1... Pressure limiting valve secondary bottom side

2

2

1

Pb2

Pa2 Jul-14

Reference (apr02)

96

2… Pressure limiting valve secondary rod side

Section arm cylinder Detail A Detail A – Regeneration High load at cylinder rod side can cause suction problems at the cylinder bottom side The check valve inside the spool transfers oil from rod- to bottom side of the cylinder Pb2

Detail B Detail B – Damping pilot pressure The throttle check valve inside the main valve block pilot cabs supports a damped movement of the arm function

Jul-14

Reference (apr02)

97

Section bucket cylinder Z003

Pa3 Pb3

1

P3

A3

B3

C001 Mobilsteuerblock

LS

1... Pressure limiting valve secondary bottom side 2… Pressure limiting valve secondary rod side

2

2

1

Pb3

Jul-14

Reference (apr02)

98

Section bucket cylinder Z003

Detail pressure compensator

Pb3

P3 LS

Jul-14

Reference (apr02)

99

Section AUX_I (Auxiliary hydraulic) xx Pb4 Pa4

P3 LS

1

A4

B4

C001 Mobilsteuerblock

1... Plug Both plugs can be changed to pressure limiting valves

1 1 Pb4

Jul-14

Reference (apr02)

100

Section swivel

T015

Pa5 Pb5

82

P3 LS 82

C001 Mobilsteuerblock

82…

A5

B5

82

82 Pb5

Jul-14

Reference (apr02)

Pa5

101

Stroke limiter Spool swivel

Section swivel 82… Stroke limiter swivel spool 82

The stroke for the spool function swivel can be limited.

Due to that, the quantity and max. speed of the swivel motor can be influenced.

C001 Mobilsteuerblock

The stroke limiter screw (82) is integrated in the main valve block pilot cab (83)

82

Jul-14

Reference (apr02)

102

Section boom swing Z005

Pa6

Pb6

P3

A B

A6

B6

C001 Mobilsteuerblock

LS

Detail boom swing spool In neutral position the spool connects the consumer canals A & B to tank line The canals of the lowering brake valve are open to tank - depressurized

Pb6

Jul-14

Reference (apr02)

103

Section boom extension (triple boom) Z004

Pa7

Pb7

P3

A B

A7

B7

C001 Mobilsteuerblock

LS

Detail boom extension spool In neutral position the spool connects the consumer canals A & B to tank line The canals of the lowering brake valve are open to tank - depressurized

Pb7

Jul-14

Reference (apr02)

104

Section dozer blade cylinder Z006

Pa8 Pb8

P3

A B

A8

B8

C001 Mobilsteuerblock

LS

Detail dozer blade spool In neutral position the spool connects the consumer canals A & B to tank line The canals of the lowering brake valve are open to tank - depressurized

Pb8

Jul-14

Reference (apr02)

105

Section AUX_II (Option) xx Pb9

Pa9

1

LS

B9

Both plugs can be exchanged by pressure limiting valves

C001 Mobilsteuerblock

A9

1... Plug

1

1 Pb9 Pa9 Jul-14

Reference (apr02)

106

BRAKE SYSTEM

Hydraulics Service brake valve C013

Service brake valve C013 Features The service (foot) brake valve consists of a pedal unit, a brake unit and accumulator loading unit 2-circuit brake system Pilot valve to control the disc brakes in front- and rear axle Pilot valve to inch the drive pump

Jul-14

Reference (apr02)

109

Service brake valve C013

B098

T1* p

T2*

S010

F N

T1

P

R1

R T2

B

R2

B098..

Sensor brake

S010..

Switch accumulator brake

Jul-14

Reference (apr02)

Adjustment accumulator loading valve

110

Service brake valve A

Pedal unit with adjustment possibility for max. work pressure and pedal angle limitation screw

B

Brake unit This unit controls the brake pressure It is designed for two brake ciruits and accumulators

C

Accumulator loading unit

D

A B

This valve controls the pressure inside the accumulators. The loading pressure can be adjusted

C

E

Jul-14

Reference (apr02)

111

D

Mechanical fixing lever

E

Adjustment screw max. brake pressure

Service brake valve

Jul-14

Reference (apr02)

112

Accumulator loading valve

Jul-14

Reference (apr02)

113

Accumulator loading valve

Jul-14

Reference (apr02)

A…

Adjustment screw loading start setting

B…

Adjustment max. pressure

C…

Stop screw, protection A

114

STEERING SYSTEM

Hydraulics Steering unit

Steering unit

Z012_Steering C016_Steering

cylinder

mode (Option) L017_Swivel

1 joint

2 C015_Steering

direction (Option)

C014_Steering

C013_Service

unit

3

brake unit

Q010 Steering

system filter

4

P4

Jul-14

Reference (apr02)

117

1

Shock valves (240 bar)

2

Check valve

3

Pressure limiting valve (175 bar)

4

Check valve

Steering unit The steering unit is assembled at the end of the steering shaft. It can be reached by tilting the cab The steering unit transforms the rotating motion at the steering wheel in a hydraulic flow to the steering cylinder – bottom or rod side.

T L P

R

Jul-14

Reference (apr02)

118

Steering unit

1

Control piston

2

Control bush

3

Rotator

4

Spring

5

Pilot valve load signal

6

Shock valve

7,8

Suction valve

9,11,12 Check valve 10

Jul-14

Reference (apr02)

119

Shut off valve

Hydraulics Steering mode valve

Steering mode valve (Option) Z012_Steering

C016_Steering

mode (Option) Z012_Steering

L017_Swivel

The steering mode valve creates the two-, four- and crap steering mode by supplying different steering cylinder ports

cylinder front axle

Y006

joint

unit

Two wheel steering

brake valve

Four wheel steering

C014_Steering

C013_Service

The optional steering mode valve C016 is located at the undercarriage, next to the front axle

cylinder rear axle

Q010 Steering

system

Crap steering

filter

Reference (apr02)

Y007 C Y036

121

B Y040

D

P4

Jul-14

A

Two wheel steering Front axle

Rear axle

R

The switch S022 energize solenoid Y006 at the steering mode valve C016 (Grid position)

R

Only the front axle is supplied during the two wheel steering mode Y006

L

Depending to the steering direction, the left or the right cylinder side is supplied with oil

L

Y006

See electric

Y006

Steering unit C014

S022 Jul-14

Reference (apr02)

122

Four wheel steering S073

Front axle

Y040

Y036

R

Der Schalter S073 in Stellung Allradlenkung bestromt Magnet Y036 und Y040 am Lenkartenventil C016 Rear axle R

Lenkzylinder Vorderachse lenkt nach links, das verdrängte Öl wird über beide Wegeventile zum Lenkzylinder der Hinterachse geleitet Bild: Lenkrichtung Links

Y007 Y006

L

L

Steering unit C014

Jul-14

Reference (apr02)

123

Crap steering mode S073

Front axle

Y040

Switch S073 in position crab steering mode energizes solenoid Y007 and Y040 at the steering mode valve C016 Rear axle

R

R

The steering cylinder front axle moves the wheel to left direction, the displaced oil pass both directional valves to the rear axle steering cylinder.

