Hamm Roller 5e5i3j

Service Training

Basiswissen / Fundamentals

Release 2011-10-07

EN EN EN

2150228 2150228 2150228

Fundamentals

HAMM COMPACTORS

Fundamentals

HAMM COMPACTORS

Fundamentals

HAMM COMPACTORS

02 - General 03 - Information systems 04 - Mechanics 05 - Basics hydraulics 06 - Hydraulics - closed circuits 07 - Hydraulics - axial piston pumps 08 - Hydraulics - axial piston motors 09 - Hydraulics - radial piston motors 10 - Basics electrics

Introduction - 01

01 - Introduction

Basic training

1

Introduction

HAMM – Rollers for soil and asphalt compaction

Basic training

2

Introduction

Products

Basic training

3

Introduction

Series

HD CompactLine

3000 Series Basic training

HD Series

HD+ Series

DV Series 4

GRW, Static rollers Introduction

Series 3000

Soil compaction

Visibility 3-point articulated t Climbing ability Hammtronic VIO-drum Basic training

5

Introduction

Series HD CompactLine

Soil & Asphalt compaction

3-point articulated t Visibility Clear side - offset Climbing ability Transportation Basic training

6

Introduction

Series HD


Crab steering Visibility Climbing ability Articulated t Water sprinkling system

Basic training

7

Introduction

Series HD+


Visibility Operator´s platform 3-point articulated t Crab steering Engine management

Basic training

8

Introduction

Series DV

Asphalt compaction

Think Forward Visibility Hammtronic Steering HI-Drive

Basic training

9

Introduction

Rubber tire rollers and static compactors


Ballast variations Overlap of the wheels 1:1 pressure distribution Water sprinkling system

Basic training

10

Introduction

Basic training

11

Introduction

Hamm Intelligent Technology

Oszillation

Basic training

12

Introduction

Hammtronic

Diesel management Diesel management

Drive control Anti slip control

Anti slip control

DV Series

Series 3000

Drive control

Vibration control

Steering Vibration control

Additional functions

Basic training

13

Introduction

Hammtronic Advantages Diesel management Diesel management Drive control

Drive control Anti slip control

Lower fuel consumption

Anti slip control

Vibration control

Ease for the driver Steering

Less operating mistakes

Vibration control

Better compaction quality Additional functions

fuel saving profitability

fuel saving

fuel saving

ety

ty

Basic training

safety

safety

profitability

fuel saving

fuel saving

safety

safety

safety profitability 14

safety

profitability

safety

profitabil Introduction

Oscillation Vibration

Oscillation

Faster compaction – no grain crushing No destructive shock waves Longer life-time and reduced noise level Basic training

15

Introduction

Oscillation

Vibration

Oscillation

Basic training

16

Introduction

Oscillation

Application of compaction systems in various temperature ranges

Basic training

17

Introduction

HCQ-Indicator

HCQ-Indicator

HCQ-Printer HCQ-AsphaltNavigator

HCQ-GPS-Navigator

Basic training

18

Asphalt compaction

Soil compaction

Hamm Compaction Quality

Introduction

Hamm Compaction Quality

HCQ Indicator

HCQ-GPSNavigator

HCQ Printer

Basic training

19

Introduction

HCQ-GPS-Navigator HMV (rigidity) Number of es Calibration of HMV-Values

Quality of compaction

Data analysis

Basic training

20

Introduction


General - 02

01 - Introduction

Necessary machine information in case of repair • Maschine type (e.g. HD O90V, DV 70 VO, 3414 HT VIO, etc...)

• 8-digit serial number • • • •

always stamped into the right side of the machine frame additional name plate (inside cabin, engine compartment or right side of the frame) the first 4 digits show the machine series the second 4 digits show the serial number for each series

H1800566 machine series Basic training

serial number 1

General

Serie 3000

Walzenzüge

Statische Walzen

Tandemwalzen knickgelenkt

Tandemwalzen schemelgelenkt

Soil compactors

Static rollers

Articulated tandem rollers

Pivot steered tandem rollers

3011/3012 4011/4012 5011 2210 2220 2315 2320 2420 2520 2620 2720 3205 3307 3410-11 3410-11 3410-11 3412-14 3516-20 3625

