Bw213-214en

Service - Manual
BW 213 DH-4 / PDH-4

BW 214 DH-4 / PDH-4
BW 213 DH-4 with attachment plate
S/N 101 583 14 .... S/N 101 583 15 ....
S/N 101 583 19 .... S/N 101 583 20 ....
S/N 101 583 37 ....
Single drum roller

Catalogue number.
008 911 71 12/2007
Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26
Maintenance 31
2.1 General notes on maintenance 32
2.2 Fuels and lubricants 33
2.3 Table of fuels and lubricants 36
2.4 Running-in instructions 37
2.5 Maintenance chart 38
Technical data 41
3.1 Technical data 42
Connection overview 55
4.1 Connection overview 56
Tests and adjustments 59
5.1 Special tools, tests and adjustments 60
5.2 Activate service mode 64
5.3 Driving against the closed brake 66
5.4 Pressure tests in the travel circuit 68
5.5 Checking / adjusting the neutral positions of the travel pump 70
5.6 Pressure measurements in the vibration circuit 72
5.7 Check the leakage rate of the vibration motor 73
5.8 Pressure test in steering circuit 74
Flushing and bleeding 77
6.1 Special tools for flushing 78
6.2 Flushing - general 83
6.3 Flushing schematic travel circuit (distribution travel pump) 85
6.4 Flushing the travel circuit (travel pump distribution) 87
6.5 Flushing schematic travel circuit (distribution axle motor) 93
6.6 Flushing the travel circuit (axle motor distribution) 98
6.7 Flushing schematic for vibration drive 103
6.8 Flushing the vibration circuit 104
6.9 Bleeding the travel circuit 108
6.10 Bleeding the vibration circuit 110
Fundamental electrics 113
7.1 Understanding circuit diagrams 114
7.2 Terminal designations 118
7.3 Current and voltage 122
7.4 Resistance 126
7.5 Series / parallel connection 128
7.6 Ohm's law 130
7.7 Electrical energy 130
7.8 Formula diagram 131
7.9 Metrology 132
7.10 Diodes, relays, fuses 134
008 911 71 BOMAG 3

Table of Contents
7.11 Batteries 137

7.12 Three-phase generator 140
7.13 Electric starter 148
7.14 Telemecanique switch 151
7.15 Inductive proximity switches 154
7.16 Angle sensor with current output 155
7.17 Plug connectors 156
7.18 Deutsch plug, series DT and DTM 157
7.19 Plugs and terminals in spring clamping technology 163
Special tools, electrics 167
8.1 Special tools, electrics 168
Machine related electrics 177
9.1 Machine related electrics 179
9.2 Electrics BEM (BOMAG Evib-meter) 269
Service Training 331
10.1 Service Training Machine 333
Engine 411
11.1 Diesel engine 412
11.2 Engine description TCD 2012 413
11.3 Engine description TCD 2013, 4 and 6 cylinder 415
11.4 Lubrication oil circuit TCD 2012 / 2013 419
11.5 Coolant circuit TCD 2012 / 2013 420
11.6 Fuel system TCD 2012 / 2013 421
11.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 425
11.8 Sensors TCD 2012 / 2013 431
11.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013 446
11.10 Exhaust gas recirculation TCD 2012 / 2013 451
11.11 Fault code monitoring with display TCD 2012 / 2013 452
11.12 Fault code display TCD 2012 / 2013 453
11.13 EMR3 List of fault codes 454
11.14 SerDia Service-Software TCD 2012 / 2013 464
11.15 General trouble shooting chart TCD 2012 / 2013 467
11.16 Valve adjustment TCD 2012 / 2013 469
11.17 Ribbed V-belt - fan drive TCD 2012 / 2013 472
11.18 Special tools, Deutz engine (TCD 2012 2V) 473
11.19 Special tools, Deutz engine (TCD 2013 2V) 488
Air conditioning system 507
12.1 Physical basics 508
12.2 Refrigerant R134a 511
12.3 Compressor oil / refrigeration oil 512
12.4 Working principle of the air conditioning system 513
12.5 Monitoring devices 513
12.6 Description of components 514
12.7 Checking the compressor oil level 520
12.8 Checking the magnetic clutch 521
12.9 Inspection and maintenance work 522
12.10 Checking, replacing the refrigerant compressor V-belt 522
4 BOMAG 008 911 71

Table of Contents
12.11 Service the air conditioning 523

12.12 Drying and evacuation 526
12.13 Emptying in case of repair 526
12.14 Leak test 527
12.15 Filling instructions 528
12.16 Trouble shooting in refrigerant circuit, basic principles 531
12.17 Trouble shooting, refrigerant circuit diagram 535
12.18 Trouble shooting procedure 536
12.19 Steam table for R134a 546
12.20 Heating control / air conditioning control 551
Replacing the cab window panes 557
13.1 Assembly of window panes 558
13.2 Special tools 559
13.3 Auxiliary materials 560
13.4 Removing and installing the window pane 562
Drum 567
14.1 Special tools, drum, single drum rollers 568
14.2 Repair overview for drum 570
14.3 Removing and installing the drum 579
14.4 Repairing the drum 586
14.5 Dismantling, assembling the change-over weights 618
14.6 Changing the rubber buffers and adjusting the pretension 621
Oscillating articulated joint 625
15.1 Special tools 626
15.2 Repair overview oscillating articulated joint 628
15.3 Removing and installing the oscillating articulated joint 631
15.4 Dismantling the oscillating articulated joint 633
15.5 Assembling the oscillating articulated joint 638
Suppliers documentation 649
16.1 Travel pump / vibration pump series 90R 651
16.2 Vibration motor A2FM 741
16.3 Travel drive series 51 771
16.4 Transmission CR 853
16.5 Axle DANA 193 879
Circuit diagrams 969
17.1 Wiring diagram 971
17.4 Hydraulic diagram 1099
17.5 Hydraulic diagram 1103
008 911 71 BOMAG 5

Table of Contents
6 BOMAG 008 911 71

1 General
008 911 71 BOMAG 7

1.1 Introduction
1.1 Introduction * The applicable documents valid at the date of print-

ing are part of this manual.
This manual is intended to support expert mechanics
in efficient repair and maintenance work. Whoever
wants to do repair work himself should have been suf-
ficiently trained and posses profound expert knowl-
edge, he should limit his work only to those parts and
components which will not affect the safety of the ve-
hicle or the passengers. It is highly recommended to
have repairs to critical systems, such as steering,
brakes and travel drive, sole carried out by a BOMAG
workshop. Untrained persons should NEVER UN-
TERTAKE SUCH REPAIR WORK.
The repair instructions describe the removal or dis-
mantling and assembly of components and assembly
groups. The repair of disassembled assembly groups
is described as far as this makes sense with respect
to available tools and spare parts supply and as far as
it can be understood by a skilled mechanic.
Documentation
For the BOMAG machines described in this training
manual the following documentation is additionally
available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Wiring diagram*
4 Hydraulic diagram*
5 Service Information
You should only use genuine BOMAG spare parts.

Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of any updating service; we
would therefore like to draw your
attention to the additionally published "technical serv-
ice information".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
Danger
!
Please observe strictly the safety regulations in

this manual, in the operating instructions as well
as the applicable accident prevention regulations.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
8 BOMAG 008 911 71

Safety regulations 1.2
Important notes ● Mark a machine that is defective or being repaired
1.2 Safety regulations
by attaching a clearly visible warning tag to the

These safety regulations must be read and ap- steering wheel.
plied by every person involved in the repair of this
machine. The applicable accident prevention in-
● On machines with articulated joint keep the articu-
lated joint locked during work.
structions and the safety regulations in the oper-
ating and maintenance instructions must be ● Use protective clothes like hard hat, safety boots
additionally observed. and gloves.
Repair work shall only performed by appropriately

● Keep unauthorized persons away from the machine
trained personnel or by the after sales service of during repair work.
BOMAG. ● Tools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
Any suggestions, safety precautions and warn-
safe condition.
ings in this section are intended as a mnemonic
aid for well trained and experienced expert me- ● Use only safe and approved lifting gear of sifficient
chanics. This manual should not be considered a load bearing capacity to remove and install parts or
bible on workshop safety. components from and to the machine.
Workshop equipment and facilities as well as the

● Be careful with cleansing agents. Do not use easily
use and waste disposal of solvent, fluids, gases inflammable or harmful substances, such as gaso-
and chemicals are subject to legal regulations, line or paint thinners for cleaning.
which are intended to provide a minimum on safe- ● Cleaning or repair work on the fuel tank is very dan-
ty. It is obviously your own responsibility to know gerous. Do not smoke or allow any ignitable sparks
and adhere to these regulations. or open fire in the vicinity when cleaning or repairing
This manual contain headers like "Note", "Attention", a tank. .
"Danger" and "Environment", which must be strictly ●
When performing welding work strictly comply with
complied with in order to avoid dangers for health and the respective welding instructions.
for the environment.
Precautions and codes of conduct for
Danger
! welding work
Paragraphs marked like this highlight possible Welding work should only be performed by specially
dangers for persons. instructed expert personnel.
Caution
! Danger
!
Paragraphs marked like this highlight possible Electric shock!
dangers for machines or parts of the machine.
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
i Note
eyes!
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine. Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
Environment grease or solvent residues, etc.!
Paragraphs marked like this point out practices ● Check welding equipment and cables for damage
for safe and environmental disposal of fuels and before use (also the validity of inspection stickers).
lubricants as well as replacement parts.
● Ensure good conductivity between earth cable and
Observe the regulations for the protection of the work piece.
environment.
● Start the extraction fan before starting work and
guide with the progressing work as required.
General
●
Always isolate the burner when laying it down (re-
●
Before starting repair work stand the machine on move possible electrode residues).
level and solid ground.
● Protect cables from being damaged, use cables
● Always secure the machine against unintended roll- with insulated couplings.
ing.
●
Ensure sufficient fire protection, keep a fire extin-
● Secure the engine reliably against unintentional guisher at hand.
starting.
008 911 71 BOMAG 9

● In case of welding work in fire or explosion endan- full face visor; a facility suitable for rinsing the eyes
gered environments, you should always ask for a should also be available.
welding permission. ● Avoid prolonged and repetitive contact with oil, es-
● Remove combustible parts from the vicinity or cover pecially with old oil. In case of open incisions and in-
such parts. juries seek medical advice immediately.
● Name a fire watch during and after welding work. ● Apply protective cream before starting work, so that
oil can be easier removed from the skin.
● Do not clamp the welding rod holder and the inert
gas welding gun under your arm and lay these parts ● Wash with soap and water to ensure that all oil has
only on an insulated top. been removed (a skin cleaning agent and a nail
brush will help). Lanolin containing agents will re-
● Place the inert gas bottles in a safe place and se-
place natural skin oils that were lost.
cure them against falling over.
● Do not use gasoline, kerosene, diesel, thinner or
● Use a protective screen or an arcing shield with
solvents to wash the skin.
welding glass, wear welding gloves and clothes,
this applies also for assisting persons. ● Do not put oil soaked cloths into your pockets.
● Switch the welding unit off before connecting weld- ● Avoid clothes, especially underpants, getting soiled
ing cables. by oil.
Behaviour in case of faults

● Overalls must be washed at regular intervals.
Clothes that cannot be washed, must be disposed
● Check electrode holders and electric cables at reg- of.
ular intervals.
●
If possible degrease components before handling.
●
In case of deficiencies switch off the welding unit
and inform supervising persons.
Environment
●
In case of an extractor fan failure or any other fault
inform the supervising persons. It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Entrust
Maintenance; waste disposal special companies with the waste disposal of old
●
Replace damaged insulating jaws and welding rod oil. If in doubt you should consult your local au-
holders immediately. thorities.
●
Replace the welding wire reels only in deenergized
Hydraulics
state.
● Hydraulic oil escaping under pressure can pene-
What to do in case of accidents; First Aid trate the skin and cause severe injury. You should
●
Keep calm. therefore relieve the pressure in the system before
disconnecting any lines.
●
Call first air helpers.
● Before applying pressure to the system make sure
●
Report the accident.
that all line connections and ports have been prop-
● In case of an electric accident: Interrupt the power erly tightened and are in perfect condition.
supply and remove the injured person from the ● Hydraulic oil leaking out of a small opening can
electric circuit. If breathing and heart have stopped
hardly be noticed, therefore please use a piece of
apply reactivation measures and call for an emer-
cardboard or wood when checking for leaks. When
gency doctor.
being injured by hydraulic oil consult a physician im-
mediately, as otherwise this may cause severe in-
Old oils fections.
Prolonged and repetitive contact with mineral oils will ● Do not step in front of or behind the drums/wheels/
remove the natural greases from the skin and causes crawler tracks when performing adjustment work in
dryness, irritation and dermatitis. Moreover, used en- the hydraulic system while the engine is running.
gine oils contain potentially hazardous contaminants, Block drums and/or wheels / crawler tracks with
which could cause skin cancer. Appropriate skin pro- wedges.
tection agents and washing facilities must therefore
be provided.
●
Wear protective clothes and safety gloves, if possi-
ble.
● If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
10 BOMAG 008 911 71