Picture: Steering direction left

Y006

L

Y007

Steering unit C014

Jul-14

Reference (apr02)

L

S073

124

Hydraulics Steering direction valve

Steering direction valve (Option) Steering cylinder

L

R

Switch S080 can be operated by opening the mechanical lock bottom C015_Steering direction valve

Y070.2

At position A the solenoid Y070.1 is activated and the steering direction of the wheels is equal to the steering direction of the steering wheel At position B the solenoid Y070.2 is activated and the steering relation is changed.

S080

The steering direction is defined by the position of switch S080 only ! (no automatic)

Y070.1

B Steering direction

S080

„Changed“

A

Steering unit C014 Steering direction „Standard“

Jul-14

Reference (apr02)

126

Steering direction

The steering direction valve is assembled between cab and engine (tilt cab)

B A Y070.1

T Y070.2

P Steering direction valve C015

Jul-14

Reference (apr02)

127

SWIVEL SYSTEM

Hydraulics Swivel motor

Swivel motor T015 Features Radial piston motor Negative brake to fix the upper carriage Pressure limiting valve with damping function Anti-cavitation valve Brake release valve with delay function

Jul-14

Reference (apr02)

130

Swivel motor Oben / top

X2

X1

M3

Z

B

A

L

M2

Jul-14

Reference (apr02)

M2

131

Swivel motor Oben / top

2 X2

X1

M3

Z

B

1 L

3

Jul-14

Reference (apr02)

M2

Pressure limiting valve

2

Negative brake

3

Valve block

X1,X2

A

1

1

M2

132

Port brake release

Swivel motor T (Pressurized) A1

B1

x

Swivel, Release park brake

F

The oil is pumped by the work pump P3 from the hydraulic tank to the main valve block C001

x 6

If function swivel is activated, oil is pumped to port A or B

6 4

3 PR

4 5

At the same time, the pilot signal of function swivel (Joystick) is passing the shuttle valve block L045 and opens the negative brake at the swivel motor.

The pilot oil supply unit C006 offers permanent pilot pressure at port PR (swivel motor)

1

Jul-14

Reference (apr02)

2

The negative brake (2) is opened, the swivel motor can turn

133

Swivel motor Negative brake closed, swivel turn stop

T (Pressurized) A1

If hat hydraulic pilot valve is not activated, the pilot pressure on X port is drained to tank, the valve 3 switches to neutral position and the oil from the negative brake chamber is drained through an orifice to tank

B1

x

x 6

6 4

3

4

Due to the throttled leakage to tank, the negative brake closes slowly. The swivel motor should stop total before the negative brake closes.

5

1

Jul-14

Reference (apr02)

2

134

Pressure limiting valve

Pressurized oil presses piston 1 against the spring If the pressure is high enough, the small piston opens the valve seat and drain the oil The pressure effects, that oil drains through the orifice (2) to the backside of the piston (3) Due to the pressure at the backside of piston (3) the spring is tensioned additional This increases the opening pressure up to the setting point The result is a 2-step pressure limiting valve

Jul-14

Reference (apr02)

135

Swivel motor T (Pressurized) A1

Pressure limiting valve

B1

x

x

The maximum possible working pressure of the swivel motor is limited by the pressure limiting valve (4).

Additional, they limit the pressure increase speed and damp fast acceleration

4

4

Function: If the pressure reaches the adjusted setting, the valve opens to the low pressure side 1

Jul-14

Reference (apr02)

The open- and close motion are damped internal

136

Swivel motor Cavitation protection

T (Pressurized) A1

During trailing throttle condition, the pressure in canal A1 has to be guaranteed to avoid cavitation inside the swivel motor

B1

x

x 6

6

If too less oil is supplied, valve 6 opens and connects to the pressurized tank port M Oil will be sucked from the tank line into the system

4

4

1

Jul-14

Reference (apr02)

2

137

Negative brake swivel motor The disc package (3) which have alternate teeth to the brake shaft and brake housing (4) is pressed together by the force of a plate spring.

The friction between the discs creates the brake torque A pressure increase inside the ring chamber (7) moves the piston (6) against the plate spring, the disc package is unfastened, the motor can swivel In case of pressure drop inside the ring chamber (7), the disc spring presses the disc package together, the brake is closed If the hydraulic system fails the negative brake can be released manual by the top screws (8) Start pressure to open the brake: 8 bar Total opened brake pressure: 11 bar

Jul-14

Reference (apr02)

138

Swivel motor

Jul-14

Reference (apr02)

139

12

Distance

13

Bearing

14

Bearing

15

Spring ring

16

Seal

17

Pin

18

Spring

19

Seal

20

Valve block

21

Screw

22

Brake piston

23

Brake disc

24

Brake disc

25

Distance

Hydraulics Shuttle valve block

Shuttle valve block L045 Position The shuttle valve block L045 is located below the cab, beside the boom offset cylinder

Function The following functions…

Arm IN (cylinder bottom side) & overload valve at the cylinder Boom offset cylinder left / right Swivel left / right …open the negative brake of the swivel motor The pressure signal of the pilot valve is sent to the shuttle valve block and further to the main valve block spools. This signal passes through the shuttle valve chain to port F. This signal pushes the negative brake valve of the swivel motor (port X2)

Jul-14

Reference (apr02)

141

Shuttle valve block Arm IN

C007 C001 / Pa2

Anti hose burst valve Arm

Boom offset cylinder Left

L063 / Pa2 C018 C001 / Pa6 X2 / Swivel motor(T015)

Boom offset cylinder right

C018 C001 / Pa6

Rotation left

C007 C001 / Pb5

Rotation right

C007 C001 / Pa5

Jul-14

Reference (apr02)

142

Function Arm IN Swivel motor T015, X2

Arm IN

C007/3

Arm cylinder C001

C001/Pa2

Jul-14

Reference (apr02)

143

Function Rotation (example left) Joystick left

Swivel motor T015, X2

C007

C001/Pb5

C001

Jul-14

Reference (apr02)

144

Function Boom offset (example left) Y123

Joystick left

Swivel motor T015, X2 C018

C007

C001/Pb6

C001

Swivel motor T015

Jul-14

Reference (apr02)

145

STABILIZE

Stabilize Function The boost pump P2 delivers pilot pressure via the boost pressure valve to the pilot oil supply unit C006. With active solenoid valve Y013 (armrest switch) the pressure signal is sent via the pilot filter and the collection tube to the pilot valve C009 in the cab.