Basic training

H133 H134 H135 H127 H132 H124 H155 H141 H142 H144 H154 H158 H159 H169 H269 H206 H160 H161 H162

HW 90 HD 14 TT HD150 TT GRW 10-24

H123 H196 H168 H183 H193 H114 H178 H190

HD10-13 HD8-10C HD10-12 HD13-14 HD85-100 HD70-75 HD90-110 HD120-130 HD+90-110 HD+120-140

H188 H189 H179

H139 H170 H171 H172 H122 H152 H153 H163 H185 H184

H199 H200 H201 H173 H187 H174 H181 H175 H182

DV 40-90

Serie 2000

EURO

Machine series - overview

DV 10 DV 2 DV 3 DV 6.4 DV 8.4 DV 6.4 PVC DV 8.4 PVC DV 6 Super DV 8 Super DV 40 DV 70 DV 90 DV 65 DV 85

H107 H125 H120 H143 H138 H150 H151 H156 H157 H164 H165 H191 H166 H192 H197 H198

H180 H176 H177

2

General


Information systems - 03

01 - Introduction

Wirtgen Group Information Systems

Wirtgen Group Network (www.hammag.net) Parts & More WIDOS

Basic training

1

Information systems


www.hammag.net Brochures Internal Reports Job Reports Ordering of information material Sales Training Training dates Technik-Infos s Media database

Basic training

2

Information systems


Parts & More Most important wear and tear parts Service Kits Emergency Kits Lubricants

Basic training

3

Information systems


WIDOS Spare parts documentation Operating and maintenance manuals Hydraulic circuit diagrams Electric circuit diagrams Machine data Safety instructions Technik-Infos Parts information Service Forms

Basic training

4

Information systems


Mechanics - 04

01 - Introduction

Dynamic compaction systems

Basic training

1

Mechanics

Working principles

Vibration

Basic training

Oscillation

2

Directed vibration

Mechanics

Vibration

Basic training

3

Mechanics

Circular vibrator with oil dampened change-over unbalances low frequency big amplitude

high frequency small amplitude

Direction of rotation Fixed unbalance Moving unbalance Amplitude

Basic training

4

Mechanics

Direction of rotation - vibrator Important! Big amplitude  vibrator turns clockwise! Otherwise danger of bearing damages!

Left side view

Series HD / DV

Vibration • Big amplitude • Small amplitude

Direction of rotation

Series 3000

clockwise

Basic training

5

Mechanics

Vibration drum HD70

Basic training

6

Mechanics

Vibration drum HD130

Basic training

7

Mechanics

Vibration drum HD75.4 – split drum

Basic training

8

Mechanics

Oscillation

Basic training

9

Mechanics

Advantages of oscillation

• • • • • • • •

No shock waves Greater temperature range Better compaction results Instant adjustment Automatic system No grain crushing Good initial grip Faster and better compaction

Basic training

10

Mechanics

Drum design - Oscillation

Basic training

11

Mechanics

Drum design - Oscillation

Basic training

12

Mechanics

Drum design - HD120 Oscillation

Basic training

13

Mechanics

Basic training

14

Mechanics

VIO

Basic training

15

Mechanics

Drum design 3412-3414 VIO

Basic training

16

Mechanics

VIO Unbalance

Unbalance mass

Unbalance shaft

Basic training

17

Mechanics

Basic training

18

Mechanics


Basics hydraulics - 05

01 - Introduction

Overview hydraulic symbols according to DIN ISO 1219-1

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Contents

CONTENTS: 1. Basic elements ............................................................................ 3 2. Reservoirs .................................................................................... 4 3. Service devices / service units .................................................. 5 4. Pumps and motors ...................................................................... 5 4.1 Pumps ...................................................................................................................... 5 4.2 Motors ...................................................................................................................... 5

5. Valves (actuators) ....................................................................... 6 5.1 Control valves .......................................................................................................... 6 5.2 Examples .................................................................................................................. 7 5.3 Check valves ............................................................................................................ 8 5.4 Pressure valves ....................................................................................................... 8 5.5 Flow-control valves ................................................................................................. 9 5.6 Types of activation (valves) .................................................................................. 10

6. Cylinders .................................................................................... 11 7. Measuring and indicating devices ........................................... 11 8. Top 10 hydraulic symbols ........................................................ 12 Notes.............................................................................................. 14

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Basic elements

1. Basic elements Working line; electr. wire

Control line; Leakage oil line

Component

Mechanic connection (drive shaft, lever, piston rod)

Flexible line (hose)

Crossing with / without connection

Closed pressure port

spring

choke

pneumatic/hydraulic

Basic symbol for pumps and motors

Adjustability in general

Basic symbol for a three-position valve HAMM AG 13/10/2009

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TReservoirs

Way and direction of a volume flow (inside a valve)

Rotary movement with rotation direction

Elektric motor

Non-electric drive unit

2. Reservoirs Pressure reservoir without/with gas-tensioning device

(Fluid) reservoir Connection to atmosphere; tube connection above/below fluid level

3.

