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Service Training

Basiswissen /

Fundamentals

Release 2011-10-07
HAMM COMPACTORS

EN
2150228
Fundamentals
HAMM COMPACTORS

EN
2150228
Fundamentals
HAMM COMPACTORS

EN
2150228
Fundamentals
Introduction - 01
01 - Introduction

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
Basic training 1 Introduction
HAMM Rollers for soil and asphalt compaction

Basic training 2 Introduction


Products

Basic training 3 Introduction


Series

HD CompactLine HD Series HD+ Series

3000 Series DV Series GRW, Static rollers

Basic training 4 Introduction


Series 3000

Soil compaction
Visibility
3-point articulated joint
Climbing ability
Hammtronic
VIO-drum

Basic training 5 Introduction


Series HD CompactLine

Soil & Asphalt compaction


3-point articulated joint
Visibility
Clear side - offset
Climbing ability
Transportation

Basic training 6 Introduction


Series HD

Soil & Asphalt compaction


Crab steering
Visibility
Climbing ability
Articulated joint
Water sprinkling system

Basic training 7 Introduction


Series HD+

Soil & Asphalt compaction


Visibility
Operators platform
3-point articulated joint
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

Soil & Asphalt compaction


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
Series 3000

DV Series
Drive control
Anti slip control

Anti slip 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

Anti slip control


Lower fuel consumption Vibration control

Ease for the driver


Steering
Vibration control Less operating mistakes
Better compaction quality
Additional functions

fuel saving
fuel saving fuel saving fuel saving fuel saving

ety safety safety safety


safety
safety safety safety

ty
profitability
Basic training
profitability profitability

14
profitability 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


Hamm Compaction Quality

Asphalt compaction
Soil compaction

HCQ-Indicator HCQ-Indicator

HCQ-Printer
HCQ-Asphalt-
Navigator

HCQ-GPS-Navigator

Basic training 18 Introduction


Hamm Compaction Quality

HCQ
Indicator

HCQ-GPS-
Navigator

HCQ
Printer

Basic training 19 Introduction


HCQ-GPS-Navigator

HMV
(rigidity)
Number of
passes
Calibration of
HMV-Values

Quality of
compaction

Data
analysis

Basic training 20 Introduction


General - 02
01 - Introduction

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
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 serial number

Basic training 1 General


Machine series - overview

Walzenzge Statische Walzen Tandemwalzen knickgelenkt Tandemwalzen schemelgelenkt

Soil compactors Static rollers Articulated tandem rollers Pivot steered tandem rollers

3011/3012 H133 HW 90 H123 HD10-13 H139 DV 10 H107


EURO

4011/4012 H134 HD 14 TT H196 HD8-10C H170 H199 DV 2 H125


5011 H135 HD150 TT H168 H183 H193 HD10-12 H171 H200 DV 3 H120
2210 H127 GRW 10-24 H114 H178 H190 HD13-14 H172 H201 DV 6.4 H143
2220 H132 HD85-100 H122 DV 8.4 H138
Serie 2000

2315 H124 HD70-75 H152 H173 H187 DV 6.4 PVC H150


2320 H155 HD90-110 H153 H174 H181 DV 8.4 PVC H151
2420 H141 HD120-130 H163 H175 H182 DV 6 Super H156
2520 H142 HD+90-110 H185 DV 8 Super H157
2620 H144 HD+120-140 H184 DV 40 H164

DV 40-90
2720 H154 DV 70 H165 H191
3205 H158 H188 DV 90 H166 H192
3307 H159 H189 DV 65 H197
Serie 3000

3410-11 H169 H179 DV 85 H198


3410-11 H269
3410-11 H206
3412-14 H160 H180
3516-20 H161 H176
3625 H162 H177

Basic training 2 General


Information systems - 03
01 - Introduction

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
Wirtgen Group Information Systems

Wirtgen Group Network (www.hammag.net)


Parts & More
WIDOS

Basic training 1 Information systems


Wirtgen Group Information Systems

www.hammag.net

Brochures
Internal Reports
Job Reports
Ordering of information material
Sales Training
Training dates
Technik-Infos
Downloads
Media database