Reattach all guards and safety installations after plastic material, a so-called fluoroelastomer. Under
all work has been completed. normal operating conditions this material is safe and
does not impose any danger to health.
Environment However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
It is strictly prohibited to drain off hydraulic oil
caustic hydrofluoric acid, which can cause severe
into the soil, the sewer system or into natural wa-
burns in contact with skin.
ters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult ● If the material is in such a state it must only be
your local authorities. touched with special protective gloves. These
gloves must be disposed of directly after use.
Fuels ● If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime wash
Danger
!
the affected parts of the skin for 15 to 60 minutes
Repair work on fuel systems must only be per- with cold water or lime water.
formed by appropriately trained personnel.
The following notes refer to general safety precau- Poisonous substances
tions for danger free handling of fuel. These notes are
Some of the fluids and substances used are toxic and
only general instructions; in case of uncertainties you
must under no circumstances be consumed.
should consult the person responsible for fire protec-
tion. Skin contact, especially with open wounds, should be
strictly avoided.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu- These fluids and substances are, amongst others,
tion with air creates an easily inflammable mixture. anti-freeze agents, hydraulic oils, washing additives,
The vapours are heavier than air and therefore sink lubricants and various bonding agents.
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por- Engine
tion of spilled fuel is therefore potentially dangerous.
● Fire extinguishers charged with FOAM, SCHAUM, Danger
!
CO2 GAS or POWDER must be available wherever
Do not work on the fuel system while the engine is
fuel is stored, filled in, drained off, or where work on
running - danger to life!
fuel systems is performed.
After the engine has stopped wait until the pres-
● The vehicle battery must always be disconnected,
sure has dropped (on Commonm Rail engines ap-
BEFORE work in the fuel system is started. While
prox. 5 minutes, other engines 1 minute), because
working on the fuel system you should not discon-
the system is under high pressure - danger to life!
nect the battery, because this could generate
sparks, which would ignite explosive fuel vapours. Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
●
Wherever fuel is stored, filled, drained off or where
leaks - danger to life!
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed. When performing work on the fuel system make
Search lights must be fire proof and well protected sure that the motor cannot be started unitention-
against possible contact with running out fuel. ally - danger to life!
● Maintenance and cleaning work on the engine must
Hot fuels onyl be performed with the engine stopped and
cooled down. Make sure that the electric system
Before draining fuel off the tank for repair work, you
has been switched off (ignition key pulled out).
must strictly apply the following measures:
● Observe the accident prevention regulations for
● Allow the fuel to cool down, to prevent any contact
electric systems (e.g. -VDE-0100/-0101/-0104/-
with a hot fluid.
0105 Electric precautions against dangerous con-
● Vent the system, by removing the filler cap in a well tact voltages).
ventilated area. Screw the filler cap back on, until ● Cover all electric components properly before wet
the tank is finally emptied.
cleaning.
Synthetic rubber
Many O-rings, hoses and similar parts, which are ap-
parently made of natural rubber, are actually made of
008 911 71 BOMAG 11

Air conditioning system from April 1989). Paragraph 10 of the pressure ves-
sel directive demands that these pressure contain-
ers must be periodically inspected and tested by a
Caution
!
specialist, according to paragraph 32. In this case
Lines in the air conditioning system must only be periodically recurring inspections consist of external
loosened by trained and explicitly instructed ex- examinations, normally on containers in operation.
perts. The refrigerant container must be visually inspected
two times per year, within the frame work of major
● Wear safety goggles! Put on your safety goggles.
inspections. Special attention must thereby be paid
This will protect your eyes against coming into con-
to signs of corrosion and mechanical damage. If the
tact with refrigerant, which could cause severe
container is in no good condition, it should be re-
damage by freezing.
placed for safety reasons, in order to protect the op-
● Wear safety gloves and an apron! Refrigerant are erator or third parties against the dangers when
excellent solvents for greases and oils. In contact handling or operating pressure vessels.
with skin they will remove the protective grease film. ● Secure pressure vessels against tipping over or roll-
However, degreased skin is very sensitive against
ing away.
cold temperatures and germs.
● Do not throw pressure vessels. Pressure vessels
● Do not allow liquid refrigerants to come into contact
may thereby be deformed to such an extent, that
with skin! Refrigerant takes the heat required for
they will crack. The sudden evaporation and escape
evaporation from the environment. Very low tem-
of refrigerant releases excessive forces. This ap-
peratures may be reached. The results may be local
plies also when snapping off valves on bottles. Bot-
frost injuries (boiling point of R134a -26.5°C at am-
tles must therefore only be transported with the
bient pressure).
safety caps properly installed.
● Do not inhale higher concentrations of refrigerant ●
Refrigerant bottles must never be placed near heat-
vapours! Escaping refrigerant vapours will mix with
ing radiators. Higher temperatures will cause higher
the ambient air and displace the oxygen required for
pressures, whereby the permissible pressure of the
breathing.
vessel may be exceeded. The pressure vessel di-
● Smoking is strictly prohibited! Refrigerants may be rective therefore specifies that a pressure vessel
decomposed by a glowing cigarette. The resulting should not be warmed up to temperatures above 50
substances are highly toxic and must not be in- °C.
haled. ●
Do not heat up refrigerant bottles with an open
● Welding and soldering on refrigeration equipment! flame. Excessive temperatures can damage the
Before starting welding or soldering work on vehi- material and cause the decomposition of refriger-
cles, (in the vicinity ant.
of air conditioning components) all refrigerant must ●
Do not overfill refrigerant bottles, since any temper-
be drawn out and the rests removed by blowing out
ature increase will cause enormous pressures.
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a Environment
strong corrosive effect, so that pipes and system In operation, during maintenance and repair work
components may be attacked. The substance is and when taking refrigeration systems our of
mainly fluorohydrogen. service it is not permitted to let refrigerant escape
● Pungent smell! In case of a pungent smell the afore into the atmosphere, which would contradict the
mentioned decomposition products have already current status of technology.
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi- Battery
ratory system, the lungs and other organs may be ● Wear goggles and face protection (acid).
harmed.
● Wear suitable clothes to protect face, hands and
● When blowing out components with compressed air body (acid).
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
●
Work and store accumulators only well ventilated
facilities (workshop exhaust systems). rooms. (Development of oxyhydrogen gas).
● Do not lean over the battery while it is under load,
Handling pressure vessels being charged or tested. (Danger of explosion).
● Since the fluid container is pressurized, the manu- ● Burning cigarettes, flames or sparks can cause ex-
facture and testing of these pressure vessels is gov- plosion of the accumulator
erned by the pressure vessel directive. (New edition ● Keep ignition sources away from the battery.
12 BOMAG 008 911 71

● Always shield eyes and face towards the battery. ● Do not heat up oil higher than 160 °C because it
● Do not use battery chargers or jump leads without may ignite.
following the operating instructions. ● Wipe off spilled oil and fuel.
● Keep the cell plugs closed. ● Do not smoke when refuelling or when checking the
● After an accident with acid flush the skin with water acid level in the battery.
and seek medical advice. ● Do not check the acid level of the battery with a na-
● Do not allow children access to batteries. ked flame, danger of explosion!
● When mixing battery fluid always pour acid into wa- ● Old batteries contain lead and must be properly dis-
ter, never vice-versa.
posed of.
●
There is a danger of scalding when draining off en-
Poisonous substances
gine or hydraulic oil at operating temperature.
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
● on machines with rubber tires a tire may busr if in-
correctly assembled. This can cause severe injury.
Skin contact, especially with open wounds, should be
strictly avoided.
● Do not exceed the specified highest permissible tire
pressure.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, washing additives,
lubricants and various bonding agents.
Special safety regulations

●
Use only genuine BOMAG spare parts for repair
purposes. Original parts and accessories have
been specially designed for this machine.
●
We wish to make explicitly clear that we have not
tested or approved any parts or accessories not
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
the specific characteristics of the machine and
thereby impair the active and/or passive driving
safety. The manufacturer explicitly excludes any li-
ability for damage caused by the use of non-original
parts or accessories.
●
Unauthorized changes to the machine are prohibit-
ed for safety reasons.
●
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine, danger of injury!
● Do not perform cleaning work while the engine is
running.
●
If tests must be performed with the engine running
do not touch rotating parts of the engine, danger of
injury.
● Exhaust gases are highly dangerous. Always en-
sure an adequate supply of fresh air when starting
the engine in closed rooms.
●
Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
● Keep used filters in a separate waste container and
dispose of environmentally.
● Dispose of oils and fuel environmentally when per-
forming repair or maintenance work.
● Do not refuel in closed rooms.
008 911 71 BOMAG 13

1.3 General repair instructions
General Electrics
●
Before removing or disassembling and parts, hoses General
or components mark these parts for easier assem-
The electric and electronic systems in construction
bly.
equipment are becoming more and more extensive.
● Before assembly oil or grease all parts, as far as this Electronic elements are increasingly gaining impor-
is necessary. tance in hydraulic and mechanical vehicle systems.
Diagnostics according to plan

A structured approach in trouble shooting saves time
and helps to avoid mistakes and expenses, especially
in the fields of electrics and electronics. Understand-
ing electronic controls requires the knowledge of
some basic terms concerning their general perform-
ance. In many cases error logs are just simply read
out and control units are replaced without any further
trouble shooting. This is in most cases unnecessary
and, even more important, very expensive.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
●
In approx. 10 % of the examined cases the prob-
lems were caused by control units.
●
In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
●
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
● Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
●
Perform trouble shooting in a systematic way. Do
not become confused by the high number and vari-
ety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
●
Do not disconnect or connect battery or generator
while the engine is running.
● Do not operate the main battery switch under load.
14 BOMAG 008 911 71

General repair instructions 1.3
● Do not use jump leads after the battery has been re- Battery
moved.
Rules for the handling of batteries
● Sensors and electric actuators on control units must
never be connected individually or between exter- Even though it may be conveniently installed in the
nal power sources for the purpose of testing, but engine compartment, it should never be used as a rest
only in connection with the control unit in question, for tools. When connecting the poles, e.g. by means
as otherwise there may be a risk of destruction of a spanner, the battery will become an "electric
(damage)! welder".
●
Disconnecting the control unit plug connectors with As a measure to avoid short circuits you should first
the control unit switched on, i.e. with the power sup- disconnect the negative pole during disassembly and
ply (terminal 15 "On"), is not permitted. Switch the reconnect the negative pole last during assembly.
voltage supply "off" first - then pull out the plug. Terminal clamps should be assembled with as little
force as possible.
● Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect Poles and terminal clamps should always be kept
polarity can cause damage to control units! clean to avoid transition resistances during starting
and the related development of heat.
● Plug-in connectors on control units are only dust
and water tight if the mating connector is plugged You should obviously also pay attention to secure fas-
on! Control units must be protected against spray tening of the battery in the vehicle.
water, until the mating connector is finally plugged
on!
●
Unauthorized opening of the control electronics (mi-
cro controller MC) as well as changes or repairs on
the wiring can lead to dangerous malfunctions.
●
Do not use any radio equipment or mobile phones
inside the driver's cab without an appropriate out-
side antenna or in the vicinity of the control electron-
ics!
Electrical system and welding work

●
Surge voltages in the electric system must be strict-
ly avoided:
●
When performing welding work always fasten the
earth clamp of the welding unit in the immediate vi-
cinity of the welding location.
!Caution
Switch off the main battery switch, doisconnect
the generator and pull the plug out on the control
unit before starting welding work.
008 911 71 BOMAG 15

Hydraulic system ● After changing a component perform a high and

charge pressure test, if necessary check the speed
of the exciter shaft.
Caution
!
● The operating pressure of the exciter shaft to a
Do not open any hydraulic components if you
great extent depends on the base under the vibrat-
have not been properly trained and without exact
ing drum. If the soil is too hard place the drums on
knowledge.
old rubber tires. Do not activate the vibration on a
Please note hard, concreted base, danger of bearing damage.
Cleanliness is of utmost importance. Make sure that ●
After the completion of all tests perform a test run
no dirt or other contaminating substances can enter and then check all connections and fittings for leaks
into the system. with the engine still stopped and the hydraulic sys-
tem depressurized.
● Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt. Before commissioning
● Before disconnecting hoses, pipes or similar relieve ● After changing a component clean the hydraulic oil
the system pressure with the engine shut down. tank thoroughly.
● During repair work keep all openings closed with ● Fill the housings of hydraulic pumps and motors
clean plastic plugs and caps. with hydraulic oil.
● Do not run pumps and motors without oil. ● Use only hydraulic oils according to the specifica-
● When cleaning hydraulic components take care not tion in the maintenance instructions.
to damage any fine machine surfaces. ●
After changing a component clean the hydraulic
● Chemical and rubber soluble cleansing agents may system as described in the flushing instructions in
only be used to clean metal parts. Do not let such order to prevent all other components from being
substances come in contact with sealing material. damaged by abrasion and metal chips remaining in
the system.
● Rinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
●
Change the hydraulic oil filter.
ately. Do not install parts that show traces of corro- Commissioning
sion.
●
Bleed the hydraulic circuits.
● Avoid the formation of rust on fine machined caused
by hand sweat. ●
Start up the system without load.
● Grease must not used as a sliding agent for assem- ●
Check the hydraulic oil level in the tank, fill up oil if
bly work. Use hydraulic oil. necessary.
●
Do not start the engine after the hydraulic oil has After commissioning
been drained off. ●
Check system pressures and speeds.
● Use only the specified pressure gauges. Risk of ● Check fittings and flanges for leaks.
damaging the pressure gauges under too high pres-
sure. ● After each repair check all adjustment data, rota-
tional speeds and nominal values in the hydraulic
● Clean ports and fittings before removal so that no
system, adjust if necessary.
dirt can enter into the hydraulic system.
● Do not adjust pressure relief valves and control
●
Check the hydraulic oil level before and after the
valves to values above their specified values.
work.
● Use only clean oil according to specification.
● Check the hydraulic system for leaks, find and rec-
tify the cause.
● Fill new hydraulic units with hydraulic oil before
starting operation.
●
After changing a component thoroughly flush and
bleed the entire hydraulic system.
● Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
16 BOMAG 008 911 71

Air conditioning system damp air is drawn into the component by the differ-
ence in temperatures.
CFC - halon prohibition ● Damaged or leaking parts of the air conditioning
The CFC - halon prohibition from May 06, 1991 regu- must not be repaired by welding or soldering, but
lates the withdrawal from the use of CFC and the han- must generally be replaced.
dling of these refrigerants.
● Do not fill up refrigerant, but extract existing refrig-
Contents: erant and refill the system.
Since 1995 CFC (R12) is no longer permitted for use ● Different types of refrigerant must not be mixed.
in new systems.
Only the refrigerant specified for the corresponding
In operation, during maintenance and repair work and air conditioning system must be used.
when taking refrigeration systems our of service it is ● Refrigerant circuits with refrigerant type R134a
not permitted to let refrigerant escape into the atmos-
must only be operated with the compressor oil / re-
phere, which would contradict the current status of
frigeration oil approved for the compressor.
technology.
● Used compressor oil / refrigeration oil must be dis-
Work on refrigeration systems must only be carried
out by persons with well founded knowledge about posed of as hazardous waste.
such systems and who have the necessary technical ● Due to its chemical properties compressor oil / re-
equipment available. frigeration oil must never be disposed of together
The use of refrigerant must be documented. with engine or transmission oil.
Old systems should be converted to refrigerants