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T Service devices / service units

Service devices / service units Filter without with pollution indicator

Manually operated (water) separator

Cooler

Silencer

4. Pumps and motors 4.1 Pumps Hydraulic pump (fixed displacement) with one/two flow directions

Hydraulic pump (variable displacement) with one/two flow directions

4.2 Motors Hydraulic motor (fixed displacement) with one/two flow directions

Hydraulic motor (variable displacement) with one/two flow directions

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TValves (HTactuatorsTTTH)

5. Valves (actuators) 5.1 Control valves Control valve with three positions and four connections general symbol

Control valve with interim positions and two endpositions, also called proportional valve general symbol

One flow path

Two closed connections

Two flow paths

Two flow paths and one closed connection

Two flow paths connected to each other

One flow path in shunt connection

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TValves (HTactuatorsTTTH) 5.2 Examples

2-port/2-way valve

3-port/2-way valve

4-port/3-way valve directional blocked center valve

4-port/3-way valve directional blocked center valve, in center position fluid is pumped to the tank

4-port/3-way valve with floating position

5.3

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TValves (HTactuatorsTTTH) Check valves Check valve simple/spring loaded

Controlled check valve closing/opening avoided by activation

Shuttle valve

Zweidruckventil (UND-Ventil)

Shut-off valve

5.4 Pressure valves

Pressure limit valve adjustable

Pressure control valve adjustable

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TValves (HTactuatorsTTTH) 5.5 Flow-control valves Choke valve Cross sectional area fixed/adjustable

Throttle-check valve

Orifice fixed cross-section

Flow-control valve

5.6

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TValves (HTactuatorsTTTH) Types of activation (valves) Activation by muscular strength

Activation by muscular strength pushbutton / pullbutton

Lever

Pedal with one/two directions

Electric activation with magnetic coil

Activation by fluid pressure directly operated; general symbol

Roller tappet

Spring

Activation by fluid pressure indirectly operated by a pneumatic pre-stage

In series activation e.g. solenoid operates a pneumatic valve which operates the main valve

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TCylinders

6. Cylinders Cylinder single-acting with return spring

Cylinder double-acting

Cylinder with (adjustable) damping at the bottom-side

7. Measuring and indicating devices Manometer

Thermometer

Volumetric flow meter / indicator

Pressure sensor

Pressure switch

Temperature sensor

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Top 10 hydraulic symbols

8. Top 10 hydraulic symbols (Fluid) reservoir Connection to atmosphere; tube connection above/below fluid level

Filter without with pollution indicator

Cooler

Hydraulic pump (fixed displacement) with one/two flow directions

Hydraulic pump (variable displacement) with one/two flow directions

Hydraulic motor (fixed displacement) with one/two flow directions

Hydraulic motor (variable displacement) with one/two flow directions

4-port/3-way valve directional blocked center valve, in center position fluid is pumped to the tank

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Top 10 hydraulic symbols

Pressure limit valve adjustable

Cylinder double-acting

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Notes

Notes

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Hydraulics - closed circuits - 06

01 - Introduction

Principle of closed hydraulic circuits

Basic training

1

Hydraulics – Principle of closed hydraulic circuits


Hochdruck High pressure

Basic training

Niederdruck Return line pressure

Saugdruck Suction pressure

Lecköldruck Case drain pressure

2

Steuerdruck Pilot pressure

Stelldruck Control pressure




Basic training




3






Basic training




4






Basic training




5






Basic training




6






Basic training




7






Basic training




8





Hydraulics - axial piston pumps - 07

01 - Introduction

Variable displacement pump with mechanic control unit

Basic training

1

Hydraulics – Variable displacement pumps

Basic training

2


Variable displacement pump with mechanic control unit External charge pressure supply

Scheme

Orifices drive control pressure


Basic training



3




Variable displacement pump with mechanic control unit Design

Caution ! No charge pump installed! Charge pressure supply via steering pump!