The pilot valve C009 controls the direction of the spool in the dozer blade section (main valve block) and following the direction of the cylinders (rod- or bottom side) The work pump oil pressure (P3) is sent through the swivel joint to the stabilizers valve (C033, C034).

If a solenoid of the stabilizer valve is not energized the oil is transferred to the cylinder.

If the solenoid is energized, the oil flow is blocked by the valve, the cylinder is stopped.

Variations Standard (without outrigger valve) With 2-solenoid stabilizer valve block (Undercarriage) With 4-solenoid stabilizer valve block (Undercarriage) EW100_V_1.2

Reference (apr02)

147

Dozer blade cylinder

Stabilize Outrigger cylinders L017 Variations

Stabilizer valve C033 Y056

Y055

Main valve block C001 S076

Dozer blade pilot valve C009

P3

Outrigger cylinders Collection tube Stabilizer valve C034 Y013

Pilot oil supply unit C006

Y055

S076

P2 EW100_V_1.2

Reference (apr02)

Y056

148

Y057

Y058

S075

Hydraulics Stabilizer valves

Stabilizer valve The stabilizer valve is located in the center of the undercarriage Depending to the switch position of the main valve block spool, P3 oil is sent to port P or T at the stabilizer valve block If a stabilizer valve block solenoid is not energized the oil is sent to the cylinder If a solenoid is energized, P3 is blocked by the stabilizer valve

P3 Y056 C003

Pa8 EW100_V_1.2

Reference (apr02)

150

Y055

Stabilizer block versions 4-solenoid stabilizer valve C034

2-solenoid stabilizer valve C033

Y057 Y055

Y058

Y055 Y056

EW100_V_1.2

Reference (apr02)

Y056

151

Y055 Y056 Y057 Y058

outrigger Left outrigger Right dozer blade left dozer blade right

AUXILIARY CIRCUITS

Hydraulics Change over valve

Change over valve AUX_II & AUX_III (Option) C1

C2

The optional change over valve is assembled between cab and engine (tilt the cab)

B1 B2

Operating the switch S056 at the left joystick activates solenoid Y051 and changes between function AUX_II & AUX_III (Power tilt, situation Y051 not energized)

A1

The rocker energizes the proportional solenoid Y080 & Y081 (see C019 Proportional valve) and controls the hydraulic pilot signal at the main valve block

A2

Y051 AUX_II S056

Joystick left, Switch

N024

Joystick left, Rocker

Left Y080 Y081 Jul-14

Reference (apr02)

Proportional valve C019 Main valve block C001, Section AUX_II 154

AUX_III

SAFETY VALVES

Hydraulics Anti hose burst valve (L001, L002)

Anti hose burst valve dozer blade cylinder

L001

A/B

L001…

Hose burst valve

Z006…

Dozer blade cyl.

L001

Main valve block C001

Both dozer blade cylinders have a direct controlled load holding valve (L001/L002) integrated. This valve block oil flow, if a hose burst at port A and prevents an abrupt drop down of the machine

Jul-14

Reference (apr02)

157

Anti hose burst valve dozer blade cylinder Extend cylinder, stabilize Oil is pumped by the work pump P3 through the section dozer blade in the main valve block C001 to cylinder port A

L001 1

The oil is pumped from port A to the check valve to the bottom side of the cylinder. At the same time the high pressure opens the check valve in the B-canal and opens the return flow from the rod side of the dozer blade cylinder.

If the pressure at port A drops down fast (hose burst) the spring of valve 1 closes the valve in blocking position

Main valve block C001

Jul-14

Reference (apr02)

158

Anti hose burst valve dozer blade cylinder Retracted cylinder The work pump P3 pumps oil through the section dozer blade in the main valve block C001 to cylinder port B The oil is pumped through the check valve to the rod side of the cylinder. At the same time the high pressure switches valve 1 and opens a throttled return flow from the bottom side of the dozer blade cylinder L001 1

Mobilsteuerblock C001

Jul-14

Reference (apr02)

159

Hydraulics Anti-hose burst valve (L062,L063)

Anti-hose burst valve boom- & arm cylinder The anti-hose burst valve blocks the oil flow if pressure is lost due to hose burst A… Supply main valve block

CT1

A1.. Boom cylinder bottom side A

E… Port Pressure sensor B066 X… Pilot signal port

CT1

A1

CT1..

Valve 1 (switch pressure 11bar)

CT2..

Valve 2 (switch pressure 340bar)

The anti-hose burst valves are assembled direct at the cylinder Only authorized persons are allowed to adjust the setting

Jul-14

Reference (apr02)

161

Anti-hose burst valve boom cylinder Boom down

Z001

If the function boom down is operated, the main spool (C001) and valve CT1 (by pilot port Pb1 and port X) is opened at the same time

B066

L062

Pressure limiting valve CT2 Valve CT2 opens if the setting pressure (340bar) is reached. The pressure closes the check valve 1 and pilots CT1

1

The oil can flow direct from A1 to A and opens the secondary pressure limiting valve (main valve block C001) to tank

Pb1

Mobilsteuerblock C001 Jul-14

Reference (apr02)

162

Anti-hose burst valve arm cylinder Z002

Arm IN If the function arm in is operated, the main spool (C001) and valve CT1 (by pilot port Pa2 and port X) is opened at the same time

L063

Pressure limiting valve CT2 Valve CT2 opens if the setting pressure (340bar) is reached. The pressure closes the check valve 1 and pilots CT1

1

The oil can flow direct from A1 to A and opens the secondary pressure limiting valve (main valve block C001) to tank

Pa2

Main valve block C001 Jul-14

Reference (apr02)

163

Hydraulics Load lowering valve (L005, L006, L007)

Load lowering valve

A load lowering valve is assembled for function boom offset cylinder (L005), boom extension (L006, L007) Position Boom offset: next to the cylinder (tilt cab)

Z005

Boom extension: at cylinder bottom side Function The work pump P3 pumps oil through the section boom offset cylinder or boom extension in the main valve block C001 at cylinder port A (pict.)