● Compressor oil / refrigeration oil is highly hydro-
harmless to ozone (refrigerant substitutes). scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
For this reason the Federal Environmental Agency at been opened over a longer period of time.
the end of 1995 published suitable replacement refrig-
erants for R 12. As a consequence old systems must ●
All O-rings as well as pipe and hose fittings must be
no longer be filled with R12. As soon as such a system oiled with compressor/refrigeration oil be-
is opened for service, the system must be converted foreiassembly.
to a suitable replacement or service refrigerant. Old ●
When replacing a heat exchanger, e.g. evaporator
systems may still be used, as long as they are leak or condenser, any compressor oil / refrigeration oil
tight. R 134a was nominated as replacement for R 12. lost by exchanging the components, must be re-
Inside the European Union the "EU-Directive 2037/ placed with fresh oil.
2000 on substances causing decomposition of the ●
A too high compressor oil / refrigeration oil level ad-
ozone layer" regulates the production, use and avail- versely affects the cooling performance and a too
ability of CFC and H-CFC. low oil level has a negative effect on the lifetime of
● In case of a repair on the refrigeration system you the compressor.
should first evacuate the air conditioning system for ●
If a air conditioning unit needs to be opened, the
at least 45 minutes to remove any moisture from the dryer must be replaced in any case.
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
● Always use new O-rings when reassembling the
only be removed from the system by changing the unit.
oil. ●
Always use two spanners when connecting pipes or
●
During repair work on refrigerant lines and compo- hoses, to prevent the pipe end from being damaged
nents, these must be kept closed as far as possible, .
in order to prevent the invasion of air, moisture and ● Tighten screw fittings with the specified torque.
dirt, because the operational reliability of the system
can only be assured if all components in the refrig-
●
Check the connections of pipes, fittings or compo-
nents thoroughly; do not use if damaged.
erant circuit are clean and dry from inside.
●
Do not leave the refrigerant circuit unnecessarily
● Make sure that no dirt or foreign parts can enter into
open to the atmosphere. Do not attempt to repair
the compressor or the air conditioning system. The
bent or burst pipes.
area around the refrigerant hoses should be
cleaned with a gasoline free solvent. ●
Compressor valves must only be opened after the
system has been properly sealed.
● All parts to be reused should be cleaned with a
gasoline free solvent and blow-dried with clean ● The use of leak detection colouring matter is not
compressed air or dried with a lint-free cloth. permitted, because its chemical composition is un-
known and its effect on compressor oil and rubber
● Before opening all components should have
elements is not predictable. The use of leak detec-
warmed up to ambient temperature, to avoid that
008 911 71 BOMAG 17

tion colouring matter makes any warranty claims Notes on cleanliness for Common Rail
null and void. engines
● Tools used on refrigeration circuits must be of ex- Special requirements with respect to cleanliness in
cellent condition, thus to avoid the damage of any the fuel system do apply for commissioning, mainte-
connections. nance and repair work, particularly for TEIRIII engines
● The dryer is to be installed last, after all connections with the DEUTZ Common Rail System. Contamina-
in the refrigerant circuit have been tightened. tion like dirt, welding residues or similar can lead to the
failure of individual components and adversely affect
● After completion of repair work screw locking caps engine operation.
(with seals) on all connections with valves and on
the service connections. Start up of the air condi-
tioning system. Observe the filling capacity.
● Before start up of the air conditioning system after a
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle
speed and maximum cooling power.
●
Never operate the compressor over longer periods
of time with high engine speeds without a sufficient
amount of refrigerant in the system. This could
probably cause overheating and internal damage.
Fig. 1
●
Spare parts should be left in their original packaging
as long as possible and should only be unpacked
just before use.
●
When parts are unpacked any connections must be
closed with suitable plugs or caps, in order to pre-
vent (Fig. 1) contamination of hose connections. If
e.g. fuel hoses are connected to one side, while the
second side cannot yet be connected, there is a
danger of dirt entering into the system. The free
connection must in this case also be appropriately
closed.
Notes and measures to be applied before starting

work in the fuel system
●
The fuel system must be closed. Visual examination
for leaks / damage in the fuel system.
●
Before starting work in the fuel system clean the
complete engine and the engine compartment with
the system still closed.
●
The engine should be dry before work is started in
the fuel system.
18 BOMAG 008 911 71

● Blow drying with compressed air is only permitted ● Do not use any previously used cleaning or testing
while the fuel system is still closed. fluids for cleaning.
● When using steam cleaning equipment cover con- ● Compressed air should never be used for cleaning
trol unit, cable plugs, all other electrical connections when the fuel system is open.
and the generator beforehand and do not expose ● Work on disassembled components must only be
these items to the direct steam jet.
carried out at a specially furnished work place.
● Electrical plug connections must be plugged in dur- ● When disassembling or assembling components
ing jet cleaning.
you should not use any materials from which parti-
● Remove loose parts (e.g. paint scales that may cles or fibres could flake off (cardboard, wood, tow-
have come off during assembly work) with an indus- els).
trial vacuum cleaner or any means of extraction. ● Dismantled parts must only be wiped off with clean,
● Vacuum cleaning equipment must generally be lint-free cloths if required. No dirt particles must be
used for cleaning when the fuel system is open. wiped into the components.
● Perform work on the fuel system only in a clean en- ● Close openings on components and engine imme-
vironment (no dust, no grinding or welding work). diately with suitable plugs/caps.
Avoid draughts (dust). The workshop floor must be ● Plugs/caps must only be removed just before the in-
cleaned at regular intervals. No brake or power test
stallation.
stand should be present or operated in the same
room. ● Keep plugs/caps in their original packaging, where
they are protected against dust and dirt, dispose of
●
Air movements, which could swirl up dust, such as after one time use.
brake repairs or starting of engines, must be strictly
avoided. ●
Take new parts out of their original packaging just
before installation.
●
For work, such as disassembly and assembly of de-
fective hydraulic components in the Common Rail ●
Disassembled components must be stored in new,
System, it is strongly recommended to set up a sep- sealable bags or – if available – in the packaging
arate workshop area, i.e. an area which is spatially material of the new components.
separated from all other areas (general vehicle re- ●
Always use the original packaging material of the
pairs, brake repairs). new part to return the disassembled old component.
●
No general machine tools should be operated in this
Notes and measures concerning the workshop
room.
area
●
Periodic cleaning of this workshop area is obligato- ●
For work, such as disassembly and assembly of de-
ry, draughts, ventilation system and heating blow-
fective hydraulic components in the Common Rail
ers must be minimized.
System, it is strongly recommended to set up a sep-
●
Engine compartment area where dirt particles could arate workshop area, i.e. an area which is spatially
come loose, should be covered with new, clean foil. separated from all other areas (general vehicle re-
●
Working means and tools must be cleaned before pairs, brake repairs).
being used for work. Use only tools without dam- ● The workshop floor must be sealed or tiled.
aged chromium coating, or tools without chromium ●
No welding equipment, grinding machines, general
coating.
machine tools, brake or power test benches must
Notes and measures to be applied during work in be operated in this room.
the fuel system ●
Periodic cleaning of this workshop area is obligato-
●
Wear clean working clothes. ry, draughts, ventilation system and heating blow-
ers must be minimized.
● Use only lint-free cleaning cloths for work in the fuel
system. Notes and measures for work place and tools in
●
Remove loose parts (e.g. paint scales that may the workshop
have come off during assembly work) with an indus- ●
A special work place must be set up for work on dis-
trial vacuum cleaner or any means of extraction. assembled components.
Vacuum cleaning equipment must generally be ● Clean disassembly and assembly tools at regular
used for cleaning when the fuel system is open.
intervals and keep these in a closed tool cabinet.
● Working means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
008 911 71 BOMAG 19

● Remove loose parts (e.g. paint scales that may Fuel hoses
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
● Working means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
Fig. 2
! Caution
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.
20 BOMAG 008 911 71

Gaskets and mating surfaces threads or splines. If no assembly sleeve is availa-
ble, you should use a plastic tube or adhesive tape to
Leaking or failing seals and gaskets can in most cases
prevent the sealing lip from being damaged.
be tracked down to careless assembly, causing dam-
age not only to the seal or gasket, but also to the mat-
ing surfaces. Careful assembly work is mandatory if
good results are to be achieved.
● Before assembling replacement seals make sure
that the running surface is free of pitting, flutes, cor-
rosion or other damage.
●
Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
● Sealing compound should only be used if specially
requested in the instructions. In all other cases
these joints should be assembled in dry condition.
● Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the Fig. 4
compound does not enter into oil galleries or blind ● Lubricate the outer rim 1 (Fig. 4) of the seal and
threaded bores.
press it flat on the housing seat.
●
Before assembly remove any residues of old seal-
ing compound. Do not use any tools that could dam-
age the sealing surfaces. i Note
If possible, use a "bell" 1 (Fig. 4), to make sure that
●
Examine the contact faces for scratches and burrs,
the seal will not skew. In some cases it may be ad-
remove these with a fine file or an oilstone; take
visable to assemble the seal into the housing first, be-
care that no grinding dust and dirt enters into
fore sliding it over the shaft. Under no circumstances
tapped bores or enclosed components.
should the full weight of the shaft rest on the seal.
●
Blow lines, ducts and gaps out with compressed air,
If you have no proper service tools at hand, use a suit-
replace any O-rings and seals that have been dis-
able drift punch with a diameter which is about 0.4mm
lodged by the compressed air.
smaller than the outer diameter of the seal. Use VERY
Assembly of radial seals LIGHT blows with the hammer if no press is available.
●
Press or knock the seal into the housing, until it is
flush with the housing surface.
Fig. 3
●
Lubricate sealing lips 1 (Fig. 3) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
●
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve 1 (Fig. 3), to pro-
tect the lip from being damaged by sharp edges,
008 911 71 BOMAG 21

Feather keys and keyways Ball and roller bearings
!Caution !Caution
Feather keys must only be reused if they show no Ball and roller bearings must only be reinstalled
differences to new feather keys, any notches must after it has been assured that they are in perfect
be considered as initial signs of wear. condition.
Fig. 5
● Clean and thoroughly examine the feather key.
● Debur and thoroughly clean the edges of the key-
way with a fine file before reassembling.
Fig. 6
● Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
●
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
●
Hold the bearing with you thumb and the index fin-
ger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
●
Move the outer race gently to and fro while holding
it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
● Lubricate the bearing with an appropriate lubricant
before reinstalling.
22 BOMAG 008 911 71

● Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between bearing and
seats. Tightening torque
● Make sure that shaft and housing are free of burrs
before assembling the bearing. !Caution
● If a bearing of a pair of bearings shows any defects, Always tighten nuts or screws to the specified
we highly recommend the replacement of both tightening torque. Tightening torques deviating
bearings. from the ones in the table are specially mentioned
in the repair instructions.
● On greased bearings (e.g. wheel bearings) fill the
space between bearing and outer seal with the rec- Damaged screws must under no circumstances
ommended type of grease before assembling the be used any longer. Recutting threads with thread
seal. cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
● Always mark the individual parts of separable bear-
roded thread pitches can cause incorrect torque
ings (e.g. taper roller bearings) to enable correct re-
value readings.
assembling. Never assemble the rollers to an outer
race that has already been used, replace the com- Self-locking nuts must be generally renewed.
plete bearing instead. The use of screws with too high strength can
cause damage!
● Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
● When checking or retightening screw joints to the
specified tightening torque you should first relieve
by a quarter turn and then tighten to the correct
torque.
● Before tightening you should lightly oil the thread, in
order to ensure low friction movement. The same
applies for self-locking nuts.
Fig. 7 ● Make sure that no oil or grease will enter into tapped
bores. The hydraulic power generated when turning
in the screw could cause breakage of the effected
Caution
!
part.
When assembling the bearing to the shaft load
must only be applied to the inner race 1 (Fig. 7).
When fitting the bearing into the housing load
must only be applied to the outer race (2).
008 911 71 BOMAG 23

Strength classes of metric screws Strength classes of metric nuts

The strength classes (from 3.6 to 12.9) are specified Nuts are differentiated by three load groups. Each
for all strength classes from a nominal diameter of load group has a special designation system for the
5mm. The corresponding identification can be found strength class assigned, so that the load group can be
where allowed for by the shape of the screw. clearly identified.
Nuts for screw joints with full load capability (4, 5,

6, 8, 10, 12)
Fig. 9 Identification of nuts

In a connection with a screw, these nuts 1 (Fig. 9)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 8 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
●
The nominal tensile strength is 12 X 100N/mm2 = 05)
1200 N/mm2.
The preceding "0" indicates that, due to their low
The second number specifies 10-times the ration be- height, nuts 2 (Fig. 9) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0.8 d (d = nominal dimension).
Nuts for screw joints without specified load factor

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
● The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
24 BOMAG 008 911 71

Identification in clock system
Fig. 10 Identification of nuts in clock system

For small nuts (Fig. 10) the clock system can be used
for identification.
● The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
●
The strength class is identified by a dash (b).
008 911 71 BOMAG 25

1.4 Tightening torques
The values specified in the table apply for screws:

● black oiled
● with surface protection A4C
● with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread1
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
1 Coefficient of friction μ tot. = 0,14
Tightening torques for screws with metric unified fine thread1
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
26 BOMAG 008 911 71

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 2401 (copper paste)
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
1 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread) 1 2
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
2 These values result in a 90% utilization of the yield point
008 911 71 BOMAG 27

The values specified in the table apply for screws:

● black oiled
● with surface protection A4C
● with surface protection DACROMET
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050
28 BOMAG 008 911 71

Tightening torques 1.4
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
008 911 71 BOMAG 29