Basic training



4




Variable displacement pump with mechanic control unit Mechanic control unit


Basic training




5




Basic training

6


Variable displacement pump with mechanic control unit Charge pressure supply from steering return line via hydraulic oil filter

Centring hydr. neutral position

M 18x1,5

Centring mech. neutral position

Port PS oil supply to the brake release valve M 14x1,5

Charge and high pressure valve

Case drain port T2 from the brake release valve

(with by for towing) reverse forward max. 350bar

M 22x1,5

Charge pressure valve max. 22 bar

Basic training

7


Variable displacement pump with mechanic control unit Emergency stop ports X3 ,X4

Connection drill

Test ports X1 ,X2

Bowden cable

5 - 22 bar (in front of orifice) M 12x1,5

Test port Fe = charge pressure max. 22 bar M 18x1,5

Air bleed R M 12x1,5

distributor block with scavenge system

Basic training

Port T1 to the cooler M 22x1,5

8


Variable displacement pump with hydraulic control unit

Basic training

9


Basic training

10


Variable displacement pump with hydraulic control unit External charge pressure supply

Scheme



Basic training



11




Variable displacement pump with hydraulic control unit Design



Basic training



12




Variable displacement pump with hydraulic control unit Hydraulic control unit


Basic training




13




Basic training

14


Variable displacement pump with hydraulic control unit Speisedruckversorgung FS Supply Valve Fa1 M 18x1,5

(von Filter) M 18x1,5

Variable displacement pump - vibration

Supply brake release valve Fa M 18x1,5

Case drain port T1 (vibration pump) M 22x1,5

High pressure cut-off max. 450 bar

Air bleed R M 12x1,5

High pressure port B = forward

Test ports control pressures X1 = forward X2 = reverse 5 - 22 bar M 12x1,5 (in front of orifice) Basic training

SAE ¾“

Remote control port Y2 = reverse

Centring hydr. neutral position 15

6 – 18 bar M 14x1,5 Hydraulics – Variable displacement pumps

Variable displacement pump with hydraulic control unit High pressure port Variable displacement A = reverse SAE ¾“ pump – vibration

Charge pressure valve

Case drain port T2

max. 22 bar

M 22x1,5

Test ports MA = reverse MB = forward max. 480 bar High pressure cut-off max. 450 bar M 12x1,5

Centring mech. neutral position

Test port PS = control pressure 22 bar (after orifice) M 14x1,5

Einspeise - u. HD.ventile (mit By zum Abschleppen) Rückwärts Vorwärts max. 500 bar Basic training

16

Remote control port Y1 = forward 6 – 18 bar M 14x1,5

Test port G =charge pressure max. 22 bar M 12x1,5 Hydraulics – Variable displacement pumps

Variable displacement pump with electric control unit

Basic training

17


Basic training

18


Variable displacement pump with electric control unit Scheme

External charge pressure supply



Basic training



19




Variable displacement pump with electric control unit Design



Basic training



20




Variable displacement pump with electric control unit Electric control unit with proportional solenoids


Basic training




21




Basic training

22


Variable displacement pump with electric control unit Test ports Variable displacement pump drive

Control pressure X1 = small amplitude X2 = big amplitude 5-22 bar M12x1,5 (in front of orifice)

Air bleed R M12x1,5

Test port Ps = control pressure 22 bar (after orifice) M14x1,5

Test port G = Charge pressure max. 22 bar M12x1,5

Charge pressure valve not installed !!! Charge pressure controlled by drive pump

Centring

Frequency adjustment

mech.neutral position high frequency small amplitude

Basic training

Case drain port T2 (from drive pump) M 22x1,5

23

Test ports MB = small amplitude MA = big Amplitude max. 423 bar high pressure cut-off 420 bar M12x1,5


Variable displacement pump with electric control unit Variable displacement pump - drive

Centring

Proportional solenoid b = big Amplitude a = small Amplitude

hydr. neutral position

High pressure cut-off max. 420 bar

High pressure port B = small Amplitude SAE ¾“

Charge and high pressure valves small amplitude big amplitude max. 420 bar

Frequency adjustment low frequency big amplitude

Test ports charge pressure M18x1,5

High pressure port A = big mplitude SAE ¾“

Basic training

Charge pressure supply Fa

Case drain port T1

(from drive pump port Fa1) M 18x1,5

M 22x1,5

24


Different valve plate designs

Basic training

25


Basic training

26


Valve plate without high pressure cut off Charge and high pressure valves with by by for towing

valve movement – charging

valve movement – high pressure


Basic training




27




Valve plate with high pressure cut off Charge and high pressure valves with by by for towing




Basic training




28




Valve plate with high pressure cut off Charge and high pressure valves with by

by for towing




Basic training




29




Basic training

30


Separating the hydrostatic drive power train (e.g. towing)

Basic training

31


Basic training

32


Separating the hydrostatic drive power train (e.g. towing) high pressure valves with by