The pressure increases at the bottom side and supports the pressure at port A. If the hydraulic force is higher than the spring force (PLV function) of the opposite valve – the load lowering valve opens to B Main valve block C001

Jul-14

Reference (apr02)

The cylinder can move, the procedure is the same for extend and retract the cylinder

165

Hydraulics Accumulators

Accumulator L018 The accumulator L018 is part of the pilot oil supply unit C006 which is located between cab and engine (tilt cab) Boost pump P2 pumps the oil to this accumulator The accumulator filling can not be refilled Technical date: Medium:

Nitrogen

Quantity:

0,1 Liter

Gas filling pressure:

15 +/-1 bar

L018

Drive pump T008

C006 Pilot oil supply unit

Jul-14

Reference (apr02)

167

Accumulator L020 & L021 The accumulator L020 & L021 is assembled at the bottom side of the cab floor (tilt cab)

Plug (20Nm) Pressure container

The gear pump P4 supplies the oil for these accumulators The gas pressure (po) can be adjusted with a fill- and test equipment

Membrane Valve plate

Valve body

Technical data: Medium: Quantity: Gas fill pressure:

C013 Bremsventil

Jul-14

Reference (apr02)

168

Nitrogen 0,75 Liter 42 +/-1 bar

Hydraulics Filter

Hydraulic oil reflux filter Q007 The hydraulic oil reflux filter Q007 is located inside the hydraulic oil tank (Counter weight area)

S005

The returning oil flows through the collecting tube L046 to the reflux filter Q007

Internal Bypass valve

Pressure switch S005 located at the filter housing controls the back pressure (see chapter electric) The bypass valve opens if the max back pressure reaches 3 bar.

The hydraulic oil of the drive system returns direct from the cooler L041 into the hydraulic oil tank

EW100_V_1.2

Reference (apr02)

170

Pressure filter Q010 The pressure filter Q010 (red) is assembled between the cab and the engine (tilt cab) Technical data: Bypass open pressure: Filter density:

7 bar 20µm

No monitoring lamp

P4

Foot brake valve C013

SW24

Jul-14

Reference (apr02)

171

Hydraulics Coolers

Drive system - Hydraulic oil cooler L041

Drive pump P1

Tank

EW100_V_1.2

L041..

Cooler hydraulic oil Drive pump

L042..

Oil tank

L060..

Check valve 1bar/2bar

Q001..

Suction filter

Q005..

Air inlet filter – hydraulic tank

Q007..

Reflux filter – working hydraulic system

Reference (apr02)

173

Work system – hydraulic oil cooler L040

Main valve block C001 S005

EW100_V_1.2

Reference (apr02)

L040..

Work hydraulic – cooler hydraulic oil

L060..

Check valve

Q007..

Reflux filter with bypass

S005..

Pressure switch hydraulic oil

174

ATTACHEMENT

Hydraulics Hydraulic quick hitch system - Easy Lock

HQH (Easy Lock) valve - C017 Y025 E

G F B

P3

Pil A

DS P3

30 bar

Main valve block C001

DS3

Pilot oil supply unit C006

E

Y025

G

F

Plate lock cylinder Jul-14

Reference (apr02)

177

A…

Port cylinder bottom side

B…

Port cylinder rod side

E…

Pressure reduction valve

F…

Check valve piloted

G…

Pressure plug (Differential pressure)

DS

Port pressure switch (not used)

DS3

Port pressure switch (not used)

Pil

Port pilot oil supply unit

P3

Port pump

T…

Port tank

Y025

Solenoid valve

HQH interlock cylinder opens Operate switch S040 & joystick switch S153 (Breaker)

30 bar

P3 E

C006

C001

G

The solenoid valve Y025 at the HQH valve can be energized (pict.)

Operating the dozer blade function creates pressure P3 which passes the pressure reduction valve, the shuttle valve and directional valve Y025. The pressure opens the check valve and the rod side of the interlocking cylinder at the QH plate

F

S040

If the dozer blade lever (C009) is moved the pressure sensor B055 at the main valve block releases the signal for the valve solenoid Y025

S153

B055

Interlock cylinder opens !

Due to the „open“ differential plug G the pressure at the pressure reduction valve E can be increased up to max. P3 (290 bar)

C017_Quick hitch system EW100

Jul-14

Reference (apr02)

(> interlock open pressure) 178

System manual EW100 ELECTRICS

CAN BUS system of the EW100 The EW100 electric system was developed new The engine- und most of the cab- & hydraulic electric from the 9503 was changed to a CAN BUS system for the EW100 Several consumers (e.g.. working lights) are supplied traditional Due to the CAN BUS system components can be controlled and monitored Failures (SPN codes) are edited in the display and stored in the controller The release of the diagnostic tool WANDA supports an up-to-date trouble shooting support The retrofitting of parts and options needs an identification by the diagnostic tool (see WANDA manual)

Jul-14

Reference (apr02)

180

Illustration of component relation The picture left shows an illustration of each component which are in relation to a certain function

G002

F901

X006

The illustration does not replace the EW100 electric diagrams !

X009

System failures are listed in the EW100 display (see operator manual) and can be edited by the Wacker Neuson diagnostic tool WANDA

S ((FNR) F015

X008

N005

F

Jul-14

Reference (apr02)

X001

X001

Y005

Y004

Additional functions of the WANDA diagnostic tool are described in the WANDA manual

R

The Wacker Neuson diagnostic tool WANDA is listed in the WN Linz special tool overview

181

Electrics Harness / parts position

Controller N004

N003

Engine harness

C3

C3

T003 Work pump

D

D M001

G001

B057

D

E

E

B007

ECM A

N003

ECM K

D R035

Y011

Y005

D

Y035

XE3

Y031

D

D EIC1

E

Y004

T008 Drive pump

S058

X018 EIC2

D

D B056

B038

G002

B037

X901

B064 X006

F021

X001

F022

B M007

GND2

F023 K007

G C3 1000326915 EW100_V_1.2 Reference (apr02)

183

F024

Main fuse box

Diagnose Perkins

Y123

Y122

Y081

Y080

C2

S004

Y034

C3

Y033

Y043

Y013

Y008

Y039

Y038

Y124

Chassis harness S011

C018 Proportionalventile

C006 Steueröleinheit C032 Y051

C1

C3

X018

XE05

Y025

B002

C017 B066

N016 SG X022

X020

M005 X021 Y070.1

C1

X002 B003

GND

Y070.2 X017

S052

C1 X016

B E016 X026 S005 X027 B001

E

B067

E C001 main valve block 1000326915 EW100_V_1.2 Reference (apr02)