30 BOMAG 008 911 71

2 Maintenance
008 911 71 BOMAG 31

2.1 General notes on maintenance
2.1 General notes on maintenance the engine's performance and temperature level as
well as the quality of the exhaust gas.
When servicing the machine pay careful attention to
If your machine has to operate permanently in "thin
all applicable safety instructions.
air" (at high altitudes) and with full power, you should
Thorough maintenance of the machine ensures max- consult the after sales service of BOMAG or the serv-
imum reliability and prolongs the lifetime of important ice department of the engine manufacturer.
components. The necessary effort can by no means
be compared with the problems and malfunctions that Notes on the hydraulic system
could occur if this is not observed.
During maintenance work in the hydraulic system
The terms left/right are always related to travel direc-
cleanliness is of utmost importance. Make sure that
tion forward.
no dirt or other impurities can enter into the system.
● Clean machine and engine thoroughly before start- Small particles can flute valves, cause pumps to seize
ing maintenance work. and block restrictors and pilot bores, thereby causing
costly repairs.
● For maintenance work park the machine on level
ground. ● If during the daily oil level check the oil level is found
to have dropped, check all lines, hoses and compo-
● Maintenance work must generally be carried out
nents for leakages.
with the engine shut down.
● Seal external leaks immediately. If necessary in-
● Depressurize hydraulic lines before working on
them. form the responsible service department.
●
Disconnect the battery and cover it with insulation
●
Do not store drums with hydraulic oil outside, or at
material before starting to work on electrical compo- least keep them under a cover. During weather
changes water may penetrate through the bung-
nents.
hole.
●
Always attach the articulation lock (transport lock) ●
Always fill the hydraulic system using the filling and
before starting to work in the articulation area of the
filtering unit (BOMAG part-no.
machine.
007 610 01). This unit is equipped with a fine filter,
which filters the hydraulic oil and prolongs the life-
Environment time of the system filter.
Catch running out oils, coolant and fuel and do ●
Clean fittings, filler caps and their immediate sur-
not let them seep into the ground or into the sew- rounding area before removing them, so that no dirt
age system. Dispose of oils, coolant and fuels en- can fall in.
vironmentally.
●
Do not leave the tank opening unnecessarily open,
cover it so that no dirt can fall in.
Notes on the fuel system
The lifetime of the diesel engine is decisively depend- Notes on the cooling system
ing on the cleanliness of the fuel.
On water cooled engines the preparation and monitor-
● Keep the engine free of dirt and water as this could ing of the coolant is of utmost importance, as other-
damage the injection elements of the engine. wise engine failures caused by corrosion, caviation
●
Zinc lined drums are not suitable for storing fuel. and freezing may occur.
● The fuel drum should rest for a longer period of time The coolant is a mixture of water and a cooling system
before drawing off fuel. protection agent.
● Do not let the suction hose disturb the sludge on the The cooling system must be permanently monitored.
bottom of the drum. Apart from the coolant level inspection this includes
also the inspection of the concentration of cooling sys-
● Do not draw off fuel from near the bottom of the fuel tem protection agent.
drum.
The concentration of the cooling system protection
●
Fuel left in the fuel drum is not suitable for the en- agent can be checked with commercially available
gine and should only be used for cleaning purpos- test instruments (glycomat).
es.
Danger
!
Notes on the engine performance
Health hazard!
Combustion air and fuel injection rates of the diesel
engine have been carefully adjusted and determine
32 BOMAG 008 911 71

Fuels and lubricants 2.2
The mixing of nitride based cooling system pro- 2.2 Fuels and lubricants
tection agents with amine based agents will cause
the generation of highly toxic nitrosamines.
Engine oil
Environment Quality
Cooling system protection agents must be dis- Lubrication oils are classified according to their per-
posed of environmentally. formance and quality class. Oils according to other
comparable specifications may be used.
Approved engine oils

Deutz DQC II-05 DQC II-05
ACAE E3/96/E5-02/ E4-99/E6-04
E7-04
API CG-4/CH-4/CI- -
4
DHD DHD-1 -
The exact assignment of the approved oil qualities

and oil change intervals can be taken from the follow-
ing section "Lubrication oil change intervals".
Consult your local service station if in doubt.
Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo-
cation of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
Optimal operating conditions can be achieved by us-
ing the opposite oil viscosity chart (Fig. 11) as a refer-
ence.
Occasionally falling short of the temperature limits will
impair the cold starting ability, but will not cause any
engine damage. In order to keep the occurring wear
as low as possible, occasional exceeding of the limits
should not happen over a longer period of time.
008 911 71 BOMAG 33

2.2 Fuels and lubricants
content of more than 1% you should consult the

responsible service agency.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and en-
sure strict cleanliness when filling in. A higher sulphur
content has a negative effect on the oil change inter-
vals. Use only winter-grade diesel fuel under low am-
bient temperatures. The fuel level should always be
topped up in due time so that the fuel tank is never run
dry, as otherwise filter and injection lines need to be
bled.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in particu-
lar in connection with low ambient temperatures.
The following fuel specifications are permitted: DIN/
EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS
2869: A1 and A2; ASTM D 975-78: 1-D and 2-D.
●
DIN/EN 590
●
BS 2869
●
ASTM D 975-78: 1-D and 2-D.
Fig. 11
●
Nato Codes: F-54, F-34, F44 and XF63
With their better temperature and oxidation stability Winter fuel
synthetic lubrication oils offer quite a few benefits.
Oil change intervals Danger

!
The longest permissible time a lubrication oil should Fire hazard!

remain in an engine is 1 year. If the following oil
Diesel fuels must never be mixed with gasoline.
change intervals are not reached over a period of 1
year, the oil change should be performed at least once For winter operation use only winter diesel fuel, to
per year, irrespective of the operating hours reached. avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
ACEA1 also be expected when using winter diesel fuel.
E3-96/E5-02/E7-04/ In most cases a sufficient cold resistance can also be
E4-99/ achieved by adding flow enhancing fuel additives.
E6-04 = 500 operating hours Consult the engine manufacturer.
API2 Operation with rape seed oil methyl ester (RME
CG-4/CH-4/ „Bio Diesel“)
CI-4 = 500 operating hours Due to the extreme quality differences of RMEW-fuels
available on the market, which are caused by the non-
!Caution existence of a standardization, BOMAG does general-
ly not approve any RME-fuels. If this is neglected the
These intervals apply only when using a diesel warranty will become null and void!
fuel with maximum 0.5 % sulphur by weight and
for ambient temperatures higher than -10 °C. However, if you still intend to operate the machine
with RME-fuels you should observe the following in-
When using fuels with a sulphur content of more formation:
than 0.5% to 1% or under ambient temperatures
below -10 °C the oil change intervals specified in
● Reduced engine power (approx. 7%), higher fuel
the table must be halved. For fuels with a sulphur consumption.
● The quality of RME-fuel should be in compliance
with DIN draft 51606.
1 Association des Constructeurs European d’Automobiles
2 American Petroleum Institute
34 BOMAG 008 911 71

Fuels and lubricants 2.2
● Avoid longer periods of standstill (formation of resin, ! Caution
corrosion in injection system)
Do not mix different coolants and additives of any
● RME-fuel can damage the paint finish of the ma- other kind.
chine.
● Fuel dilution of engine oil, therefore shortening of oil ! Danger
change intervals to half.
Health hazard!
● Rubber parts, such as leak fuel return lines, seats
will be damaged in the long run and need to be re- The mixing of nitrite based anti-freeze agents with
placed on a regular basis or should be replaced by amine based agents results in the formation of
parts made of fluorinated rubber. However, fluori- health affecting nitrosamines.
nated rubber is not resistant against normal diesel
fuel. Environment
● If the fuel filter is clogged the filter change intervals Cooling system protection agents must be dis-
must be shortened accordingly. posed of environmentally.
Coolant, anti-freeze agent Hydraulic oil

The correct quality of water is highly important when The hydraulic system is operated with hydraulic oil HV
preparing coolant. Clear and clean water within the 46 (ISO) with a kinematic viscosity of
boundaries of the following analysis values should 46 mm2/s at 40°C. For topping up or for oil changes
generally be used. use only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV ac-
cording to ISO 6743/3. The viscosity index (VI) should
Water quality
be at least 150 (observe information of manufacturer).
Analysis values min. max.
pH-value at 20 °C 6,5 8,5 Bio-degradable hydraulic oil
Chloride ion content [mg/dm3] - 100
On request the hydraulic system can also be filled with
Sulphate ion content [mg/dm3] - 100 ester based biodegradable hydraulic oil (Panolin HLP
Total hardness*1 [°dGH] ] 3 12 Synth. 46). The biologically quickly degradable hy-
*1Proportion of carbonate hardness on the total hard- draulic oil meets all demands of a mineral oil based
ness min. 3 dGH hydraulic oil according to DIN 51524.
Information concerning the water quality can be ob- In hydraulic systems filled with Panolin HLP Synth. 46
tained from the waterworks. always use the same oil to top up. When changing
from mineral oil based hydraulic oil to an ester based
A test case for checking the water quality can be or- biologically degradable oil, you should consult the lu-
dered from the engine manufacturer. brication oil service of the oil manufacturer for details.
If the values of the analysis deviate, the water must be Check the filter more frequently after this change.
treated accordingly.
●
pH-value too low
! Caution
Adding of caustic lye of soda or caustic potash so-
lution. Oil change bio-degradable hydraulic oil:
●
Total hardness too high: Perform regular oil analyses for content of water
Mixing with dehardenede water. and mineral oil.
●
Total hardness or carbonate hardness too low: Replace the hydraulic oil filter element every 500
Mixing with harder water. operating hours.
● Chlorides and/or sulphates too high:
Mixing with dehardenede water.
Oil for drive axle
For the drive axle use only multi-purpose transmission
As a protection against frost, corrosion and boiling
oil of API-class GL5 with viscosity class SAE 90.
point anti-freeze agents must be used under any cli-
matic conditions. The additives in this oil ensure low wear lubrication
under all operating conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the wa-
ter. Lubrication grease
For lubrication use only EP-high pressure grease, lith-
ium saponified (penetration 2).
008 911 71 BOMAG 35

2.3 Table of fuels and lubricants
2.3 Table of fuels and lubricants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine Engine oil ACEA: E3-96/E5-02 or approx. 15,5 litres incl. oil
filter
API: CG-4/CH-4
SAE 10W/40
(-20 °C to +40 °C)
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 340 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 °C
Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litres
Drive axle Gear oil SAE 90, API GL5 approx. 11 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 2 litre per side
Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres
Drum drive gear Gear oil SAE 90, API GL5 approx. 3,2 litres
Air conditioning system Refrigerant R134A approx. 1400 g
Engine cooling system Cooling system protection agent approx. 16 litres
Tires Water approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)
36 BOMAG 008 911 71

Running-in instructions 2.4
2.4 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:
! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes

● Retighten the V-belt
After 250 operating hours

● Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
● Retighten the bolted connections on the machine.
● Retighten all wheel fastening screws with the spec-
ified tightening torque.
● 1. Oil change vibration bearings
● Diesel engine oil change with replacement of oil fil-
ter cartridge
● Oil change in drive axle
● Oil change in wheel hubs
● Oil change, axle reduction gear
● 1. Oil change, drum drive reduction gear
After 500 operating hours

● 2. Oil change vibration bearings
●
2. Oil change, drum drive reduction gear
008 911 71 BOMAG 37

2.5 Maintenance chart
every 10 operating hours, daily
every 1000 operating hours


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine X
and hydraulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel X
hubs
5.16 Check the oil level in the axle re- X
duction gear
5.17 Check the oil level in the drum re- X
duction gear
5.18 Check the oil level in the vibration X
bearings
5.19 Change engine oil and oil filter car- min. 1x per year X X
tridge1
5.20 Change the fuel filter cartridge X
5.21 Drain the sludge from the fuel tank X
5.22 Battery maintenance Pole grease X
5.23 Change the fuel pre-filter cartridge X
5.24 Check, replace the refrigerant X
compressor V-belt
5.25 Service the air conditioning X
5.26 Check, adjust the valve clearance Intake = 0,4 mm X
Exhaust = 0,6 mm
5.27 Adjusting the control piston play X
38 BOMAG 008 911 71

Maintenance chart 2.5


as required
5.28 Check, tension, replace the V-belt X
5.29 Check the engine mounts X X
5.30 Oil change in drive axle min. 1x per year X X
5.31 Oil change in wheel hubs min. 1x per year X X
5.32 Oil change, axle reduction gear min. 1x per year X X
5.33 Oil change in drum drive reduction min. 1x per year X X
gear**
5.34 Oil change vibration bearings2 see foot note, min. X X
1 x per year
5.35 Retighten the fastening of the axle X
on the frame
5.36 Tighten the wheel nuts X X
5.37 Check the ROPS X
5.38 Clean the oil bath air filter min. 1x per year X
5.39 Change hydraulic oil and breather at least every 2 X
filter3 years
5.40 Change the hydraulic oil filter4 at least every 2 X
years
5.41 Change the coolant at least every 2 X
years
5.42 Replace the crankcase ventilation at least every 2 X
valve years
5.43 Electronic injector test EMR X
5.44 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2
years
5.45 Adjusting the scrapers X
5.46 Adjust the parking brake X
5.47 Change the tires X
5.48 Change the fresh air filter in the X
cabin
008 911 71 BOMAG 39



as required
5.49 Tightening torques X
5.50 Engine conservation X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.
3 Also in case of repair in the hydraulic system.
4 Also in case of repair in the hydraulic system.
40 BOMAG 008 911 71

3 Technical data
008 911 71 BOMAG 41

3.1 Technical data
3.1 Technical data
42 BOMAG 008 911 71

Technical data 3.1
Fig. 12
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 213 DH-4 2960 2250 1500 2268 2972 490 5808 60 60 35 2130
BW 213 PDH-4 2960 2250 1480 2268 2972 490 5808 60 60 25 2130
1
BW 213 DH-4 BW 213 PDH-4
Weights
Operating weight (CECE) kg 12700 13100
with ROPS and cabin
Axle load, drum (CECE) kg 7200 7600
Axle load, wheels (CECE) kg 5500 5500
Static linear load kg/cm 33,8 -
Travel characteristics
Speed km/h 0 ... 13 0 ... 13
Max. gradability (depend- % 55 58
ing on soil)
Engine
Engine manufacturer Deutz Deutz
Type TCD 2013 L04 2V TCD 2013 L04 2V
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 kW 119 119
Rated speed rpm 2200 2200
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Permissible ambient tem- °C -20 ... +50 -20 ... +50
perature
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
008 911 71 BOMAG 43