A

B

Disengaging closed hydraulic circuits: Unscrew the nut (B) by two turns. Then screw in the hexagon socket bolt (A) on the high pressure valves until it is flush with the nut (Pos. 2). Re-engaging closed hydraulic circuits: Unscrew the hexagon socket bolt (A) up to the stop. Then tighten up the nut (B) Basic training

33


Basic training

34



Hydraulics - axial piston motors - 08

01 - Introduction

Fixed displacement axial piston motors

Grundlagenschulung

1

Hydraulik - Axialkolbenmotoren

Grundlagenschulung

2


Fixed displacement axial piston motors without scavenge valve Scheme


Grundlagenschulung


3



Fixed displacement axial piston motors with scavenge valve Scheme

B

B B

A

T A A


Grundlagenschulung


4



Fixed displacement axial piston motors with scavenge valve Scheme

T

(T)


Grundlagenschulung


5



Fixed displacement axial piston motors with scavenge valve High pressure port A

Important !

big amplitude M 27x2

Check direction of rotation after repair!

High pressure port B small amplitude M 27x2

Integrated scavenge system (controlled by orifice)

Scavenge valve

Connection T1

Case drain port T2

M 16x1,5 (closed)

M 16x1,5

Grundlagenschulung

6


Axial piston motor with variable displacement – electrically controlled

Grundlagenschulung

7


Grundlagenschulung

8


Axial piston motor – variable displacement Scheme


Grundlagenschulung


9




Axial piston motor – variable displacement Design


Grundlagenschulung


10




Axial piston motor – variable displacement Adjusting screw displacement V min.

Proportional solenoid Verstellung

Case drain port T M 18x1,5

Test port G 80 - 400 bar M 14x1,5

Connection rpm sensor High pressure port A SAE ¾“

High pressure port B SAE ¾“

Test port M1

Grundlagenschulung

Adjusting screw

M 14x1,5

displacement V max.

Shuttle

Scavenge valve 11

Scavenge block Hydraulik - Axialkolbenmotoren

Grundlagenschulung

12



Hydraulics - radial piston motors - 09

01 - Introduction

Radial piston motors

Basic training

1

Hydraulic – Radial piston motors

Design

Basic training

2


MS Motor – View and connectors

Case drain port - 1 High pressure - L

Gear shifting - Y Parking brake High pressure - R

Basic training

3


MS Motor – Sectional view

Basic training

4


MS Motor – Exploded view

Basic training

5


MS Motor - Assembly

Bearing

Basic training

Hydrobase

6

Parking brake


Functioning

Basic training

7


MS Motor - Functioning 1-Gear

Basic training

2-Gear

8


Assembly: Hydrobase

Basic training

9


MS Motor - Hydrobase MS MOTOR

Hydrobase

Bearing

Parking brake

Drive unit Piston Cam ring Cylinder block Valving

Bearing

Basic training

10

Hydrobase

Parking brake


MS Motor – Cylinder block

Mono-block

block

Bi-block

Basic training

11


MS Motor - Piston Roller Piston Bushing

block + piston without lunambule  lateral skidding

Clip

block + piston + lunambule without clips  rotation

Piston ring Lunambule

block + piston + Lunambule + Clips

Basic training

12


MS Motor - Valving

2-C valving

1-C valving

Basic training

13


MS Motor - Valving

Machined valving

Basic training

Molded valving

14


MS Motor - Valving

nb of holes = 2x nb of cams Basic training

nb of pistons= nb of holes 15


MS Motor - Valving

2 indexes

Mind mounting orientation!!! Basic training

16


MS Motor – Valving sealings Static sealing

O-Ring Back-up ring

Spool / cover Basic training

17


MS Motor - Bearing MS MOTOR

Hydrobase

Bearing

Parking brake

Roller Bearing Sealing

Bearing

Basic training

Hydrobase

Parking brake

18


MS Motor - Bearing Bearing grease case / external ambiance sealing Tapered roller bearings – “O-Mounting” Front tapered roller bearing Snap ring