X019

X023

GND1

B055

184

Undercarriage harness

L017 Swivel joint F

C016 Steering mode valve

X027

Y006

F

Y040 XE06 Y007

Y036

N014 controller undercarriage

F

F S134

S134.1

F B009

B005

T017 Gear box sensor

F Y055

1000326915 EW100_V_1.2 Reference (apr02)

Y056

Y057

C034 Stabilizer valve

Y058

Gear box T017 / Rear axle T020 185

Switches harness

Switch panel right

XE01

A

A

S018

S001

S017

S016

S042

S021

S080

S024

S073

S022

XE02

A

A Diagnose

XE04 F019

F011

F018

F010

F017

F009

F016

F008

F015

F007

F014

F006

F013

F005

F012

F004

X006 X008

X012

B

X001 X016

E015 N005 X004

XA01

A B019

X005

X005.1

1000326915 EW100_V_1.2 Reference (apr02)

186

X007 X015

X002

A Cab fuses

X025

XE90

K010

K108

B

B

Sear console harness A

X013

S028

S075

S076

S040

X011

S119

R012

A

A X007

S015

M004

C2

X008

X010

X009

X027 X014

B X024

1000326915 EW100_V_1.2 Reference (apr02)

187

Boom lights harness E011 X022

E017

Engine auto idle harness K051

Y059

X014 S089 S089.2 S089.1

S090 1000326915 EW100_V_1.2 Reference (apr02)

188

Gear box sensor harness Chassis H047

X014/6 X004/3 X1.2/4

X005/5

K036

Gear box sensor harness Undercarriage X017/5

X033

S134

X018/5

1000326915 EW100_V_1.2 Reference (apr02)

189

Steering direction change harness S080.1 S070.1

C2

S022

Steering wheel shaft

Steering wheel shaft harness C2 S010

A B054

X025

B X015

X026

C2 S030

1000326915 EW100_V_1.2 Reference (apr02)

B098

190

A S012

S065

S019

S020

Rear lights harness X023

E004

1000326915 EW100_V_1.2 Reference (apr02)

E002

191

Parts location Part B

Harness

B001 B002 B003 B005 B007 B009 B019 B037 B038 B054 B055 B056 B057 B064 B066 B067 B098

Harness Chassis Harness Chassis Harness Chassis Harness Undercarriage Harness Engine Harness Harness Switches Harness Engine Harness Engine Harness Steering wheel Harness Chassis Harness Engine Harness Engine Harness Engine Harness Chassis Harness Chassis Harness Steering wheel

Area E C2

Counter weight area Valve area

F E F

Undercarriage Counter weight area Undercarriage

D D A E D D

Engine area Engine area Cab Counter weight area Counter weight area Counter weight area

E C2

Counter weight area Valve area

B

Electric compartment

C3 C3

Valve area Valve area

Access

Part group Fuel tank Signal

Rear axle Gear box

Cab floor

Steering sensor Hydraulic oil tank Speed sensor Engine Engine Drive pedal Main valve block Engine Engine

Brake valve

Main valve block Sensor

Engine controller Engine controller

Plug Plug

E E002 E004 E011 E015 E016 E017 ECM-A ECM-K EIC1 EIC2

EW100_V_1.1

Harness Rear lights Harness Rear lights Harness Boom lights Harness Switches Harness Chassis Harness Boom lights Harness Engine Harness Engine Harness Engine Harness Engine

Reference (apr02)

192

Symbol

Parts location Part F

Harness

F004 F005 F006 F007 F008 F009 F010 F011 F012 F013 F014 F015 F016 F017 F018 F019 F021 F022 F023 F024

Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Switches Harness Engine Harness Engine Harness Engine Harness Engine Harness Engine Harness Engine Harness Chassis Harness Chassis Harness Engine

Area

Access

Part group

A A A A A A A A A A A A A A A A C3 C3 C3 C3

Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Cab Valve area Valve area Valve area Valve area

Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Seat area Right Left from the battery Left from the battery Left from the battery Left from the battery

Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Cab fuse box Main fuse box Main fuse box Main fuse box Main fuse box

D C

Engine Valve area

G G001 G002 GND GND1 GND2

EW100_V_1.1

Reference (apr02)

Engine Battery

193

Symbol

Parts location Part H

Harness

H047

Gear box sensor Chassis

Area

Access

Part group

Left of battery

Main fuse box Relays direction lights

K K007 K010 K036 K051 K108

Harness Engine Harness Switches Gear box sensor Chassis Engine auto idle harness Harness Switches

C3 B

Valve area Electric compartment

B

Electric compartment

Harness Engine Harness Seat console Harness Chassis Harness Engine

E C2 D E

Engine area Valve area Engine area Service cover

Harness Engine Harness Cab Harness Chassis Harness Switches

C3 A F C3

Valve area Cab Undercarriage Valve area

Harness Seat console Harness Engine

A D

Cab Engine area

M M001 M004 M005 M007

Next to cooler package Service cover

Engine Van Wiper pump Fuel tank filling pump

N N004 N005 N014 N016

Radio housing Undercarriage central

Engine controller Cab controller Undercarriage controller Chassis controller

R R012 R035

EW100_V_1.1

Reference (apr02)

Arm rest left

194

Throttle lever Engine

Symbol

Parts location Part S

Harness

S001 S004 S005 S010 S011 S012 S015

Harness Switches Harness Chassis Harness Chassis Harness Steering wheel Harness Chassis Harness Steering wheel Harness seat console

S016

S017

S018 S019 S020

Harness Switches

Harness Switches

Harness Switches Harness Steering wheel Harness Steering wheel

S021

Harness Switches

S022

Harness Switches & Haress Steering direction

EW100_V_1.1

Reference (apr02)

A C3 E C2 C3 A

A

A

A A A

A

A

Area

Access

Part group

Cab Valve area Engine area Valve area Valve area Cab

Electric compartment Air intake filter Hydraulic oil tank Service brake valve Pilot oil supply unit C006 Steering wheel

Ignition switch Pressure switch air filter Reflux filter Pressure switch Park brake pressure switch Stalk switch

Electric compartment

Switch panel right 057 Boom lights

Electric compartment

Switch panel right 061 Cab lights

Cab

Cab

Cab Cab Cab

Cab

Cab

Electric compartment

Switch panel right 061 Turning lights Steering wheel Steering wheel

Electric compartment

Switch panel right 060 2nd gear

Electric compartment

Switch panel right 054 Drive mode

195

Symbol

Parts location Part S

S024 S028 S030

S040

S042 S052 S058 S065 S070.1

S073

S075

EW100_V_1.1

Reference (apr02)

Harness

Harness Switches Harness Seat console Harness Steering wheel

Harness Seat console

Harness Switches Harness Chassis Harness Engine Harness Steering wheel Steering direction change harness

Harness Switches

Haress Seat console

Area

A A

A

Cab Cab

Cab

Access

Part group

Electric compartment Left arm rest

Switch panel right 055 Axle lock switch Arm rest safety switch

Left arm rest

Switch panel left 067 Hydraulic quick hitch

A

Cab

A

Cab

Park brake switch

Cab

Electric compartment

Switch panel right 058 Steering mode

Left arm rest

Switch panel left 069 Stabilizer Front / rear

A

A

Cab

Electric compartment

Switch panel right 056 Over load warning dev Pressure switch AC

196

Symbol

Parts location Part S

Harness

S076

S080 S080.1 S089 S089.1 S089.2 S090

Harness seat console

Harness switches Steering direction change H Engine auto idle harness Engine auto idle harness Engine auto idle harness Engine auto idle harness