Basic training 2 Information systems


Wirtgen Group Information Systems

Parts & More

Most important wear and tear parts


Service Kits
Emergency Kits
Lubricants

Basic training 3 Information systems


Wirtgen Group 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

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
Dynamic compaction systems

Basic training 1 Mechanics


Working principles

Directed
Vibration Oscillation vibration

Basic training 2 Mechanics


Vibration

Basic training 3 Mechanics


Circular vibrator with oil dampened
change-over unbalances

low frequency high frequency


big amplitude 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
clockwise Series 3000

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

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
Overview hydraulic symbols

according to DIN ISO 1219-1

HAMM AG 1/14 # 2145194


13/10/2009
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

HAMM AG 2/14 # 2145194


13/10/2009
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 3/14 # 2145194


13/10/2009
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 de-


vice

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

3.

HAMM AG 4/14 # 2145194


13/10/2009
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

HAMM AG 5/14 # 2145194


13/10/2009
TValves (HTactuatorsTTTH)

5. Valves (actuators)
5.1 Control valves

Control valve with three positions and four connec-


tions
general symbol

Control valve with interim positions and two end-


positions, 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

HAMM AG 6/14 # 2145194


13/10/2009
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

HAMM AG 7/14 # 2145194


13/10/2009
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

HAMM AG 8/14 # 2145194


13/10/2009
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

HAMM AG 9/14 # 2145194


13/10/2009
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

HAMM AG 10/14 # 2145194


13/10/2009
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

HAMM AG 11/14 # 2145194


13/10/2009
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

HAMM AG 12/14 # 2145194


13/10/2009
Top 10 hydraulic symbols

Pressure limit valve


adjustable

Cylinder
double-acting

HAMM AG 13/14 # 2145194


13/10/2009
Notes

Notes

HAMM AG 14/14 # 2145194


13/10/2009
Hydraulics - closed circuits - 06
01 - Introduction

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
Principle of closed hydraulic circuits

Basic training 1 Hydraulics Principle of closed hydraulic circuits


Principle of closed hydraulic circuits

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 2 Hydraulics Principle of closed hydraulic circuits


Principle of closed hydraulic circuits

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 3 Hydraulics Principle of closed hydraulic circuits


Principle of closed hydraulic circuits

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 4 Hydraulics Principle of closed hydraulic circuits


Principle of closed hydraulic circuits

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 5 Hydraulics Principle of closed hydraulic circuits


Principle of closed hydraulic circuits

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 6 Hydraulics Principle of closed hydraulic circuits


Principle of closed hydraulic circuits

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 7 Hydraulics Principle of closed hydraulic circuits


Principle of closed hydraulic circuits

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 8 Hydraulics Principle of closed hydraulic circuits


Hydraulics - axial piston pumps - 07
01 - Introduction

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
Variable displacement pump
with mechanic control unit

Basic training 1 Hydraulics Variable displacement pumps


Basic training 2 Hydraulics Variable displacement pumps
Variable displacement pump
with mechanic control unit
External charge pressure supply
Scheme

Orifices drive
control pressure

Hochdruck Niederdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Case drain pressure Pilot pressure Control pressure

Basic training 3 Hydraulics Variable displacement pumps


Variable displacement pump
with mechanic control unit
Design

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

Hochdruck Niederdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Case drain pressure Pilot pressure Control pressure

Basic training 4 Hydraulics Variable displacement pumps


Variable displacement pump
with mechanic control unit
Mechanic control unit

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 5 Hydraulics Variable displacement pumps


Basic training 6 Hydraulics Variable displacement pumps
Variable displacement pump
with mechanic control unit
Charge pressure supply
Centring from steering return line
hydr. neutral position via hydraulic oil filter
M 18x1,5

Centring
mech. neutral position

Port PS
oil supply to the brake
release valve
M 14x1,5 Charge and high pressure
valve
(with bypass for towing)
Case drain port T2 from reverse
the brake release valve forward
M 22x1,5 max. 350bar
Charge pressure valve
max. 22 bar

Basic training 7 Hydraulics Variable displacement pumps


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

Connection drill Test ports


Bowden cable X1 ,X2
5 - 22 bar
Test port (in front of orifice)
Fe = charge pressure M 12x1,5
max. 22 bar
M 18x1,5