Valving tapered roller bearing

Shims

Housing / bearing grease case sealing Basic training

19


Basic training

20


Assembly: Parking brake

Basic training

21


MS Motor - Parking brake MS MOTOR

Hydrobase

Bearing

Parking brake

Discs Other parts

Bearing

Basic training

Hydrobase

Parking brake

22


MS Motor - Parking brake

Inner disc Outer disc

Basic training

23



Static sealing

Dynamic sealing Basic training

24



Gehäuse Valving Sealing Bearing

Brake piston

Belleville washer

Moving O-Ring

Brake shaft Basic training

25



Release of parking brake without hydraulic pressure

Basic training

26


MK 04

Basic training

27


MK 04 Claw brake

SAE Flange Basic training

28


MK 05 - radial

Basic training

29


Basic training

30



Basics electrics - 10

01 - Introduction

Electric symbols

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Contents

CONTENTS: CONTENTS:..................................................................................... 2 1. Earth, ground, equipotential ...................................................... 3 2. Fuses ............................................................................................ 3 3. Connectors .................................................................................. 3 4. Switches ....................................................................................... 4 4.1 s in general ................................................................................................. 4 4.2 Delayed s ..................................................................................................... 4 4.3 Additional symbols ................................................................................................. 5 4.4 Schalter mit mehreren Schaltstellungen ............................................................... 6

5. Electromechanic drives .............................................................. 6 6. Accumulators und fuel cells ...................................................... 7 7. Electronic devices ....................................................................... 7 7.1 Resistors .................................................................................................................. 7 7.2 Capacitors ................................................................................................................ 7 7.3 Light sources ........................................................................................................... 8 7.4 Inductance ............................................................................................................... 8

8. Electronic devices ....................................................................... 8 8.1 Diodes ...................................................................................................................... 8 8.2 Transistors ............................................................................................................... 9

9. Monitoring and reproducing devices ........................................ 9 10. Antennas and radio .................................................................. 9 11. Measuring, control and control systems............. 10 11.1

Displaying measuring devices ......................................................................... 10

11.2

Electrical clocks ................................................................................................ 10

11.3

Remote monitoring devices ............................................................................. 10

11.4

Indicator lamps, signaling devices .................................................................. 10

12. Top 10 Electric symbols ........................................................ 12 Notes.............................................................................................. 13

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Earth, ground, equipotential

1. Earth, ground, equipotential ground (general symbol)

function ground

2. Fuses fuse (general, lead fuse)

fuse with alarm

fuse switch

fuse disconnector

fuse load disconnector

3. Connectors female connector

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Switches

4. Switches 4.1 s in general Normally open ; switch in general three alternative display formats

break

4.2 Delayed s

normally open activation delayed

normally open activation delayed

break fall-back delayed

break fall-back delayed

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Switches 4.3 Additional symbols

power switch

disconnector

normally open with automatic fall-back

break with automatic fall-back

limit switch normally open

limit switch break

two-way switch with automatic fall-back from left position (filled triangle) and non-automatic fall-back from right position (open circle)

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Electromechanic drives 4.4 Schalter mit mehreren Schaltstellungen

multi-position switch with four positions

multi-position switch with position chart activation direction and field are shown by arrows positions are labeled by numbers

multi-position switch in any position three successive s are bridged

5. Electromechanic drives electromechanic drive with one coil

thermo relay e.g. with a bi-metal

electromechanic drive with a response delay

electromechanic drive with a fall-back delay

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Accumulators und fuel cells

6. Accumulators und fuel cells fuel cell, accumulator

7. Electronic devices 7.1 Resistors resistor

variable resistor

resistor with a sliding (potentiometer)

resistor with a sliding and „off“-position

varistor (resistor depending from voltage)

7.2 Capacitors capacitor

polarized capacitor; electrolytic capacitor

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Electronic devices 7.3 Light sources light bulb

light-emitting diode

7.4 Inductance

Inductance

*)

According to DIN EN 60617-4 only the version with the 4 arcs is valid. The version with the rectangle filled black is no longer valid.

8. Electronic devices 8.1 Diodes diode

photodiode

light-emitting diode

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Monitoring and reproducing devices

8.2 Transistors NPN-transistor with housing

PNP-transistor with housing

9. Monitoring and reproducing devices

speakers (SP)

microphone

10. Antennas and radio

antenna

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Measuring, control and control systems

11. Measuring, control and control systems 11.1 Displaying measuring devices voltmeter

amperemeter

11.2 Electrical clocks clock general symbol

clock with switch

11.3 Remote monitoring devices

telemetry transmitter

telemetry receiver

11.4 Indicator lamps, signaling devices indicator lamp lamp, general symbol

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Measuring, control and control systems

indicator lamp flashing

visual alarm electromechanic, indicator, falling disk

position indicator idle position and two working positions

acknowledge indicator

horn

buzzer

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Top 10 Electric symbols

12. Top 10 Electric symbols ground (general symbol)

fuse (general, lead fuse)

normally open

electromechanic drive with one coil

fuel cell, accumulator

resistor

capacitor

inductance

diode (general symbol)

light bulb

HAMM AG 18/08/2009

12/14

# 2145192

Notes

Notes

HAMM AG 18/08/2009

13/14

# 2145192

Notes

HAMM AG 18/08/2009

14/14

# 2145192

Terminal designations agreeable to DIN 72552

HAMM AG 18/08/2009

1/8

# 2145190

CONTENTS:

CONTENTS: CONTENTS:..................................................................................... 2 1. Ignition system ............................................................................ 3 2. Preheating system ...................................................................... 3 3. Battery .......................................................................................... 3 4. Electric motors ............................................................................ 3 5. Direction indicators .................................................................... 4 6. Alternating current generator .................................................... 4 7. Alternator ..................................................................................... 4 8. Lighting system ........................................................................... 5 9. Washer system ............................................................................ 5 10. Akustische Warnanlage........ Fehler! Textmarke nicht definiert. 11. Switches .................................................................................... 6 12. Relays ........................................................................................ 6 13. s .................................................................................... 7 14. Additional terminal designations............................................ 7 Notes................................................................................................ 8

HAMM AG 18/08/2009

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# 2145190

Ignition system

1. Ignition system Terminal 1 1a, 1b

Meaning ignition coil, ignition distributor, low voltage ignition distributor with 2 separate circuits

2

Kurzschließklemme, magneto

4

ignition coil, ignition distributor, high voltage

4a, 4b

ignition distributor with 2 separate circuits, high voltage

7

Terminal of base resistors, to / from ignition distributor

15

switched plus after battery

15a

output of series resistor to ignition coil and starter

2. Preheating system Terminal

Meaning

15

input ignition switch

17

start

19

preheat

50

starter control

3. Battery Terminal

Meaning

15

battery plus via switch

30

direct input from battery plus

30a

input 2nd battery and change-over relay 12/24V

31

return wire battery minus or ground

31a

return wire to 2nd battery minus, change-over relay 12/24V

31b

return wire to battery minus or ground via switch

31c

return wire to 1st battery minus, change-over relay 12/24V

4. Electric motors Terminal

Meaning

32

return wire

33

main connector (interchanging 32 und 33 possible)

33a

limit stop

33b

shunt field

33f

2nd lower speed step

HAMM AG 18/08/2009

3/8

# 2145190

Direction indicators 33g

3rd lower speed step

33h

4th lower speed step

33L

rotation direction left

33R

rotation direction right

86

input terminal of or

5. Direction indicators Terminal

Meaning

49

input flasher unit

49a

output flasher unit, input direction indicator switch

49b

output 2nd direction indicator circuit

49c

output 3rd direction indicator circuit

C

1st direction indicator control lamp

C2

2nd direction indicator control lamp

C3

3rd direction indicator control lamp

L

direction indicators left

R

direction indicators right

L54

output for combined direction indicator and brake lights on tractors and trailers (left)

R54

output for combined direction indicator and brake lights on tractors and trailers (right)

6. Alternating current generator Terminal

Meaning

51

direct-current voltage at rectifier

51e

like 51, with additional choke coil for day operation

59

output alternating voltage, input rectifier, switch

59a

output charge armature

59b

output rear light armature

59c

output brake light armature

63

controller terminal to change voltage

63a

controller terminal to change current

64

generator control wire

7. Alternator Terminal 61 HAMM AG 18/08/2009

Meaning charge control 4/8

# 2145190

Lighting system B+

battery plus

B-

battery minus

D+

generator plus

D-

generator minus

DF

dynamo field

DF1

dynamo field 1

DF2

dynamo field 2

U, V, W

three-phase current terminals

8. Lighting system Terminal

Meaning

54

brake light in case of combined lights and on trailer outlet

55

fog lights

56

high beam

56a

high beam and control lamp

56b

low beam

56d

headlight flasher

57

parking light motorcycle

57a

parking light

57L

left parking light

57R

right parking light

58

side-marker lamps, licence plate illumination, instument lighting, tail light

58L

light switch terminal for left side-marker lamps and tail light (if switchable separately)

58R

light switch terminal for right side-marker lamps and tail light (if switchable separately)

58b

Tail light changeover for two-wheel tractors

58c

Trailer plug, single-wired taillight fused in trailer

58d

adjustable instrument lighting

9. Washer system Terminal

Meaning

53

input wiper motor plus

53a

limit stop plus

53b

shunt coil

53c

window washer pump

HAMM AG 18/08/2009

5/8

# 2145190

Acoustic warning system 53e

brake coil

53i

wiper motor with permanent magnet, third brush for higher speed

10. Acoustic warning system Terminal

Meaning

71

input tone sequence control unit

71a

output to horn 1 and 2 low

71b

output to horn 1 and 2 high

72

alarm switch - rotating flashing beacon

85c

alarm switch – sound on

11. Switches Terminal

Meaning

81

input for break , change-over

81a

1st output

81b

2nd output

82

input for normally open

82a

1st output

82b

2nd output

82z

1st input

82y

2nd input

83

input multi-position switch

83a

output 1

83b

output 2

12. Relays Terminal

Meaning

84

input actuator and relay (start of coil)

