Hamm Roller

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

Products

Series
HD CompactLine HD Series HD+ Series
3000 Series DV Series GRW, Static rollers

Series 3000
Soil compaction
Visibility
3-point articulated joint
Climbing ability
Hammtronic
VIO-drum

Series HD CompactLine
Soil & Asphalt compaction

Visibility
Clear side - offset
Climbing ability
Transportation

Series HD

Crab steering
Visibility
Climbing ability
Articulated joint
Water sprinkling system

Series HD+

Visibility
Operators platform
Crab steering
Engine management

Series DV
Asphalt compaction
Think Forward
Visibility
Hammtronic
Steering
HI-Drive

Rubber tire rollers and static compactors

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

Hamm Intelligent Technology
Oszillation

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

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

Oscillation
Vibration
Oscillation

Oscillation
Application of compaction systems in various temperature ranges

Hamm Compaction Quality
Asphalt compaction
Soil compaction
HCQ-Indicator HCQ-Indicator
HCQ-Printer
HCQ-Asphalt-
Navigator
HCQ-GPS-Navigator

Hamm Compaction Quality
HCQ
Indicator
HCQ-GPS-
Navigator
HCQ
Printer

HCQ-GPS-Navigator
HMV
(rigidity)
Number of
passes
Calibration of
HMV-Values
Quality of
compaction
Data
analysis

General - 02
01 - Introduction
02 - General
04 - Mechanics
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
04 - Mechanics
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
Downloads
Media database

Parts & More
Most important wear and tear parts

Service Kits
Emergency Kits
Lubricants

WIDOS
Spare parts documentation

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

Mechanics - 04
01 - Introduction
02 - General
04 - Mechanics
Dynamic compaction systems
Basic training 1 Mechanics

Working principles
Directed
Vibration Oscillation vibration

Vibration

Circular vibrator with oil dampened
change-over unbalances
low frequency high frequency

big amplitude small amplitude
Direction of rotation
Fixed unbalance
Moving unbalance
Amplitude

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

Vibration drum HD70

Vibration drum HD130

Vibration drum HD75.4 split drum

Oscillation

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

Drum design - Oscillation

Drum design - Oscillation

Drum design - HD120 Oscillation

VIO

Drum design 3412-3414 VIO

VIO Unbalance
Unbalance mass
Unbalance shaft

Basics hydraulics - 05
01 - Introduction
02 - General
04 - Mechanics
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

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
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
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
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
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

Hydraulic motor (fixed displacement) with one/two

flow directions
Hydraulic motor (variable displacement) with

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
04 - Mechanics
Principle of closed hydraulic circuits
Basic training 1 Hydraulics 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













Hydraulics - axial piston pumps - 07
01 - Introduction
02 - General
04 - Mechanics
Variable displacement pump
with mechanic control unit
Basic training 1 Hydraulics Variable displacement pumps

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

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


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

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

with hydraulic control unit

External charge pressure supply
Scheme
Orifices drive
control pressure


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


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

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
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

with electric control unit

Scheme External charge pressure supply
Orifices drive
control pressure


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


Electric control unit with proportional solenoids


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

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

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

Different valve plate designs

Valve plate without high pressure cut off
Charge and high pressure valves
with bypass
bypass for towing
valve movement
charging
valve movement
high pressure


Valve plate with high pressure cut off
with bypass
bypass for towing
valve movement
charging
valve movement
high pressure


Valve plate with high pressure cut off
with bypass
bypass for towing
valve movement
high pressure
valve movement
charging


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

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)

Hydraulics - axial piston motors - 08
01 - Introduction
02 - General
04 - Mechanics
Fixed displacement axial piston motors
Grundlagenschulung 1 Hydraulik - Axialkolbenmotoren

without scavenge valve
Scheme
Hochdruck Niederdruck Leckldruck

High pressure Return line pressure Case drain pressure

with scavenge valve
Scheme
B A
T A


with scavenge valve
Scheme
(T)


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)

Axial piston motor with variable displacement
electrically controlled

Axial piston motor variable
displacement
Scheme
Hochdruck Niederdruck Leckldruck Stelldruck

High pressure Return line pressure Case drain pressure Control pressure

displacement
Design
Hochdruck Niederdruck Leckldruck Stelldruck

High pressure Return line pressure Case drain pressure Control pressure

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

Hydraulics - radial piston motors - 09
01 - Introduction
02 - General
04 - Mechanics
Radial piston motors
Basic training 1 Hydraulic Radial piston motors

Design

MS Motor View and connectors
Case drain port - 1
High pressure - L
Gear shifting - Y
Parking brake
High pressure - R

MS Motor Sectional view

MS Motor Exploded view

MS Motor - Assembly
Bearing
support Hydrobase Parking brake

Functioning

MS Motor - Functioning
1-Gear 2-Gear

Assembly: Hydrobase

MS Motor - Hydrobase
MS MOTOR
Hydrobase Bearing support Parking brake
Drive unit
Piston
Cam ring
Cylinder block
Valving
Bearing Hydrobase Parking brake

support

MS Motor Cylinder block
Mono-block
block
Bi-block

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

MS Motor - Valving
2-C valving
1-C valving

MS Motor - Valving
Machined valving Molded valving

MS Motor - Valving
nb of holes = nb of pistons=
2x nb of cams nb of holes
MS Motor - Valving
2 indexes
Mind mounting orientation!!!

MS Motor Valving sealings
Static sealing
O-Ring
Back-up ring
Spool / cover

MS Motor - Bearing support
MS MOTOR
Roller Bearing
Sealing
Bearing
Hydrobase Parking brake
support

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

Assembly: Parking brake

MS Motor - Parking brake
MS MOTOR
Discs
Other parts
Bearing
Hydrobase Parking brake
support

Inner disc
Outer disc

Static sealing
Dynamic sealing

Gehuse
Valving
Sealing
Bearing
Brake piston Belleville

washer
Moving O-Ring
Brake shaft
Release of parking brake

without hydraulic pressure

MK 04

MK 04
Claw brake
SAE Flange

MK 05 - radial

Basics electrics - 10
01 - Introduction
02 - General
04 - Mechanics
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

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

with automatic fall-back
break contact
with automatic fall-back
limit switch
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
with a response delay
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)
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

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