Air bleed R
M 12x1,5

distributor block
with scavenge Port T1 to the cooler
system M 22x1,5

Basic training 8 Hydraulics Variable displacement pumps


Variable displacement pump
with hydraulic control unit

Basic training 9 Hydraulics Variable displacement pumps


Basic training 10 Hydraulics Variable displacement pumps
Variable displacement pump
with hydraulic control unit
External charge pressure supply
Scheme

Orifices drive
control pressure

Hochdruck Niederdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Case drain pressure Pilot pressure Control pressure

Basic training 11 Hydraulics Variable displacement pumps


Variable displacement pump
with hydraulic control unit
Design

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

Hochdruck Niederdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Case drain pressure Pilot pressure Control pressure

Basic training 12 Hydraulics Variable displacement pumps


Variable displacement pump
with hydraulic control unit
Hydraulic control unit

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 13 Hydraulics Variable displacement pumps


Basic training 14 Hydraulics Variable displacement pumps
Variable displacement pump
with hydraulic control unit
Variable displacement
Speisedruckversorgung FS pump - vibration
(von Filter)
Supply Valve Fa1 M 18x1,5
M 18x1,5

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
Test ports B = forward
control pressures SAE
X1 = forward
X2 = reverse Remote control port
5 - 22 bar Y2 = reverse
M 12x1,5 Centring 6 18 bar
(in front of orifice) hydr. neutral position M 14x1,5

Basic training 15 Hydraulics Variable displacement pumps


Variable displacement pump
with hydraulic control unit
Charge pressure valve Case drain port T2
High pressure port max. 22 bar M 22x1,5
Variable displacement A = reverse
pump vibration SAE 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

Remote control port


Einspeise - u. Y1 = forward
6 18 bar
HD.ventile M 14x1,5
(mit Bypass zum
Abschleppen) Test port
Rckwrts G =charge pressure
Vorwrts max. 22 bar
max. 500 bar M 12x1,5

Basic training 16 Hydraulics Variable displacement pumps


Variable displacement pump
with electric control unit

Basic training 17 Hydraulics Variable displacement pumps


Basic training 18 Hydraulics Variable displacement pumps
Variable displacement pump
with electric control unit
Scheme External charge pressure supply

Orifices drive
control pressure

Hochdruck Niederdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Case drain pressure Pilot pressure Control pressure

Basic training 19 Hydraulics Variable displacement pumps


Variable displacement pump
with electric control unit
Design

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

Hochdruck Niederdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Case drain pressure Pilot pressure Control pressure

Basic training 20 Hydraulics Variable displacement pumps


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

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 21 Hydraulics Variable displacement pumps


Basic training 22 Hydraulics Variable displacement pumps
Variable displacement pump
with electric control unit
Test ports
Control pressure
Variable X1 = small amplitude
Air bleed R X2 = big amplitude
displacement M12x1,5
pump drive 5-22 bar
M12x1,5
(in front of orifice)

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

Test ports
MB = small amplitude
MA = big Amplitude
Centring Frequency adjustment Case drain port T2 max. 423 bar
mech.neutral position high frequency (from drive pump) high pressure cut-off
small amplitude M 22x1,5 420 bar
M12x1,5

Basic training 23 Hydraulics Variable displacement pumps


Variable displacement pump
with electric control unit
Variable displacement
Centring pump - drive
Proportional solenoid hydr. neutral position
b = big Amplitude
a = small Amplitude

High pressure cut-off


max. 420 bar

High pressure port


B = small Amplitude
SAE

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

Frequency adjustment
low frequency
big amplitude
Test ports
charge pressure High pressure port Charge pressure supply Fa Case drain port T1
M18x1,5 A = big mplitude (from drive pump port Fa1) M 22x1,5
SAE M 18x1,5

Basic training 24 Hydraulics Variable displacement pumps


Different valve plate designs

Basic training 25 Hydraulics Variable displacement pumps


Basic training 26 Hydraulics Variable displacement pumps
Valve plate without high pressure cut off
Charge and high pressure valves
with bypass

bypass for towing

valve movement
charging

valve movement
high pressure

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 27 Hydraulics Variable displacement pumps


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

bypass for towing

valve movement
charging

valve movement
high pressure

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 28 Hydraulics Variable displacement pumps


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

with bypass

bypass for towing

valve movement
high pressure

valve movement
charging

Hochdruck Niederdruck Saugdruck Leckldruck Steuerdruck Stelldruck


High pressure Return line pressure Suction pressure Case drain pressure Pilot pressure Control pressure