84a

output actuator (end of coil)

84b

output relay

85

output actuator (end of coil, minus)

86

input actuator (start of coil)

86a

input 1st coil

86b

input 2nd coil

HAMM AG 18/08/2009

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# 2145190

s

13. s Terminal 87 87z, y, x 87a 87b, c, d 88

Meaning input break and changeover input break and changeover (several inputs) output break and changeover output break and changeover (several outputs) input normally open

88z, y, x

input normally open (several inputs)

88a (87)

output normally open and changeover

88b, c, d

output normally open and changeover (several outputs)

14. Additional terminal designations Terminal

Meaning

52

signal from trailer

54g

solenoid valve for permanent brake in trailer

75

radio, cigarette lighter

77

door valve control

HAMM AG 18/08/2009

7/8

# 2145190

Notes

Notes

HAMM AG 18/08/2009

8/8

# 2145190

Cable colours and cross-sections agreeable to DIN 72551

HAMM AG 18/08/2009

1/4

# 2145186

CONTENTS:

CONTENTS: CONTENTS:..................................................................................... 2 1. Cable colours: ............................................................................. 3 1.1 Most common colours, abbreviations and applications ...................................... 3 1.2 Most important wires of direction indication and lighting system...................... 3

2. Wire cross-sections .................................................................... 4

HAMM AG 18/08/2009

2/4

# 2145186

Cable colours:

1. Cable colours: Um die einzelnen Leitungen einfacher auseinander zu halten, wird ein Farbsystem verwendet, mit welchem die einzelnen Leitungen gekennzeichnet sind. Je nach Herkunftsland und Alter des Fahrzeugs können diese Farben sich unterscheiden, die hier angegebenen Farben sollten sich aber in jedem deutschen Fahrzeug, das nach dem 2. Weltkrieg gebaut wurde, wiederfinden (wie in der DIN 72551 festgelegt). Viele Leitungen sind zweifarbig. Die erste Farbe (Grundfarbe) dient zur Feststellung des Verwendungszwecks, die zweite Farbe (Kennfarbe) dient zur Identifizierung der speziellen Leitung (z.B. Blinker links/rechts). Die Kennfarbe ist meist in Form einer (verdrillten) Linie oder Ringen auf der Leitung angebracht.

1.1 Most common colours, abbreviations and applications Colour

Abbreviation

Application

light blue

hb

control and signal lamps

brown

br

ground

yellow

ge

low beam

green

gn

ignition coils to interruptors

grey

gr

rear lights, side-marker lights and licence plate illumination

violet

li

code colour

red

rt

starter to alternator, ignition and light switch; load/fuses directly connected to terminal 30

black

sw

battery to starter, ignition and light switch, ignition in general

white

ws

high beam

1.2 Most important wires of direction indication and lighting system Base colour

Code colour

ws ws

Application high beam left

sw

ge

high beam right low beam left

ge

sw

low beam right

gr

sw

parking light left

gr

ro

parking light right

sw

ws

direction indicator left

sw

gn

direction indicator right

HAMM AG 18/08/2009

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# 2145186

Wire cross-sections

2. Wire cross-sections The most common cable cross-sections in vehicles are 0.5, 0.75, 1.0, 1.5, 2.5, 4, 6 and 10mm2. For single laid wires cable cross-sections above 1 mm2 are recommended for stability issues. For cable bundles the single wires may be thinner. There are two rules of thumb for wire cross-sections:  

max. 5A/mm2 for permanent load max. 10A/mm2 for short-term load

If the load limit for a wire is achieved, the next bigger cross-section should be chosen especially for longer wires. Examples for cross-sections to use: Current < 2,5 A

Cross-section

Application

2

0,5 - 0,75 mm rear light, parking light, inside light, control lamps

<8A

1,5 mm2

direction indicators, head lights, wipers, horn

< 16 A

2,5 mm2

collector wires for head lights

< 40 A

2

> 40 A

HAMM AG 18/08/2009

6,0 mm

power supply, ignition switch, fuse box 2

16 - 35 mm

starter (depending on cable length and power)

4/4

# 2145186

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