3.1 Technical data
1
BW 213 DH-4 BW 213 PDH-4
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1
Frequency Hz 30 ... 36 30 ... 36
Amplitude mm 2,0 / 0,9 1,84/0,9
Tires
Tire size 23.1/18-26/TL-8PR-AWT 23.1-26/12TL R1
Air pressure bar 1,4 1,4
Filling capacities
Engine Litres 12,5 12,5
Fuel Litres 340 340
Hydraulic oil Litres 60 60
1 The right for technical modifications remains reserved
44 BOMAG 008 911 71

Technical data 3.1
Fig. 13
mm
BW 214 DH-4 2960 2250 1500 2268 2972 490 5808 60 60 35 2130
BW 214 PDH-4 2960 2250 1480 2268 2972 490 5808 60 60 35 2130
1
BW 214 DH-4 BW 214 PDH-4
Weights
Operating weight (CECE) kg 14390 14790
with ROPS and cabin
Axle load, drum (CECE) kg 8890 92900
Axle load, wheels (CECE) kg 5500 5500
Static linear load kg/cm 41,7 -
Speed km/h 0 ... 13 0 ... 13
Max. gradability (depend- % 50 53
ing on soil)
Engine
Engine manufacturer Deutz Deutz
Type TCD 2013 L04 2V TCD 2013 L04 2V
Cooling Water Water
Number of cylinders 4 4
Rated power ISO 3046 kW 119 119
Rated speed rpm 2200 2200
Electrical equipment V 12 12
Driven axles 2 2
Permissible ambient tem- °C -20 ... +50 -20 ... +50
peratures
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
008 911 71 BOMAG 45

3.1 Technical data
1
BW 214 DH-4 BW 214 PDH-4
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1
Frequency Hz 31 ... 36 31 ... 36
Amplitude mm 2,0 / 0,9 1,84/0,9
Tires
Tire size 23.1/18-26/TL-8PR-AWT 23.1-26/12TL R1
Air pressure bar 1,4 1,4
Filling capacities
Engine Litres 12,5 12,5
Fuel Litres 340 340
Hydraulic oil Litres 60 60
46 BOMAG 008 911 71

Technical data 3.1
BW 213 DH-4 with attachment plates
Fig. 14
mm
BW 213 DH-4 2960 2250 1500 2268 2972 490 6626 60 60 35 2130
1 BW 213 DH-4
Weights
Operating weight (CECE) kg 14100
with ROPS and cabin
Axle load, drum (CECE) kg 6345
Axle load, wheels (CECE) kg 7755
Static linear load kg/cm 29,8
Speed km/h 0 ... 14
Max. gradability with/with- % 55/58
out vibration (soil depend-
ent)
Engine
Engine manufacturer Deutz
Type TCD 2013 L04 2V
Cooling Water
Number of cylinders 4
Rated power ISO 3046 kW 119
Rated speed rpm 2200
Electrical equipment V 12
Drive system hydrostatic
Driven axles 2
Brakes
Service brake hydrostatic
Parking brake hydr.-mech.
Steering
008 911 71 BOMAG 47

3.1 Technical data
1
BW 213 DH-4
Type of steering articulated
Steering operation hydrostatic
Vibration, drum
Frequency Hz 30/36
Amplitude mm 2,00/1,00
Vibration, attachment
plates
Frequency Hz 30 ... 55
Tires
Tire size 23.1/18-26/12PR
Air pressure bar 1,8
Filling capacities
Engine Litres 15
Fuel Litres 340
Hydraulic oil Litres 60
48 BOMAG 008 911 71

Technical data 3.1
Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 700 - 800
High idle speed rpm 2200 - 2250
Spec. fuel consumption g/kWh 226
Valve clearance intake mm 0,4
Valve clearance exhaust mm 0,6
Injection valves opening pressure bar DRC / 1600
Travel pump
Manufacturer Sauer
Type 90R 075 (EP)
System Axial piston/swash plate
Max. displacement cm3/rev. 75
Max. flow capacity ccm x n l/min 75
High pressure limitation bar 400
Charge pressure, high idle bar 25 ± 1
Drum reduction gear

Type CR 31
Transmission ratio 45,6
Drum drive motor

Manufacturer Sauer
Type 51C 110 (EP)
System Axial piston – bent axle
Displacement (stage 1) cm3/rev. 110
Displacement (stage 2) cm3/rev. 31,4
Perm. leak oil rate l/min 2 ± 10
Flushing rate l/min 10
Flushing limitation bar 16
Axle drive motor

Manufacturer Sauer
Type 51D 110 (EP)
Max. displacement (stage 1) cm3/rev. 110
Min. displacement (stage 2) cm3/rev. 55,3
Perm. leak oil rate l/min 2 ± 10
Flushing limitation bar 16
Vibration pump
Manufacturer Sauer
Type 90R 075 (EP)
System Axial piston/swash plate
Max. displacement cm3/rev. 75
Start up pressure bar 365 ± 65
Operating pressure (soil depend- bar approx. 100
ent)
Vibration motor
Manufacturer Bosch-Rexroth
Type A2FM 56 HDD
System Axial piston/bent axle
Displacement cm3/rev. 56
008 911 71 BOMAG 49

3.1 Technical data

Flushing pressure limitation bar 13
Steering/charge pump, machine

without attachment plates
Type HY/ZFFS11/16
System Gear pump
Max. steering pressure bar 175 + 26
Steering/charge pump, BW 213

DH-4 with attachment plates
Type HY/ZFFS11/16+8
System Tandem gear pump
Displacement cm3/rev. 16/8
Max. steering pressure bar 205 ± 15
Attachment plate vibration mo-

tor
Type A2FM16
Frequency Hz 30 / 55
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Rear axle
Manufacturer Dana
Type CHC 193/66LD
Differential No-Spin
Degree of locking % 100
Reduction ratio 65,08
50 BOMAG 008 911 71

Technical data 3.1
The following noise and vibration data acc. to
- EC Machine Regulation edition (98/37/EC) and
- Noise Emission Regulation 2000/14/EC
were determined at nominal speed of the drive engine and with vibration running. The machine was
standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level at the work place of the operator (with cabin):
LpA = BW 213 DH-4 85 dB(A)
LpA = BW 213 PDH-4 85 dB(A)
LpA = BW 214 DH-4 78 dB(A)
LpA = BW 214 PDH-4 78 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:

LWA = BW 213 DH-4 106 dB(A)
LWA = BW 213 PDH-4 106 dB(A)
LWA = BW 214 DH-4 106 dB(A)
LWA = BW 214 PDH-4 106 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204
for sound pressure level (LpA) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire boy (driver’s seat)

The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2.
Hand-arm vibration values

The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 , is γ
≤2.5 m/sec2.
008 911 71 BOMAG 51

3.1 Technical data
BW 213 DH-4 with attachment plates
52 BOMAG 008 911 71

Technical data 3.1
The following noise and vibration data acc. to
- EC Machine Regulation edition (98/37/EC) and
- Noise Emission Regulation 2000/14/EC
were determined at nominal speed of the drive engine and with vibration running. The machine was
standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level at the work place of the operator (with cabin):
LpA = 76,8 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:

LWA = 111 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204
for sound pressure level (LpA) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire boy (driver’s seat)

The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2.
Hand-arm vibration values

The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 , is
γ ≤2.5 m/sec2.
008 911 71 BOMAG 53

3.1 Technical data
54 BOMAG 008 911 71

4 Connection overview
008 911 71 BOMAG 55

4.1 Connection overview
Fig. 1
56 BOMAG 008 911 71

Connection overview 4.1
1 Proportional valve, vibration low frequency 16 Charge pressure test port
2 Proportional valve, vibration high frequency 17 Multi-function valve 400 bar (boost check and
3 Proportional valve, travel drive forward pressure relief valve), vibration high frequency
4 Proportional valve, travel drive reverse 18 Multi-function valve 400 bar (boost check and
pressure relief valve), vibration low frequency
5 Multi-function valve 400 bar (boost check and
pressure relief valve), travel system 19 Pressure test port, vibration low frequency
6 Multi-function valve 400 bar (boost check and 20 Pressure test port, vibration high frequency
pressure relief valve), travel system 21 High pressure port, high frequency
7 High pressure port B, reverse 22 High pressure port, low frequency
8 High pressure port A, forward 23 Charge pressure relief valve vibration pump
9 Charge pressure relief valve, travel pump 24 Port L2 (connection to travel pump 12)
10 Charge pressure (connection to travel pump 15) 25 Leak oil port (connection to thermostat housing
11 Charge oil to filter port A)
12 Port L2 (connection to vibration pump 24) 26 Port S, suction line between hydraulic oil tank and
charge pump (charge pump in vibration pump)
13 Pressure test port MA, high pressure forward
27 Charge pump (only in vibration pump)
14 Pressure test port MB, high pressure reverse
28 Pressure test port X1/X2, travel pump, control
15 Charge pressure to solenoid valve for brake and
chamber
speed range selection (charge oil vibration 10)
29 Adjustment screw, mechanical neutral position
008 911 71 BOMAG 57

4.1 Connection overview
58 BOMAG 008 911 71

5 Tests and adjustments
008 911 71 BOMAG 59

5.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80
Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C
Fig. 3
4. Digital rpm-meter for petrol engines
Fig. 4
60 BOMAG 008 911 71

Special tools, tests and adjustments 5.1
5. Digital rpm-meter for petrol engines
Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use
Fig. 6
7. Infrared manual thermometer, -18 to 275°C
Fig. 7
8. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 8
008 911 71 BOMAG 61

9. Hydraulic test case, small
i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses
Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 11
12. Adapter for pressure test hose
Fig. 12
62 BOMAG 008 911 71

Special tools, tests and adjustments 5.1
13. Gear pump testing device
Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 14
008 911 71 BOMAG 63

5.2 Activate service mode
5.2 Activate service mode

Activate the input mode
1. Set the travel lever to braking position
i Note
The function can only be activated when the trav-
el lever is engaged in braking position.
2. Switch on the ignition.
3. Press both Info-buttons (Fig. 1) longer than three
seconds to access the input mode.
Fig. 1
Activate service mode
T
i Note
The input mode starts with flashing of the left
hand digit (Fig. 2). Here you have the possibility
to change to the service mode using access code
"9999".
The green buttons F2, F4 (Fig. 3) can be used to
increase or reduce the corresponding digit.
With the blue button F5, F3 (Fig. 4) you can jump
to the corresponding next digit.
Once the last digit has been entered the code will
Fig. 2 be transmitted to the control by pressing the right
hand blue button (F3) again.
4. Enter access code "9999".
T
Fig. 3
64 BOMAG 008 911 71

Activate service mode 5.2
i Note
If the access code has been entered correctly,
the "spanner" symbol appears in the display and
the first digit flashes again.
Individual operating states can now be inter-

rogated, activated or deactivated by transmit-
ting further input codes to the control.
Deactivating the service mode

5. Quit the service mode by switching the ignition
off.
Fig. 4
008 911 71 BOMAG 65

5.3 Driving against the closed brake
i Note
On this machine the electric plug connection to
the brake valve must not be pulled off, because
the ESX-control would in this case detect a line
interruption in the current path to the brake.
Activate the input mode
1. Set the travel lever to braking position
i Note
The function can only be activated when the trav-
el lever is engaged in braking position.
2. Switch on the ignition.
3. Press both Info-buttons (Fig. 1) longer than three
seconds to access the input mode.
Fig. 1
Activate service mode
T
i Note
The input mode srats with flashing of the left hand
digit (Fig. 2). Here you have the possibility to
change to the service mode using access code
"9999".
The green buttons F2, F4 (Fig. 3) can be used to
increase or reduce the corresponding digit.
With the blue button F5, F3 (Fig. 4) you can jump
to the corresponding next digit.
Once the last digit has been entered the code will
Fig. 2 be transmitted to the control by pressing the right
hand blue button (F3) again.
4. Enter code number "9999".
T
Fig. 3
66 BOMAG 008 911 71

Driving against the closed brake 5.3
i Note
If the access code has been entered correctly,
the "spanner" symbol appears in the display and
the first digit flashes again.
Fig. 4
Activating the brake function
5. Enter code number "0500" via the LC display
(Fig. 5).
The brake will not be released when actuating the
travel lever.
The warning buzzer sounds to inform the opera-
tor about this status. The brake control light in the
LC display remains activated.
Deactivating the brake function

6. Enter code number "501" or switch the ignition off
to stop this function.
Fig. 5
008 911 71 BOMAG 67

5.4 Pressure tests in the travel circuit
5.4 Pressure tests in the travel circuit

Special tools
Hydraulic test case
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
! Danger
The closed brake mode must be activated!
i Note
Drive against the closed brake, see correspond-
ing chapter.
2. Enter code number "0500" to close the brake
(Fig. 2).
Fig. 2
3. Connect 600 bar pressure gauges to the high
pressure test ports for "forward travel" and "re-
verse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 3).
4. Start the engine and run it with maximum speed.
5. Read charge and high pressure gauges.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = charge pressure at high
Fig. 3 idle
Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.
68 BOMAG 008 911 71

Pressure tests in the travel circuit 5.4
6. Move the travel lever (Fig. 4) quickly forward and
backward, read the pressure gauge.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = pressure override
Evaluation of test
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
Fig. 4
the high pressure test, check the components in-
dividually.
Deactivate the closed brake mode

7. Quit this mode by switching the ignition off.
008 911 71 BOMAG 69

5.5 Checking / adjusting the neutral positions of the travel pump
5.5 Checking / adjusting the neutral posi-

tions of the travel pump
Special tools
Hydraulic test case
! Caution
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
! Danger
i Note
ing chapter.
2. Enter code number "0500" to close the brake
(Fig. 2).
Fig. 2
3. Connect a 600 bar pressure gauge each to the
high pressure test ports for "forward travel" and
"reverse travel" (Fig. 3).
Fig. 3
70 BOMAG 008 911 71

Checking / adjusting the neutral positions of the travel pump 5.5
! Danger
i Note
ing chapter.
4. As a measure to avoid signal residues from the
hydraulic neutral position connect both control
chambers X1 and X2 with a hose (Fig. 4).
Fig. 4
6. Read the high pressure gauges (Fig. 5).
Nominal value
Both pressure gauges (Fig. 5) must show equal
pressure (charge pressure).
i Note
If necessary repeat the pressure test with 60 bar
pressure gauges, for more accurate readings.
Fig. 5
Evaluation of test
If pressure builds up on one side, adjust the me-

chanical neutral position (Fig. 6), until the pres-
sures on both pressure gauges are identical.
Fig. 6
008 911 71 BOMAG 71