Basic training 29 Hydraulics Variable displacement pumps


Basic training 30 Hydraulics Variable displacement pumps
Separating the hydrostatic drive
power train (e.g. towing)

Basic training 31 Hydraulics Variable displacement pumps


Basic training 32 Hydraulics Variable displacement pumps
Separating the hydrostatic drive
power train (e.g. towing)
high pressure valves A
with bypass 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 Hydraulics Variable displacement pumps


Basic training 34 Hydraulics Variable displacement pumps
Hydraulics - axial piston motors - 08
01 - Introduction

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
Fixed displacement axial piston motors

Grundlagenschulung 1 Hydraulik - Axialkolbenmotoren


Grundlagenschulung 2 Hydraulik - Axialkolbenmotoren
Fixed displacement axial piston motors
without scavenge valve
Scheme

Hochdruck Niederdruck Leckldruck


High pressure Return line pressure Case drain pressure

Grundlagenschulung 3 Hydraulik - Axialkolbenmotoren


Fixed displacement axial piston motors
with scavenge valve
Scheme

B A

T A

Hochdruck Niederdruck Leckldruck


High pressure Return line pressure Case drain pressure

Grundlagenschulung 4 Hydraulik - Axialkolbenmotoren


Fixed displacement axial piston motors
with scavenge valve
Scheme

(T)

Hochdruck Niederdruck Leckldruck


High pressure Return line pressure Case drain pressure

Grundlagenschulung 5 Hydraulik - Axialkolbenmotoren


Fixed displacement axial piston motors
with scavenge valve
High pressure port A
big amplitude
Important ! M 27x2

Check direction of
rotation after repair! High pressure port B
small amplitude
M 27x2

Integrated scavenge system


(controlled by orifice)

Scavenge valve

Case drain port T2 Connection T1


M 16x1,5
M 16x1,5
(closed)

Grundlagenschulung 6 Hydraulik - Axialkolbenmotoren


Axial piston motor with variable displacement
electrically controlled

Grundlagenschulung 7 Hydraulik - Axialkolbenmotoren


Grundlagenschulung 8 Hydraulik - Axialkolbenmotoren
Axial piston motor variable
displacement
Scheme

Hochdruck Niederdruck Leckldruck Stelldruck


High pressure Return line pressure Case drain pressure Control pressure

Grundlagenschulung 9 Hydraulik - Axialkolbenmotoren


Axial piston motor variable
displacement
Design

Hochdruck Niederdruck Leckldruck Stelldruck


High pressure Return line pressure Case drain pressure Control pressure

Grundlagenschulung 10 Hydraulik - Axialkolbenmotoren


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

High pressure port B


SAE

Test port M1 Adjusting screw


M 14x1,5 displacement
V max.

Shuttle Scavenge valve


Scavenge block

Grundlagenschulung 11 Hydraulik - Axialkolbenmotoren


Grundlagenschulung 12 Hydraulik - Axialkolbenmotoren
Hydraulics - radial piston motors - 09
01 - Introduction