S119 S134 S134 S134.1

EW100_V_1.1

Harness Seat console Harness Undercarriage Harness gear box sensor Undercarriage Harness Undercarriage

Reference (apr02)

Area

A

A

Access

Part group

Left arm rest

Left switch panel 068 Stabilisator Left/right

Electric compartment

Switch panel right 059 Steering direction

Cab

Cab

A F

Cab Undercarriage

Left arm rest Gear box

Switch panel left 066 DPF Gear box sensor

F F

Undercarriage Undercarriage

Gear box Gear box

Gear box sensor Gear box sensor

197

Symbol

Parts location Part X

Harness

X001 X001

Harness Engine Harness Switches Gear box sensor harness Chassis Harness Chassis Harness Switches Harness Switches Harness Gear box sensor Chassis Harness Switches Gear box sensor harness Chassis Harness Switches Engine harness Switches harness Switches harness Seat console harness Switches harness Seat console harness Seat console harness Seat console harness Seat console harness Switches harness Seat console harness Seat console harness Engine auto idle harness Gear box sensor harness Chassis Switches harness Steering wheel harness Chassis harness Switches harness Chassis harness & Gear box sensor Undercarriage Engine harness Chassis harness Gear box sensor harness Uc

X001.2 X002 X002 X004 X004 X005 X005 X005.1 X006 X006 X007 X007 X008 X008 X009 X010 X011 X012 X013 X014 X014 X014 X015 X015 X016 X016 X017 X018 X018 X018

EW100_V_1.1

Reference (apr02)

Area B B

Electric compartment Electric compartment

B B

Electric compartment Electric compartment

B

Electric compartment

B

Electric compartment

B B B B B B

Electric compartment Electric compartment Electric compartment Electric compartment Electric compartment Electric compartment

B

Electric compartment

B B B B

Electric compartment Electric compartment Electric compartment Electric compartment

C1

Valve area

198

Access

Part group

Chassis floor

Swivel joint plug Chassis side

Symbol

Parts location Part X

Harness

X019 X020 X021 X022 X022 X023 X023 X024 X025 X025

Chassis harness Chassis harness Chassis harness Chassis harness Harness boom lights Chassis harness Rear lights harness Seat console harness Switches harness Steering wheel harness

X026

Chassis harness

X026

Steering wheel harness

X027 X033 X901

EW100_V_1.1

Chassis & Undercarriage & Seat console harness Gear box sensor Undercarriage Engine harness

Reference (apr02)

F

Area

Access

Part group

Undercarriage

Undercarriage

Swivel joint plug Undercarriage side

199

Symbol

Parts location Part X

Harness

Area

Access

Part group

XA01 XE01 XE02 XE03 XE04 XE05 XE06 XE90

Switches harness Switches harness Switches harness Engine harness Switches harness Chassis harness Undercarriage harness Switches harness

A A A E A C3 F B

Cab Electric compartment Cab Radio housing Cab Radio housing Counter weight area Left Cab Diagnose tool interface cover Valve area Undercarriage Undercarriage Electric compartment

Display Cab controller N004 Cab controller N004 Diagnose plug Perkins Diagnose plug Chassis controller Controller Undercarriage

Engine harness Engine harness Undercarriage harness Undercarriage harness Chassis harness Engine harness Chassis harness Chassis harness Engine harness Chassis harness Chassis harness

E E F F C3 E C3 C3

Counter weight area Counter weight area Undercarriage Undercarriage Valve area Counter weight area Valve area Valve area

Drive pump Drive pump Front axle Front axle Pilot oil supply unit C006 Work pump Pilot oil supply unit C006 Main fuse box

Drive pump Drive pump Steering mode valve Steering mode valve SV axle lock Working pump SV Safety valve Easy Lock valve (HQHS)

C2 C2

Valve area Valve area

Proportional valve C018 Proportional valve C018

PSV AUX_I PSV AUX_I

Y Y004 Y005 Y006 Y007 Y008 Y011 Y013 Y025 Y031 Y033 Y034

EW100_V_1.1

Reference (apr02)

200

Symbol

WANDA

Parts location Part Y

Harness

Y035 Y036 Y038 Y039 Y040 Y043 Y051 Y055 Y056 Y057 Y058 Y059 Y070.1 Y070.2 Y080 Y081 Y122 Y123 Y124

Engine harness Undercarriage harness Chassis harness Chassis harness Undercarriage harness Chassis harness Chassis harness Undercarriage harness Undercarriage harness Undercarriage harness Undercarriage harness Engine auto idle harness Chassis harness Chassis harness Chassis harness Chassis harness Chassis harness Chassis harness Chassis harness

EW100_V_1.1

Reference (apr02)

Area

Access

Part group

F C3 C3 F C3 C2 F

Undercarriage Valve area Valve area Undercarriage Valve area Valve area Undercarriage

Next front axle Pilot oil supply unit C006 Pilot oil supply unit C006 Next front axle Pilot oil supply unit C006 Cab floor

Steering mode valve SV 1.gear SV 2.gear Steering mode valve SV Park brake Hydraulic switch valve AUX

C2 C2 C2 C2 C3

Valve area Valve area Valve area Valve area Valve area

Proportional valve C019 Proportional valve C019 Proportional valve C018 Proportional valve C018 Pilot oil supply unit C006

PSV AUX_II PSV AUX_II PSV boom offset cylinder PSV boom offset cylinder PSV Drive

201

Symbol

Electrics Controller

Diesel engine controller - N004

Plug ECM K

The engine controller N004 is located between engine and cab, next to the engine intake air filter

Plug ECM A

Jul-14

Reference (apr02)

203

Cab controller - N005

Plug XE1

The cab controller N005 is located in the cab. To reach the controller remove the radio and radio housing

Plug XE2

Jul-14

Reference (apr02)

204

Undercarriage controller – N014 The undercarriage controller N014 is located below the undercarriage frame. It can be reached from below

Plug XE6

Jul-14

Reference (apr02)

205

Chassis controller – N016 The chassis controller N016 is located next to the engine controller, between cab and engine (next engine intake filter)

Stecker XE5

Jul-14

Reference (apr02)

206

Engine pre-glow controller- N003 The pre-glow controller N003 is located next to the engine controller, between cab and engine

Jul-14

Reference (apr02)

207

Components B054.. Drive pedal / cab N023.. Jog Dial operator controller P014.. Indicator with display R012.. Throttle lever / cab N023

B054

Jul-14

Reference (apr02)

P014

R012

208

Electrics Fuses

Fuses The fuses F4 to F19 are located in the cab, right beside the operator seat

Jul-14

Reference (apr02)

210

Fuses The fuses F1, F2, F21 and F24 is located between the cab and engine, next to the battery (tilt the cab)

Jul-14

Reference (apr02)

211

F1…

Main fuse

50A

F2…

Main fuse

50A

F21..