5.6 Pressure measurements in the vibration circuit
5.6 Pressure measurements in the vibra-

tion circuit
Special tools
Hydraulic test case
! Caution
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
3. Apply the brake.
Fig. 1
4. Connect a 60 bar pressure gauge (Fig. 2) to the
charge pressure test port.
5. Connect a 600 bar pressure gauge each to the
high pressure test ports for "high amplitude" and
"low amplitude".
7. Switch on vibration at high or low frequency and
read the pressure gauge.
Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Fig. 2 Start-up pressure = vibration pump start-up pres-
sure (see technical data of vibration pump).
Operating pressure = vibration pump operating
pressure (see technical data of vibration pump).
Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.
72 BOMAG 008 911 71

Check the leakage rate of the vibration motor 5.7
5.7 Check the leakage rate of the vibration
motor
! Caution
1. Drive the drum of the machine on an elastic base
(rubber buffers) (Fig. 1) and block the wheels ad-
ditionally with suitable chocks.
1. Apply the brake.
Fig. 1
2. Block the flushing pressure relief valve (Fig. 2)
with washers.
Fig. 2
3. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
5. Switch the vibration on and measure the running
out leak oil during one timed minute.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
Fig. 3
008 911 71 BOMAG 73

5.8 Pressure test in steering circuit

Special tools
Hydraulic test case, gear pump testing equipment
! Caution
ture of the hydraulic oil (approx. 50 °C).
Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it at idle speed.
! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
3. Turn the steering against an end stop.
4. Read the pressure gauge.
Nominal value
Fig. 1
see technical data, max. steering pressure of
Evaluation of test 1
If the nominal value is reached, check the steer-
ing cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) on the steering cylinders and close
them with plugs.
6. Start the engine and run it at idle speed.
7. Turn the steering wheel.
8. Read the pressure gauge.
Nominal value
see technical data for steering/charge pump.
Fig. 2 If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
9. Reconnect the hydraulic hoses to the steering
cylinders.
74 BOMAG 008 911 71

Pressure test in steering circuit 5.8
Measurement 3
10. Close the pump outlet port (Fig. 4) with the gear
pump test equipment.
11. Crank the engine with the starter
Nominal value
see technical data for steering/charge pump.
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
Fig. 3 steering/charge pump.
008 911 71 BOMAG 75

76 BOMAG 008 911 71

6 Flushing and bleeding
008 911 71 BOMAG 77

6.1 Special tools for flushing

1. Filling and filtering unit with oil bag

2. Filter element
Fig. 1
3. Flushing filter (S connection)

4. Filter element 1μ

5. Flushing hose 20S - 25S (2 pieces)

6. Screw socket R1“ - 25S (2 pieces)
Fig. 2
7. Flushing filter (L connection)

8. Filter element

9. Flushing hose 15L (2 pieces)

10. Screw socket R3/4“ -- 15L (2 pieces)
Fig. 3
11. SAE-flange 1“ - 20S

12. O-ring
BOMAG part-no. 062 203 30
Fig. 4
78 BOMAG 008 911 71

Special tools for flushing 6.1
13. Flanged plate 1“ - 25S

14. O-ring
BOMAG part-no. 062 202 22
Fig. 5
15. Reducing fitting 18L - 15L
Fig. 6
16. Reducing fitting 25S - 20S
Fig. 7
17. Reducing fitting 20S - 16S
Fig. 8
008 911 71 BOMAG 79

18. Connecting socket 15L
Fig. 9
19. Connecting socket 18L
Fig. 10
20. Connecting socket 16S
Fig. 11
21. Connecting fitting 20S
Fig. 12
80 BOMAG 008 911 71

Special tools for flushing 6.1
22. Connecting fitting 25S
Fig. 13
23. Angular fitting 18L
Fig. 14
24. Elbow fitting 16L
Fig. 15
25. Elbow 20S
Fig. 16
008 911 71 BOMAG 81

26. Elbow 25S
Fig. 17
27. Pipe connection 16S - 16S
Fig. 18
28. Connecting hose 15L
Fig. 19
82 BOMAG 008 911 71

Flushing - general 6.2
6.2 Flushing - general Clean the hydraulic tank
Caution
!
Solid particles in the circuit will very quickly

cause damage to machine components.
Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
Changing a component
Fig. 2
Caution
!
Always flush the complete oil circuit after !Caution

you have replaced a component. Change the oil in case of excessive contam-
ination, oil discoloration or if the oil change
Chips (abrasion) in the oil interval is almost due.
● Open and clean all components in the oil ● Filter the tank content with the filling and fil-
circuit, replace if necessary. tering unit and pump it into the oil bag.
● Clean all high pressure hoses in the oil cir- ● Mark all hoses and disconnect them from
cuit, replace if necessary. the hydraulic oil tank.
● If abrasion is found in the travel circuit you ● Clean the oil tank thoroughly from inside, if
should also flush the vibration circuit. necessary remove the complete tank cover.
● If abrasion is found in the vibration circuit ● Reconnect all hoses.
you should also flush the travel circuit.
● Fill the hydraulic oil tank again with the fill-
ing and filtering unit.
Before flushing
Change the filter element Bleeding
Fig. 3
Fig. 1
● Change the hydraulic oil filter element (1). ● Always bleed closed hydraulic circuits if
lines had been removed or connected.
008 911 71 BOMAG 83

6.2 Flushing - general
Servicing the flushing filter kit
Fig. 4
● Replace the filter element of the flushing fil-

ter when the red control pin of the contami-
nation indicator is pressed out during the
filtering process.
● Clean hoses and connections and store the
flushing kit in a clean and protected envi-
ronment.
84 BOMAG 008 911 71

Flushing schematic travel circuit (distribution travel pump) 6.3
008 911 71 BOMAG 85

6.3 Flushing schematic travel circuit (distribution travel pump)
1 Elbow union (tool) 13 High pressure hose (A, drum drive motor for-
ward)
2 Connecting union (tool)
14 High pressure hose (B, axle motor reverse)
3 Drum drive motor
15 High pressure hose (A, axle motor forward)
4 Axle motor
16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool)
17 High pressure port (B, drum drive motor reverse)
6 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1μ (tool)
9 Elbow union (tool)
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (B, drum drive motor reverse)
86 BOMAG 008 911 71

Flushing the travel circuit (travel pump distribution) 6.4
6.4 Flushing the travel circuit (travel
pump distribution)
Flushing the drum drive

Replacing the hydraulic oil filter element
Cleaning the hydraulic oil tank
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
1. Disconnect the high pressure hose 12 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 17) and connect
it with the flushing hose (7) (flushing filter inlet
"IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port 17) on the travel
pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 2
008 911 71 BOMAG 87

6.4 Flushing the travel circuit (travel pump distribution)
Bleeding the travel circuit
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6
88 BOMAG 008 911 71

Flushing the drum drive motor
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
Fig. 9 15. Remove the flushing filter and reconnect the high
pressure lines.
008 911 71 BOMAG 89

Flushing the axle drive

"IN").
17. Connect the flushing hose (19) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Fig. 10
Disconnecting the axle motor
18. Take the axle drive motor out of the hydraulic cir-
15) on the axle drive motor together.
Fig. 11
i Note
Fig. 12
90 BOMAG 008 911 71

Flushing the hoses
Fig. 13
i Note
flushing process.
Fig. 14
! Caution
direction forward.
axle drive motor.
Fig. 15
Flushing the axle motor
!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
24. Jack up the rear of the machine, so that the
wheels can rotate freely.
25. Secure the drum with wheel chocks.
Fig. 16
008 911 71 BOMAG 91

i Note
flushing process.
Fig. 17
! Caution
pressure lines.

31. Bleed the travel circuit (see corresponding chap-
ter).
Keep circulating the tank content.

32. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.
Function test
33. Check the hydraulic oil level in the tank, fill up if
necessary.
34. Check all connections for leaks with the engine
running (visual inspection).
35. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
36. Check all ports and connections for leak tightness
(visual inspection).
Fig. 19
92 BOMAG 008 911 71

Flushing schematic travel circuit (distribution axle motor) 6.5
008 911 71 BOMAG 93

6.5 Flushing schematic travel circuit (distribution axle motor)
94 BOMAG 008 911 71

008 911 71 BOMAG 95

6.5 Flushing schematic travel circuit (distribution axle motor)
96 BOMAG 008 911 71

1 Elbow union (tool) 13 High pressure hose (drum drive motor forward)
2 Connecting union (tool) 14 High pressure hose (B, axle motor reverse)
3 Drum drive motor 15 High pressure hose (A, axle motor forward)
4 Axle motor 16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool) 17 not used
6 not used 18 Flushing hose 25S - 20S (tool)
7 not used 19 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1μ (tool)
9 not used
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (drum drive motor reverse)
008 911 71 BOMAG 97

6.6 Flushing the travel circuit (axle motor distribution)
6.6 Flushing the travel circuit (axle motor

distribution)
Flushing the drum drive

i Note
! Caution
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
"IN").
2. Connect the flushing hose (18) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
13) on the drum drive motor together.
Fig. 2
98 BOMAG 008 911 71

Flushing the travel circuit (axle motor distribution) 6.6
i Note
Fig. 3
Flushing the hoses
i Note
flushing process.
Fig. 4
Fig. 5
! Caution
direction forward.
drum drive motor.
Fig. 6
008 911 71 BOMAG 99

Flushing the drum drive motor
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
Fig. 9
100 BOMAG 008 911 71

Flushing the travel circuit (axle motor distribution) 6.6
Flushing the axle motor
!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
15. Jack up the rear of the machine, so that the
wheels can rotate freely.
16. Secure the drum with wheel chocks.
Fig. 10
i Note
flushing process.
Fig. 11
! Caution
pressure lines.

22. Bleed the travel circuit (see corresponding chap-
ter).

15 minutes.
008 911 71 BOMAG 101

Function test
necessary.
25. Check all connections for leaks with the engine
running (visual inspection).
26. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
Fig. 13
102 BOMAG 008 911 71

Flushing schematic for vibration drive 6.7
1 Elbow union (tool) 7 Flushing hose 25S - 20S (tool)

2 Connecting union (tool) 8 Flushing filter with filter element 1μ (tool)
3 Vibration motor 9 SAE flange (tool)
4 Vibration pump 10 High pressure hose (B, high frequency)
5 Screw socket R1 - 25S (tool) 11 High pressure hose (A, low frequency)
008 911 71 BOMAG 103

6.8 Flushing the vibration circuit

i Note
! Caution
so that only cleaned oil will enter the vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
Fig. 1
ter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port A) on the vibra-
tion pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic cir-
11) on the vibration motor together.
Fig. 2
104 BOMAG 008 911 71

Flushing the vibration circuit 6.8
Bleeding the vibration circuit
i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Fig. 3
Flushing the hoses
Fig. 4
i Note
flushing process.
Fig. 5
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
5. Switch on vibration with high frequency.
7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
Fig. 6 vibration motor.
008 911 71 BOMAG 105

Flushing the vibration motor

10. Unscrew the fastening screws for the vibration
motor and pull the motor out of the coupling.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
utes. Switch the vibration on and off at intervals of
approx. 30 seconds.
14. Remove the flushing filter and reinstall the vibra-
tion motor.
Fig. 9
Bleeding the vibration circuit
15. Bleed the vibration circuit (see corresponding
chapter).

15 minutes.
106 BOMAG 008 911 71

Flushing the vibration circuit 6.8
Function test
necessary.
18. Test drive.
Fig. 10
008 911 71 BOMAG 107

6.9 Bleeding the travel circuit
6.9 Bleeding the travel circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
! Danger
The engine should not start.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Operate the starter motor for approx. 30 seconds.
Wait one minute and repeat this procedure, until
oil starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
108 BOMAG 008 911 71

Bleeding the travel circuit 6.9
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.
Fig. 4
! Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
!Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to for-
ward direction.
Fig. 5 12. After approx. 1 to 2 minutes shut down the engine
for a minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 911 71 BOMAG 109

6.10 Bleeding the vibration circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeat-
ing this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
110 BOMAG 008 911 71

Bleeding the vibration circuit 6.10
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.
Fig. 4
! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
10. For bleeding switch on vibration with high fre-
quency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.
Fig. 5 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 911 71 BOMAG 111

112 BOMAG 008 911 71

7 Fundamental electrics
008 911 71 BOMAG 113

7.1 Understanding circuit diagrams
7.1 Understanding circuit dia- ● The sequence in which current flows through the in-
dividual elements in the electric circuit.
grams ● Connections between the examined, faulty electric
Wiring diagrams are graphical representations of cir- circuit and other circuits in the vehicle wiring sys-
cuitry conditions, related to the electrical system. They tem.
do not contain any information about the actual type of ● Pin assignment of plug-and-socket connections.
wiring, they only serve the purpose of visualizing the
circuitry logics. Structure:
The wiring diagram is indispensable for effective and
● Table of contents
systematic trouble shooting in the vehicle wiring sys- ● Function groups
tem. This plan provides the following information: ● List of components
● Number and type of individual elements in the ex-
amined electric circuit, such as plug connectors, Table of contents
fuses, switches, consumers, relays, ... The table of contents lists all function groups.
Fig. 6 Table of contents
Example:
Function group "Warning systems“, drawing number
XXX XX can be found on page no. 8.
114 BOMAG 008 911 71

Understanding circuit diagrams 7.1
Function groups ● From top (plus potential) to bottom (minus poten-
On the individual pages the electric circuits are com- tial).
bined to function groups. ● From left to right.
● From function group to function group.
Arrangement of current paths
● Via cross references for potentials and relays.
The individual current paths must be read as follows:
Fig. 7 Function groups Relay cross reference