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
Radial piston motors

Basic training 1 Hydraulic Radial piston motors


Design

Basic training 2 Hydraulic Radial piston motors


MS Motor View and connectors

Case drain port - 1

High pressure - L

Gear shifting - Y

Parking brake

High pressure - R

Basic training 3 Hydraulic Radial piston motors


MS Motor Sectional view

Basic training 4 Hydraulic Radial piston motors


MS Motor Exploded view

Basic training 5 Hydraulic Radial piston motors


MS Motor - Assembly

Bearing
support Hydrobase Parking brake

Basic training 6 Hydraulic Radial piston motors


Functioning

Basic training 7 Hydraulic Radial piston motors


MS Motor - Functioning

1-Gear 2-Gear

Basic training 8 Hydraulic Radial piston motors


Assembly: Hydrobase

Basic training 9 Hydraulic Radial piston motors


MS Motor - Hydrobase

MS MOTOR

Hydrobase Bearing support Parking brake

Drive unit

Piston
Cam ring
Cylinder block

Valving

Bearing Hydrobase Parking brake


support

Basic training 10 Hydraulic Radial piston motors


MS Motor Cylinder block

Mono-block

block

Bi-block

Basic training 11 Hydraulic Radial piston motors


MS Motor - Piston

Roller

Piston
Bushing block + piston without
lunambule
Clip lateral skidding

block + piston + lunambule


without clips
Piston ring rotation

Lunambule

block + piston +
Lunambule + Clips

Basic training 12 Hydraulic Radial piston motors


MS Motor - Valving

2-C valving

1-C valving

Basic training 13 Hydraulic Radial piston motors


MS Motor - Valving

Machined valving Molded valving

Basic training 14 Hydraulic Radial piston motors


MS Motor - Valving

nb of holes = nb of pistons=
2x nb of cams nb of holes
Basic training 15 Hydraulic Radial piston motors
MS Motor - Valving

2 indexes

Mind mounting orientation!!!

Basic training 16 Hydraulic Radial piston motors


MS Motor Valving sealings

Static sealing

O-Ring

Back-up ring

Spool / cover

Basic training 17 Hydraulic Radial piston motors


MS Motor - Bearing support

MS MOTOR

Hydrobase Bearing support Parking brake

Roller Bearing

Sealing

Bearing
Hydrobase Parking brake
support

Basic training 18 Hydraulic Radial piston motors


MS Motor - Bearing support

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 Hydraulic Radial piston motors


Basic training 20 Hydraulic Radial piston motors
Assembly: Parking brake

Basic training 21 Hydraulic Radial piston motors


MS Motor - Parking brake

MS MOTOR

Hydrobase Bearing support Parking brake

Discs

Other parts

Bearing
Hydrobase Parking brake
support

Basic training 22 Hydraulic Radial piston motors


MS Motor - Parking brake

Inner disc
Outer disc

Basic training 23 Hydraulic Radial piston motors


MS Motor - Parking brake

Static sealing

Dynamic sealing

Basic training 24 Hydraulic Radial piston motors


MS Motor - Parking brake

Gehuse
Valving

Sealing

Bearing

Brake piston Belleville


washer

Moving O-Ring

Brake shaft
Basic training 25 Hydraulic Radial piston motors
MS Motor - Parking brake

Release of parking brake


without hydraulic pressure

Basic training 26 Hydraulic Radial piston motors


MK 04

Basic training 27 Hydraulic Radial piston motors


MK 04

Claw brake

SAE Flange

Basic training 28 Hydraulic Radial piston motors


MK 05 - radial

Basic training 29 Hydraulic Radial piston motors


Basic training 30 Hydraulic Radial piston motors
Basics electrics - 10
01 - Introduction

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
Electric symbols

HAMM AG 1/14 # 2145192


18/08/2009
Contents

CONTENTS:
CONTENTS:..................................................................................... 2
1. Earth, ground, equipotential ...................................................... 3
2. Fuses ............................................................................................ 3
3. Connectors .................................................................................. 3
4. Switches ....................................................................................... 4
4.1 Contacts in general ................................................................................................. 4
4.2 Delayed contacts ..................................................................................................... 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 feedback 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

HAMM AG 2/14 # 2145192


18/08/2009
Earth, ground, equipotential

1. Earth, ground, equipotential

ground (general symbol)

function ground

2. Fuses

fuse (general, lead fuse)

fuse with alarm contact

fuse switch

fuse disconnector

fuse load disconnector

3. Connectors

female connector

HAMM AG 3/14 # 2145192


18/08/2009
Switches

4. Switches
4.1 Contacts in general

Normally open contact; switch in general

three alternative display formats

break contact

4.2 Delayed contacts

normally open contact


activation delayed

normally open contact


activation delayed

break contact
fall-back delayed

break contact
fall-back delayed

HAMM AG 4/14 # 2145192


18/08/2009
Switches

4.3 Additional symbols

power switch

disconnector

normally open contact


with automatic fall-back

break contact
with automatic fall-back

limit switch
normally open contact

limit switch
break contact

two-way switch
with automatic fall-back from left position (filled tri-
angle) and non-automatic fall-back from right posi-
tion (open circle)

HAMM AG 5/14 # 2145192


18/08/2009
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 contacts 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

HAMM AG 6/14 # 2145192


18/08/2009
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 contact (potentiometer)

resistor with a sliding contact and off-position

varistor (resistor depending from voltage)