ECU engine

15A

F22

ECU engine

15A

F23

ECU engine

5A

F24

Controller

5A

Elektrics Electric swivel joint

Electric swivel joint (L017) The electrical swivel joint is assembled at the top of the hydraulic swivel joint Plug X017 is located in the valve area (C), plug X27 in an undercarriage central position (Deutsch plugs) The wiring for the undercarriage is drained inside the hydraulic swivel joint The electric swivel joint version is related to the options realized in the excavator

E-swivel joint

X017

Chassis plug

X027

Undercarriage plug

L017 Hydraulic Swivel joint HARNESS CHASSIS EW100_Jul-14

Reference (apr02)

213

Electric swivel joint (L017) See wiring diagram

X017

Plug located in the valve area

CHASSIS HARNESS

L017 Hydraulic Swivel joint X027

Plug located in the undercarriage

See wiring diagram

EW100_Jul-14

Reference (apr02)

214

Electrics Relays

Relays The relays are located between cab and engine (tilt cab)

Jul-14

Reference (apr02)

216

K7..

Start relay

K901

Relais 12V15

K902

ECU engine

Electrics Joysticks

Joysticks left Not used

S145 S056

Function S153

N024 Rocker AUX_II or AUX_III

N024

S056 Bottom AUX_II <> AUX_III Handle left

S145 Bottom Auto idle S153 Breaker bottom, WN Easy Lock

S153

Jul-14

Reference (apr02)

218

Joysticks right Not used

S027

S147

Functions Switch N025

N025 Rocker AUX_I (ZH)

Forward/Backward and Neutral

S027 Boom offset cylinder S147 Cruise control

Handle right

V Switch Forward/Backward

R N

and Neutral Jul-14

Reference (apr02)

219

Electrics Diagnostic

Diagnostic

The Wacker Neuson diagnostic plug XE4 is located behind a cover, right beside the operator seat.

This plug XE4 is the interface for the Wacker Neuson onboard diagnostic tool. The EW100 controller can be connected with a tablet or PC by the interface The possibilities given by the WANDA service tool are descripted in the WANDA manual

XE4

WN Diagnostic Tool Jul-14

Reference (apr02)

221

Electrics Safety

Deactivation pilot system (Relations) STOP of the work functions…

Additional to the arm rest (following slide), a failure of the following solenoids / part causes a deactivation of Y013.

This causes a deactivation of the work hydraulic system (safety)

>>>

Jul-14

Y025

Solenoid quick hitch lock

Y033

Solenoid Auxiliary hydraulic AUX_I

Y034

Solenoid Auxiliary hydraulic AUX_I

Y080

Solenoid Auxiliary hydraulic AUX_II

Y081

Solenoid Auxiliary hydraulic AUX_II

K108

Relay release Power tilt (AUX_III)

Y013

Solenoid Safety valve pilot system

Reference (apr02)

223

Pilot system deactivation (Safety valve) G002

Power supply F902

X006

F901

S001

X006

F005

Ignition lock

X007

F015

S028

Safety switch arm rest

N005

Cab controller

X008

N005

X016

Y013

Jul-14

Reference (apr02)

Solenoid pilot oil supply unit C006

224

Electrics Power mode pump P3

Pump power mode G002 F901

F902

X006

X006

Power supply

S001 F015

Ignition lock

F004 N023

Jog Dial operator controller

X008

F016

N016

Chassis controller

X018

Y011 Solenoid pump power mode

Jul-14

Reference (apr02)

226

T003_Work pump

Electrics Swing boom offset

Swing boom offset G002

Power supply

X009

F901

S027 X006

N025

F015

S027

Switch, Joystick right

N025

Rocker, Joystick right

X009

X008

X007

N005

N005

Controller cab

X016 1

Jul-14

Reference (apr02)

Y122

2

Solenoid boom offset, Valve block C018

Y123

228

Electrics Auxiliary circuits (AUX)

AUX_I G002

Power supply

F901

X009 N025

X006

X009

F015

X008

N005

N025

Rocker, Joystick right

N005

Controller cab

X016 1

Jul-14

Reference (apr02)

Y033

2

Solenoid AUX 1, Valve block C018

Y034

230

AUX_II G002

Power supply

F901

X013 N024

X006

X013

F015

X008

N005

N024

Rocker, Joystick left

N005

Controller cab

X016 1

Jul-14

Reference (apr02)

Y080

2

Y081

Solenoid AUX 2, Valve block C019

231

AUX_III (Power tilt) G002

Power supply

S056

S056

Switch, Joystick left

N024

Rocker, Joystick left

N016

Controller Chassis

N005

Controller cab

F901 N024 X006

X011

X008

N005

X027

F016

X013

F015

N016

X008

N005

K108

X016 X002 1 Y080

2

Solenoid AUX_2, Valve block C019

Y081

Y051

Jul-14

Reference (apr02)

Y051

232

Solenoid, C032 (AUX II <> AUX III

Electrics Stabilizer / Dozer blade

Stabilizer / dozer blade G002

Power supply

F901

F902 X006 S001

F017

F015

Ignition lock

F005 X007 S075

Switch Stabilizer F/R, L/R

S076

X002

S076

X007 X017

N005

X027

Controller cab

N014

Jul-14

Controller Undercarriage

Y055

Y056

Y057

Y058

Hi / Li

Hi / Re

Vo / Li

Vo / Re

Reference (apr02)

Solenoid, Valve block C034

234

S075

Electrics Pendulum axle lock

Pendulum axle lock G002

F901

Power supply

F902

X006 S001 F015

Ignition lock

F005 X007 X025 S024

B098 X025

N005

S024

Switch, Pendulum axle lock

B098

Brake sensor, Service brake valve C013

N005

Controller cab

X016 Solenoid pendulum axle lock, Pilot oil supply unit C006

Y008

Jul-14

Reference (apr02)

236

Electrics Drive

Deactivation Drive PMV (Relation) STOP of the drive function…

In case of a failure of the following valves or part, the function drive will be stopped. All components are deactivated, the EW100 will stop for safety reason

Jul-14

Y004

Solenoid drive direction forward (Drive pump)

Y005

Solenoid drive direction backward (Drive pump)

Y124

Solenoid drive pump control signal PMW (Pilot oil supply unit)

B054

Drive pedal (Foot pedal)

Reference (apr02)