Potential cross references Relay cross references serve the tracking of signals,
which need to be tracked for components with outgo-
Potential cross references serve the purpose of track-
ing contacts.
ing signals, which are transmitted from one function
group to another. A mimic diagram with information about the contact
types of a relay and their positions in the wiring dia-
Example: gram is additionally attached to the bottom of each
Potential "15" on page no. 6 is continued to the left on contactor coil.
page no. 4 in current path "10" and to the right on page
Example:
no. 8 in current path "1“.
The coil of relay (K99) is located on page no. 8 in cur-
rent path "6".
The mimic diagram under the relay informs that a
change-over switch with contact types 30, 87 and 87a
is triggered.
The changeover contact can be found on page no. 8
in current path "3".
008 911 71 BOMAG 115

7.1 Understanding circuit diagrams
Current paths
The pages of a circuit diagram are sub-divided into
current paths (Fig. 8) (0 ..... 20).
Fig. 8 Current paths
List of components
Here you find all components used in alphabetical or-
der, related to the name of the component (A01,
A02....).
Fig. 9 List of components
Component cross references
Example:
The warning horn "B 11" is located on page no. 8 in
current path 3.
116 BOMAG 008 911 71

Understanding circuit diagrams 7.1
Graphic symbol serves the purpose of global understanding and fault
free connection of appliances, especially in automo-
Graphic symbols are standardized representations for
bile repairs.
electrical appliances. They serve the purpose of a
simplified representation of complete systems, from Since the wiring diagram is intended to show only the
which, however, the function can be clearly identified. most essential aspects, the graphic symbol only
This standardization is in compliance with the globally shows as much of the function, as is needed for easy
valid regulations of the IEC (International Electrical recognition and for the avoidance of mistakes.
Commission). For Germany these symbols were in-
cluded in the DIN-Standard. The standardization
Fig. 10 Graphic symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10 Backup
11 Line connection (fixed)
12 Line connection (separable)
Fig. 11 Graphic symbol

1 Diode
2 Transistor
3 NPN-Transistor
4 changeable resistance
5 Condenser
6 Working current relay
008 911 71 BOMAG 117

7.2 Terminal designations
7.2 Terminal designations the individual connection terminals is determined by

the standard DIN 72552. The following table repre-
For easier connection work almost every connection sents a section with the most important terminals from
on a consumer or switch used in a motor vehicle has this standard.
a terminal designation. In Germany the designation of
Terminal designa- Meaning

tion
1 Ignition coil, ignition distributor low voltage
1a Ignition distributor with 2 separate electric circuits, to ignition timer 1
1b Ignition distributor with 2 separate electric circuits, to ignition timer 2
2 Short circuit terminal (magneto ignition)
4 Ignition coil, ignition distributor high voltage

4a Ignition distributor with 2 separate electric circuits, from ignition coil 1, terminal 4
4b Ignition distributor with 2 separate electric circuits, from ignition coil 2, terminal 4
15 Switch plus (after battery) : Output of ignition-travel switch

15a Output from dropping resistor to ignition coil and starter
17 Preheating starter switch, preheating
19 Preheating starter switch, starting
30 Battery plus direct

30a Battery changeover relay 12V / 24V, input from battery 2 plus
31 Battery minus direct or ground

31a Battery changeover relay 12V / 24V return line to battery 2 minus
31b Return line to battery minus or ground via switch or relay (switched minus)
31c Battery changeover relay 12V / 24V return line to battery 1 minus
32 Electric motors, return line
33 Electric motors, main connection

33a Electric motors, limit shut down
33b Electric motors, shunt field
33f Electric motors, for 2nd lower speed range
33g Electric motors, for 3rd lower speed range
33h Electric motors, for 4th lower speed range
33L Electric motors, counter-clockwise rotation
33R Electric motors, clockwise rotation
45 Starter, separate starter relay output; starter: Input (main current)

45a 2-starter parallel operation, start relay for engagement current, output starter 1
45b 2-starter parallel operation, start relay for engagement current, output starter 2
48 Terminal on starter and on start repeat relay, monitoring of starting process
49 Input flasher relay

49a Output flasher relay
49b Flasher relay output 2nd flasher circuit
49c Flasher relay output 3rd flasher circuit
50 Starter, starter control

50a Battery changeover relay, output for starter control
50b Starter control, parallel operation of 2 starters with sequence control
118 BOMAG 008 911 71

Terminal designations 7.2
tion
50c Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 1
Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 2
50d Start locking relay, input
50f Start locking relay, output
50g Start repetition relay, input
50h Start repetition relay, output
51 A.C.-generator, direct voltage on rectifier

51a A.C.-generator, direct voltage on rectifier with reactance coil for day travel
52 Trailer signals: further signals from trailer to towing vehicle
53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding
53c Electric windscreen washer pump
53e Wiper, braking effect
53i Wiper motor with permanent magnet and 3rd brush for higher speed
54 Trailer signals, trailer plug device and lamp combination, brake light
54g Trailer signals, compressed air valve for permanent brake in trailer, electromag-
netically operated
55 Fog light
56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light
57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right
58 Side lights, tail light, number plate light, dashboard light

58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right
59 A.C.-generator (magneto generator), alternating voltage output or rectifier input

59a A.C.-generator, charging armature output
59b A.C.-generator, tail light armature output
59c A.C.-generator, brake light armature output
61 Generator control
71 Intermittent tone control unit, input

71a Intermittent tone control unit, output to horn 1 + 2 (low)
71b Intermittent tone control unit, output to horn 3 + 4 (high)
72 Alarm switch (flashing beacon)
008 911 71 BOMAG 119

7.2 Terminal designations

tion
75 Radio, cigarette lighter
76 Loudspeaker
77 Door valve control
81 Switch (breaker and two-way contact), input

81a Switch (breaker and two-way contact), output 1
81b Switch (breaker and two-way contact), output 2
82 Switch (maker), input

82a Switch (maker), output 1
82b Switch (maker), output 2
82z Switch (maker), input 1
82y Switch (maker), input 2
83 Switch (multi-position switch), input

83a Switch (multi-position switch), output position 1
83b Switch (multi-position switch), output position 2
83L Switch (multi-position switch), output position left
83R Switch (multi-position switch), output position right
84 Current relay, input drive and relay contact

84a Current relay, output drive
84b Current relay, output relay contact
85 Switching relay, output drive winding end (minus or ground)
86 Switching relay, input drive winding start

86a Switching relay, input drive winding start 1st winding
86b Switching relay, input drive winding start 2nd winding
87 Relay contact on breaker and two-way contact, input

87a Relay contact on breaker and two-way contact, output 1 (breaker side)
87b Relay contact on breaker and two-way contact, output 2
87c Relay contact on breaker and two-way contact, output 3
87z Relay contact on breaker and two-way contact, input 1
87y Relay contact on breaker and two-way contact, input 2
87x Relay contact on breaker and two-way contact, input 3
88 Relay contact for maker

88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3
B+ Battery Plus
B- Battery Minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
120 BOMAG 008 911 71

Terminal designations 7.2
tion
DF2 Dynamo field 2 (generator excitation current)
U Three-phase generator, three-phase terminal

V Three-phase generator, three-phase terminal
W Three-phase generator, three-phase terminal
C Travel direction indicator (flasher relay) control light 1

C0 Main connection for control light separated from flasher relay
C2 Travel direction indicator (flasher relay) control light 2
C3 Travel direction indicator (flasher relay) control light 3 (e.g. for 2 trailer operation)
L Indicator left
R Indicator right
008 911 71 BOMAG 121

7.3 Current and voltage
7.3 Current and voltage The following statements concerning electric volt-
age can be made
● electric voltage is the pressure or force applied to
General
free electrons.
If one wants to describe electric current, this can most ● the electric voltage is the cause of electric current
simply be accomplished by means of a comparison:
● electric voltage is a result of the equalization at-
One simply compares electric current with water. tempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt
The electric voltage (U) is measured in Volt (V).
Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.
Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
122 BOMAG 008 911 71

Current and voltage 7.3
Current Types of current
Electric current generally describes the directed Direct current (D.C.)
movement of charge carriers.
● The charge carriers may either be electrons or ions.
● Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
● The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.
Unit, Ampere Fig. 1 Direct current (D.C.)
The electric amperage (I) is measured in Ampere Direct current flows with steady voltage and amper-
(A). age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
The technical flow direction is specified from
tors or batteries.
PLUS to MINUS.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
i Note the consumers switched on, the voltage is not con-
Current actually flows from minus to plus, because the stant, but drops gradually according to the battery
current flow is made up of negatively charged elec- charge condition.
trons.
The internal resistance of the battery also causes per-
But since this was only discovered after the poles of a manent changes in the vehicle voltage, as soon as
current source had already been designated, the as- consumers are switched on or off.
sumption that current flows from plus to minus was
maintained for historic reasons. Alternating current (A.C.)
Circuit
Fig. 2 Alternating current (A.C.)
Fig. 3 Circuit Alternating current not only changes its direction, but
also its amperage.
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring. Pulsating direct current
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).
Fig. 3 Pulsating direct current

Converting alternating current into a direct current sig-
nal by means of a rectifier results in an pulsating direct
current.
008 911 71 BOMAG 123

7.3 Current and voltage
Pulse width modulation (PWM)
Fig. 4 PWM
The PWM signal is in most cases generated by a con-
trol and can be used to trigger proportional valves.
The signal (square wave signal) is changed in its
pulse control factor, the period, however, remains un-
changed.
The following applies:
●
The signal voltage cannot be measured.
●
The current can be measured.
Caution
!
Solenoid valves must not be interference sup-

pressed with suppressor diodes.
124 BOMAG 008 911 71

Current and voltage 7.3
Controller Area Network (CAN) Real-time critical, robust and low price communication
created by Bosch at the end of the eighties for auto- of control units, such as transmission and engine con-
mobile applications. trol, but also less time critical applications in the field
of convenience electronics, such as air conditioning.
Development objectives:
Fig. 5 CAN Characteristics of CAN

Why CAN? It is a kind of serial data transmission. The individual
bits are transmitted one after the other, only 2 lines are
● Networking of control units for the realization of
required.
complex functions.
●
Reduction of the extend of wiring and plug connec- CAN lines are twisted together 30 to 40 times per me-
tions. tre. Electromagnetic interferences therefore always
occur simultaneously in both lines, the software is
●
Better diagnostic possibilities (central diagnostics thus able to filter out interfering signals more easily.
socket).
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
008 911 71 BOMAG 125

7.4 Resistance
7.4 Resistance ● The cleaner the contacts, the better the current.
● The quality of the ground cable is of the same im-
portance as the supply line.
Resistance and voltage drop
While current flows through a conductor the current
Unnecessary resistances
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance. Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.
Bad
Fig. 1 Various size resistors

Fig. 1 Screw-type terminals
Each conductor has its specific resistance, which is
characteristic for the corresponding material. A good Copper wires are squashed and thus become faulty.
conductor has a low resistance, a poor conductor has
Better
a high resistance.
Fig. 2 Spring clamps

Connecting clamps for flexible conductors
BOMAG No. 057 565 72
Ampacity up to 20 Amp.
Cable cross-section 0.08 to 2.5 qmm
Fig. 2 Potentiometer, infinitely adjustable resistor
The resistance can only be measured with a Multime-
ter.
Symbol, R
Unit, Ohm Ω
The electric resistance (R) is measured in Ohm Ω.

Rule of thumb:
●
The thicker the cable cross-section, the lower the
voltage loss.
●
The shorter the cable, the better the current.
126 BOMAG 008 911 71

Resistance 7.4
Sometimes the flanks of flat plugs bend open. If these
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.
Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.
Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.
Fig. 4 Balistol oil
008 911 71 BOMAG 127

7.5 Series / parallel connection
7.5 Series / parallel connection ● In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
Series connection ond battery.
In a series circuit the resistors (consumers) are lined ● The sum of all individual voltages is applied to the
up one after the other and the same current (I) passes free poles.
through each of the consumers However, series con- ● The total capacity (Ah) is identical with the capacity
nection of consumers is not suitable in practice, as of the individual battery.
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).
Fig. 1 Series connection
Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3
Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3
Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3
Series connection of batteries
Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.
128 BOMAG 008 911 71

Series / parallel connection 7.5
Parallel connection ● In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
● All resistances (consumers) are supplied with the
same voltage.
● Plus and minus poles have the voltage of the single
battery applied.
● Each of the resistances (consumers) draws as
much current as required.
● The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.
Fig. 3 Parallel connection
Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3
Resistance
The total resistance is less than the lowest individual
resistance.
Parallel connection of batteries
Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.
008 911 71 BOMAG 129

7.6 Ohm's law
7.6 Ohm's law 7.7 Electrical energy

In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.
Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm Ω).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM Ω
130 BOMAG 008 911 71

Formula diagram 7.8
7.8 Formula diagram Example:
P = 150 Watt
Description:
U = 24 Volt
● Select the desired value from the inner circle.
Sought for = Current in Ampere
● Determine the formula variables in the quarter circle
● Calculate I = P : U = 150 W : 24 Volt = 6.25 Ampere
Fig. 1 Formula diagram
Resistance, R Ohm Ω
Voltage, U Volt
Current, I Ampere
Power, P Watt
008 911 71 BOMAG 131

7.9 Metrology
7.9 Metrology Multimeter

This tester is a multimeter and can be used to meas-
Test lamps ure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
Test lamp frequency.
Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
●
the range selector switch must be correctly set for
the corresponding measurement.
! Caution ●
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- ●
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic ●
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp ●
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The ● In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.
Resistance and continuity measurement with mul-
timeter
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
● The component to be measured must not be con-
nected to the power supply during the measure-
ment.
● At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
● Polarity is of no significance.
Fig. 2 Diode test lamp

If voltage is present, the corresponding light emitting
diode will light up.
132 BOMAG 008 911 71

Metrology 7.9
Voltage and voltage drop measurement with mul- Clip-on measuring instrument
timeter
The clip-on measuring instrument can be used to
measure current, voltage and resistance.
Fig. 2 Voltage measurement

● The meter is always connected parallel to consum-
er, component or power source.
● Measurement at the voltage source measures the
currently available Voltage.
● A measurement at the consumer measures the volt-
age drop at this component.
Current measurement with the multimeter
Fig. 1 Clip-on measuring instrument

●
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 3 Current measurement

●
During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened. The meter is connected in series
with the consumer.
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
008 911 71 BOMAG 133

7.10 Diodes, relays, fuses
Magnet tester 7.10 Diodes, relays, fuses
Diodes
Fig. 1
Fig. 1 Magnet tester
A diode consists of two different semi-conductors,
The magnet tester is used to test solenoid valves and which are connected by a separating layer. The max.
magnetic coils. conducting state current must not be exceeded.
The test lamp responds to the magnetic fields of A.C- Plus-voltage on diode:
voltage, D.C.-voltage and permanent magnets. ● At 0.6 – 0.7 Volt (silicium diode) the diode becomes
●
The component to be tested does not need to be re- conductive.
moved.
Negative voltage on diode:
● The magnetic coil can also be tested under a pro-
tective cap.
● The diode does not allow current to pass through.
Fig. 2 Marking of the cathode

Diodes are used:
●
For rectifying A.C. voltage.
●
For absorbing voltage peaks (free-wheeling diode).
●
For construction of logical circuits.
134 BOMAG 008 911 71

Diodes, relays, fuses 7.10
Diode logics and free-wheeling diode Light emitting diodes
Fig. 4 LED
The light emitting diode, also referred to as LED, is a
semi-conductor diode, which generates (emits) light
during operation in forward direction. A semi-conduc-
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the
head. Light emitting diodes are available in various
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.
Fig. 3 Diode circuitry

● The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
● Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
● Solenoid valve Y21 is supplied, if the switch is in po-
sition "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.
008 911 71 BOMAG 135

7.10 Diodes, relays, fuses
Relays 85 = Ground supply for coil

30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact
Fuses
Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
A free-wheeling diode prevents induction voltage from
flowing back from the coil into the vehicle wiring sys-
tem, which would cause interference with electronic
components (control units).
With the possibility of using breaker - maker contacts
the effect of an information can be reversed.
Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.
Caution
!
Fuses must not be repaired or bridged.