7.2 Capacitors

capacitor

polarized capacitor; electrolytic capacitor

HAMM AG 7/14 # 2145192


18/08/2009
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

HAMM AG 8/14 # 2145192


18/08/2009
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

HAMM AG 9/14 # 2145192


18/08/2009
Measuring, control and feedback control
systems

11. Measuring, control and feedback 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

HAMM AG 10/14 # 2145192


18/08/2009
Measuring, control and feedback control
systems

indicator lamp
flashing

visual alarm
electromechanic, indicator, falling disk

position indicator
idle position and two working positions

acknowledge indicator

horn

buzzer

HAMM AG 11/14 # 2145192


18/08/2009
Top 10 Electric symbols

12. Top 10 Electric symbols

ground (general symbol)

fuse (general, lead fuse)

normally open contact

electromechanic drive
with one coil

fuel cell, accumulator

resistor

capacitor

inductance

diode (general symbol)

light bulb

HAMM AG 12/14 # 2145192


18/08/2009
Notes

Notes

HAMM AG 13/14 # 2145192


18/08/2009
Notes

HAMM AG 14/14 # 2145192


18/08/2009
Terminal designations
agreeable to DIN 72552

HAMM AG 1/8 # 2145190


18/08/2009
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. Contacts .................................................................................... 7
14. Additional terminal designations............................................ 7
Notes................................................................................................ 8

HAMM AG 2/8 # 2145190


18/08/2009
Ignition system

1. Ignition system
Terminal Meaning
1 ignition coil, ignition distributor, low voltage
1a, 1b ignition distributor with 2 separate circuits
2 Kurzschlieklemme, 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 3/8 # 2145190


18/08/2009
Direction indicators

33g 3rd lower speed step


33h 4th lower speed step
33L rotation direction left
33R rotation direction right
86 input terminal of contactor

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
output for combined direction indicator and brake lights on tractors and
L54
trailers (left)
output for combined direction indicator and brake lights on tractors and
R54
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 Meaning
61 charge control
HAMM AG 4/8 # 2145190
18/08/2009
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
light switch terminal for left side-marker lamps and tail light (if switchable
58L
separately)
light switch terminal for right side-marker lamps and tail light (if switchable
58R
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 5/8 # 2145190
18/08/2009
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 contact, change-over contact
81a 1st output
81b 2nd output
82 input for normally open contact
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 contact (start of coil)
84a output actuator (end of coil)
84b output relay contact
85 output actuator (end of coil, minus)
86 input actuator (start of coil)
86a input 1st coil
86b input 2nd coil

HAMM AG 6/8 # 2145190


18/08/2009
Contacts

13. Contacts
Terminal Meaning
87 input break contact and changeover contact
87z, y, x input break contact and changeover contact (several inputs)
87a output break contact and changeover contact
87b, c, d output break contact and changeover contact (several outputs)
88 input normally open contact
88z, y, x input normally open contact (several inputs)
88a (87) output normally open contact and changeover contact
88b, c, d output normally open contact and changeover contact (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 7/8 # 2145190


18/08/2009
Notes

Notes

HAMM AG 8/8 # 2145190


18/08/2009
Cable colours and
cross-sections
agreeable to DIN 72551

HAMM AG 1/4 # 2145186


18/08/2009
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 2/4 # 2145186


18/08/2009
Cable colours:

1. Cable colours:
Um die einzelnen Leitungen einfacher auseinander zu halten, wird ein Farbsystem ver-
wendet, mit welchem die einzelnen Leitungen gekennzeichnet sind. Je nach Herkunftsland
und Alter des Fahrzeugs knnen 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
rear lights, side-marker lights and licence plate illumina-
grey gr
tion
violet li code colour
starter to alternator, ignition and light switch; load/fuses
red rt
directly connected to terminal 30
battery to starter, ignition and light switch, ignition in gen-
black sw
eral
white ws high beam

1.2 Most important wires of direction indication and lighting system


Base colour Code colour Application
ws high beam left
ws sw high beam right
ge 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 3/4 # 2145186


18/08/2009
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 sta-
bility 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 es-
pecially for longer wires.

Examples for cross-sections to use:

Current Cross-section Application


2
< 2,5 A 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
2
< 40 A 6,0 mm power supply, ignition switch, fuse box
2
> 40 A 16 - 35 mm starter (depending on cable length and power)

HAMM AG 4/4 # 2145186


18/08/2009