238

Drive signal PMW (DA signal) G002

Power supply

F901

X006

F015

B054 X025

R012

B054

Drive pedal

R012

Hand throttle

N005

Cab controller

X016 Y124

Jul-14

Reference (apr02)

Solenoid, Pilot oil supply unit C006

239

Drive direction (forward/backward signal) G002

Power supply

F901

X006

X009 Right joystick/ direction lever

S (FNR) F015

V

X008

N

N005

F

Jul-14

Reference (apr02)

Cab controller

X001

X001

Y005

Y004

R

R

Solenoid drive pump T008

240

Electrics Brakes

Park brake Power supply

G002

F901

F902

F901 X006 S001

F015

Ignition lock F016

F005 X007 X025

X002 P>

S011

Pressure switch, Pilot oil supply unit C006

S065

Switch Park brake

N016

Controller Chassis

N005

N005

Controller cab

X016

P014

Indicator display

Y043

Solenoid, Pilot oil supply unit C006

S065

X025

S011

N016

P014 Y043

Jul-14

Reference (apr02)

242

Foot- (Service) brake G002

Power supply

F902

F901 X006

Ignition lock

S001 F005 X007 F015

X025

B098

S010

B098

Brake sensor, Service brake valve C013

S010

Pressure switch accumulator, Service brake valve C013

N005

Controller cab

X016

P014

Indicator, Display

Y008

Y008

Solenoid pendulum axle lock, Pilot oil supply unit C006

P>

X025

N005 P014

Jul-14

Reference (apr02)

243

Sensor Brake valve C013

B098

T1* p

T2*

S010

F N

T1

P

R1

R T2

B

R2

B098..

Sensor Brake pressure

S010..

Switch Accumulator pressure

Jul-14

Reference (apr02)

244

Elektrik Change Work- / travel mode

Change work- / travel mode G002

Power supply

F902

F901 X006

S001 F017 X002 X017

F015

Ignition lock

F005

X007

S022

X002

N005

X017

S022

Switch drive mode

N005

Controller cab

N014

Controller undercarriage

B005

Steering sensor, rear axle T020

B009

Speed sensor, T017

B054

Drive pedal, cab

R012

Hand throttle, cab

S134

„Switch“ gear position, T017

X027

X027 B005

B009

N014

S134

T017… Schaltgetriebe Hinterachse Jul-14

Reference (apr02)

246

Sensors Rear axle / Gear box

S134 B005

Steering cylinder position sensor

B009

Speed sensor

S134

Switch gear position

B009

S134 T020_Rear axle

Jul-14

Reference (apr02)

T017_Gear box

247

Steering cylinder

Gear box

T017_Gear box 40 km/h

B005

Gear box sensors

B009

S134

Jul-14

Reference (apr02)

248

B009

Speed sensors

S134

Switch gear position

Electrics Change drive gear

Change drive gear Power supply

G002

F901

F902 X006 S001 Ignition lock

F016

F005

F015 X025

X007

X002

X017

B098 X025

S021

X027

N005

B005

N016

1

Jul-14

Reference (apr02)

Y038

B009

N014 Y039

S134

S021

Switch 1 & 2 gear

S134

„Switch“ gear position, T017

B005

Steering pos. Sensor, rear axle

B009

Speed sensor, gear box

B098

Sensor Brake valve

N005

Controller cab

N016

Controller Chassis

N014

Controller Undercarriage Solenoid 1 & 2 gear, Pilot oil supply unit C006

2

250

Change drive gear

S134

B005

Steering sensor

B009

Speed sensor

S134

„Switch“ gear position

B009

S134 T020 Rear axle

Jul-14

Reference (apr02)

T017 Gear box

251

Lenkzylinder

Schaltgetriebe

T017, Schaltgetriebe 40 km/h

B005

Sensors Change drive gear

B009

Speed sensor

B098

Pressure sensor, brake valve C013

S134

„Switch“ gear position

B009

B098 S134

T017 Gear box

Jul-14

Reference (apr02)

C013 Pilot valve brake 252

Electrics Steering mode

Steering mode G002

F901

Power supply

F902 X006 S001

F017

F015

Ignition lock F005

S073 X002

S022

N005

Switch Steering mode X016

X017

S022

S073

N005

Controller cab

B005

Steering cylinder sensor, Rear axle T020

N014

Controller Undercarriage

X017

X027

B005

X027

N014

Solenoids Steering mode valve C016

Jul-14

Y007

Y036

Y040

Allrad_1

Hundegang

Allrad_2

Reference (apr02)

Y006 Vorderachse

254

Steering cylinder sensor – rear axle B005

Jul-14

Reference (apr02)

Steering cylinder

Gear box

Position sensor steering cylinder

B005

255

Electrics Steering direction change

Steering direction change G002

Power supply

F901

F902

X006 S001 F015

Ignition lock

F005

F016

S080

S080

Switch steering direction

N005

N005

Controller cab

N016

Controller Chassis

N016 X016

1

Jul-14

Reference (apr02)

Y070.1

Y070.2

Solenoid, Steering direction valve C015

2

257

Electrics Quick hitch system (WN Easy Lock)

Quick hitch system (WN Easy Lock) G002

F901

Power supply

F902

X006

S001

Ignition lock

F005

F015

X007 S153

S040

B055

B055

Pressure sensor, Main valve block C001

S153

Bottom, Joystick Le, C007

S040

Switch SWS Easy Lock

N005

Controller cab

X016

Y025

Jul-14

Reference (apr02)

Solenoid Easy Lock valve C017

259

Quick hitch system (WN Easy Lock) A8

Section dozer blade

Operating the function dozer blade (C009) the pressure sensor B055 releases the signal easy lock (main valve block) The solenoid valve Y025 (easy lock valve C017) will be energized, the lock cylinder of the quick hitch plate opens

B055

N005 P3 B8 MA1

Jul-14

Reference (apr02)

260

C017 Easy Lock valve

Electrics Engine auto idle system

Engine auto idle system G002

Power supply

F902

F901 X006

S001

F015

F016

F005

N005

X007

X011

X002

S145 X027

N016 Jul-14

Reference (apr02)

Ignition lock

B067

Controller cab

N005

S145

Bottom Auto idle Joystick left

B067

Pressure sensor, Main valve block C001

N016

Controller Chassis

262

Engine auto idle system

Inlet section

Ls2

B067

MA1

Jul-14

Reference (apr02)

263

Pressure sensor

Appendix

Erklärung Elektrokomponente

Elektrik Bauteil Elektronik Bauteil Steckverbindung Sicherung

Hydraulikkomponente

Pa2

Hydraulik Bauteil

Anschluss Bezeichnung Anschluss Tank

C001, Y025, L063… Bauteilcode laut BMK Liste

1000326918_EW100_V_1.1 Reference (apr02)

265

End