The melting time at 23 °C is:
● approx. 1 hour with 1.5 times the rated current
● approx. 1 minute with 2.5 times the rated current.
A 5 Amp fuse loaded with 1.5 times the rated current
(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A
Fig. 2 Relay circuitry

The windscreen wiper and washer motors can only be
operated via switches S20 and S21, when relay K32
is supplied with electric current (Fig. 2).
86 = Positive supply for coil
136 BOMAG 008 911 71

Batteries 7.11
7.11 Batteries Battery maintenance
Battery – accumulator
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
Fig. 1 a subsequent charging process.
In vehicles batteries are used to start the engine. The In the worst case the accumulator can only be dis-
ability to start the engine depends on the charge con- posed of after such an exhaustive discharge.
dition of the batteries. The following therefore applies for longer downtimes:
Lead collectors or accumulators are secondary ele- ● Remove the battery and store it in a cool, dry and
ments, i.e they can be recharged after discharging frost protected room.
electric current. ● Check the open circuit voltage on the battery at reg-
The basic element of a lead accumulator is the cell. It ular intervals (at least once every month).
contains the plate blocks consisting of positive and ● Recharge immediately if the open circuit voltage
negative plates. These plates are separated from has dropped to 12.25 Volt (no rapid charging).
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of i Note
the cells. The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.
Battery test in general

●
Is the battery leaking? Can traces of impact, shock
or compression be found in the leaking area?
●
Check for e.g. incorrect fastening, foreign bodies on
the battery mounting surface and similar.
Testing batteries with screw plugs

Checking the acid density:
● The cells are filled with diluted sulphuric acid as
electrolyte (approx. 25 Vol% sulphuric acid in dis-
tilled water), also referred to as accumulator acid,
Fig. 2 which has a density of 1.285 kg/dm3 at a tempera-
All cells are filled with a conductive fluid, the electro- ture of +27° Celsius. This means that one litre of
lyte. For a 12 Volt battery 6 cells are connected in se- electrolyte has a weight of 1.285 kg. As the cell is
ries. being discharged lead sulphate (PbSO4) will form
on both electrodes and the electrolyte will increas-
Capacity ingly change to water. Since water has a lower spe-
is a synonym for the amount of current taken up and cific weight than diluted sulphuric acid the density of
discharged by a battery over a specified period of the electrolyte will also drop during the discharge
time. and with a fully discharged cell and a temperature
of 27°C it will only be 1.18 kg/dm3.
● With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead
008 911 71 BOMAG 137

7.11 Batteries
battery. The so-called acid tester (hydrometer) is

used for this purpose. In a battery of good condition
the acid density should be the same in all cells.
Acid density at 27 °C in kg/dm3

● 1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
Battery is charged.
● 1.20 -1.24, open circuit voltage approx.12.4 to 12.5
Volt, is 50% discharged. Charging is necessary.
● 1.19 and less, open circuit voltage less than 12.3
Volt. Battery is insufficiently charged. Battery needs
to be recharged immediately.
Fig. 4 Battery and generator tester

i Note
The battery and generator tester comes with an 8-line
If the current consumption during charging is not 1/20 LC display with background illumination and is able to
of the nominal capacity (example 100 Ah battery: print out test results via an (optional) integrated ther-
100Ah x 1/20 = 5 A) or full charging of the battery re- mal printer.
sults in a final acid density of only 1.24 kg/dm3 or less,
the battery shows normal wear by aging. The battery
was insufficient charging or exhaustive discharge. i Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.
Fig. 3 Reading the acid level

●
Maximum permissible tolerance between highest
and lowest measuring value of the 6 cells: 0.03 kg/
dm3.
Testing batteries without screw plugs

On closed batteries the acid density cannot be meas-
ured, we therefore recommend testing with the follow-
ing mobile tester:
138 BOMAG 008 911 71

Batteries 7.11
Charge condition with hydrometer
Fig. 5 Charge condition

Green = Charge condition >65%
Dark = Charge condition <65%
Light = Electrolyte level too low
! Danger
Danger of explosion!!! If the electrolyte level is too

low, the battery must no longer be charged.
008 911 71 BOMAG 139

7.12 Three-phase generator
7.12 Three-phase generator Design and function

In the generator the armature windings are located in-
General side the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.
! Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be Fig. 6 Rotor with claw poles
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
When cleaning the generator with a steam or wa-
ter jet make sure not to direct the steam or water
jet directly on or into the generator openings or
ball bearings. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
Fig. 7 Stator with 3 windings
The three stator windings (Fig. 7) are electrically offset
to each other by 120°. The excitation of the magnetic
field requires direct current, which is fed to the rotor
via two carbon brushes and slip rings.
140 BOMAG 008 911 71

Three-phase generator 7.12
This includes :
● Electric motors
● Relays
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
es work with alternating or three-phase current.
This includes :
● Accumulators
● Control units
● All electronics
● Communication equipment.
Charge control light

It has by no means the function to show whether the
ignition is switched on or off. It has the function of in-
dicating that the generator works correctly. Under nor-
mal operating conditions the generator should work
and the charge control light should be off. The charge
control lamp receives (+) from the battery at one pole.
The other pole is connected to (D+), i.e. the (+) carbon
Fig. 8 3-phase current of the generator. If the generator is working correctly,
The generator first of all produces three-phase volt- (+) is attached to both connections on the charge con-
age / three-phase current. trol lamp. Since there is no difference in voltage, no
current can flow, the lamp does not light up. If the gen-
The wiring diagram (Fig. 8) shows the 3 windings in Y- erator does not work, current flows via the (+) carbon
connection and the 6 associated rectifier diodes. through the armature winding, via the (-) carbon to
The diodes D1, D2, D3 are also referred to as minus ground and from there back to the battery. The electric
diodes, because they have B- as common connection circuit is closed, battery voltage is applied to the
(minus plate). charge control lamp and the lamp lights up. Since the
The other diodes are the plus diodes. generator does not work when the engine is not run-
ning, the charge control lamp is not connected directly
The rectifier diodes have the effect that the negative to the battery, but via the ignition switch. When the ig-
half-wave is suppressed and only the positive section
nition is off, the charge control lamp is dead.
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage. Voltage regulator
Reverse current protection A generator without regulator would just work light a
bicycle dynamo. The power output would increase
The rectifier diodes also prevent discharging of the with rising speed. The voltage output would fluctuate
battery via the stator windings. The current can only with the load. (In case of a bicycle dynamo the tail light
flow from the generator to the battery. bulb is overloaded when the head light does not con-
Why does three-phase current need to be rectified sume any power). The function of the regulator is the
and how does this work? provision of a uniform vehicle voltage, almost com-
pletely independent from speed and load of the gen-
There are a few components for which can either be
erator.
operated with alternating current or direct current, be-
cause they work independently from the current flow
direction.
This includes :
●
Incandescent lamps
●
Fluorescent lamps
●
Glow lamps
●
Electric heating elements.
There are also a few components that could be oper-
ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
008 911 71 BOMAG 141

Checking the generator

First one must check whether the generator is actually
defective.
● This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
● When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
● Cable connections on the generator OK?
● V-belt OK?
● Generator ground (engine ground) OK?
● Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
Fig. 9 Regulator with diode plate and rectifier diodes
replaced or the following trouble shooting procedure
In most cases voltage regulators (Fig. 9) with carbon must be performed.
brushes form a compact component. The voltage reg-
ulator is maintenance free and the wear of carbon
brushes is only so little, that they hardly ever need to
be replaced during the lifetime of a machine.
The regulator has the following function:
●
To maintain the vehicle voltage under any operating
conditions below 14.4 V.
●
To match the regulator voltage to the temperature.
●
Smooth rising of generator current when switching
loads (convenience function to avoid jerking of the
engine).
142 BOMAG 008 911 71

Checking the pre-excitation circuit Measuring the charge current
The most common reason for a 3-phase alternator not ● All plug-and-socket connectors must be free of cor-
charging is a too low pre-excitation current. The pre- rosion and intermittent contact.
excitation current through connection D+ depends on ● The generator ground connection must be OK.
the connected consumer (resistance), e.g. charge ● During the measurement switch on as many con-
control light or relay of a MD+ engine control.
sumers as possible.
The pre-excitation current should be approx. 250 mA 1 Attach the clip-on ammeter around the B+ line.
at 12 Volt. This corresponds with a 3 Watt light bulb or
an equivalent combination of light bulb + resistance or 2 Gradually increase the engine speed.
an LED + resistance. 3 The generator current must be at least as high as
the total current of all consumers.
The total resistance of the disconnected dead supply
line D+ max. should not exceed 48 Ohm.
In case of faults like
● charge control light stays on
● no voltage increase, e.g. from 12 V to 14 V
one should check that the correct resistance is as-
sured.
Fig. 10 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
● Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 10). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.
008 911 71 BOMAG 143

Checking the rotor Checking the stator
i Note
The rotor coils can only be measured in disassembled
state.
Fig. 11 Rotor
●
Remove the regulator with carbon brush.
Fig. 12 Stator
●
Contact the rotor slip ring with the tester points.
●
The resistance should be between 3 and 6 OHM Ω.
i Note
●
The rotor coils should not have continuity to ground. The stator coils can only be measured in disassem-
bled state.
● Measure the resistance of all three coils.
● The coils should not have contact among each oth-
er.
144 BOMAG 008 911 71

Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
Fig. 14
● All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 13 ● The generator ground connection must be OK.
The generator test assesses the regulator voltage and ●
The battery should be in good condition – the idle
the ripple factor of the generator voltage. speed voltage of the battery should be at least 12.6
●
All plug-and-socket connectors must be free of cor- Volt.
rosion and intermittent contact. ●
If possible switch off all consumers.
●
The generator ground connection must be OK. ●
Perform the measurement at raised engine speed.
●
The battery should be in good condition – the idle ●
The voltage (B+) should adjust itself at 13 to 14 Volt.
speed voltage of the battery should be at least 12.6
Volt.
●
If possible switch off all consumers.
●
Perform the measurement at raised engine speed.
008 911 71 BOMAG 145

Checking the regulator in disassembled state

On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator. Fig. 16
E.g minus controlled regulator
i Note One connects the regulator (Fig. 16) with D+ and D- to
When testing the regulator one should be aware that the power source, as shown in the illustration, and the
there are 2 different types of regulators: lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
● If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal,
With this test the major difficulty is the problem to re-
this is DF.
move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)
Fig. 17
Fig. 18
Fig. 15
The illustrations (Fig. 17) and (Fig. 18) show two dif-
● If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
146 BOMAG 008 911 71

Replacing carbon brushes
● On a Bosch generator unscrew two fastening
screws for the regulator and lift the regulator off.
Pull out the carbon brushes from underneath. Their
minimum length is 5 mm, shorter carbon brushes
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
●
For replacing the carbon brushes in the Delco-
Remy generator the generator needs to be disas-
sembled and partly dismantled. The carbon brush
holder is located inside the collector ring bearing.
008 911 71 BOMAG 147

7.13 Electric starter
7.13 Electric starter ● establish the gear connection between starter and
combustion engine.
The starter converts the electric energy stored in the ● to maintain this connection.
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
● to switch on the starter current.
capacity is available. After starting the engine:
Duties of the starter: ● to return the starter pinion to initial position.
● to accelerate the combustion engine to start speed ● to switch off the starter current.
with lowest possible current consumption.
Fig. 1 Electric starter For purposes like e.g. purging the fuel systems,
1 Pinion starters may be operated for maximum 1 minute
2 Roller free-wheeling without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again.
3 Steep thread During the 1 minute starting period this process
4 Guide ring should not be interrupted.
5 Spring winding Starter motors must not be cleaned with high
6 Armature pressure steam cleaning equipment.
7 Pole shoe The contacts on starter terminals 30, 45, 50 must
8 Carbon brushes be protected against unintended shorting (jump
protection).
9 Armature brake
10 Collector When replacing the starter the ring gear on the en-
gine flywheel must be checked for damage and its
11 Magnetic switch number of teeth - if necessary replace the ring
12 Engagement lever gear.
Always disconnect the battery before starting as-
!Caution sembly work in the starter area of the engine or on
So-called jump starting (using an additional exter- the starter itself.
nal battery) without the battery connected is dan-
gerous. When disconnecting the cables from the
poles high inductivities (arcs, voltage peaks) may
occur and destroy the electrical installation.
148 BOMAG 008 911 71

Electric starter 7.13
Function of pre-engaged-drive starting motor
This type of starter uses a solenoid to engage the pin-
ion with the ring gear. The engaging solenoid contains
switching contacts for the starting current. When clos-
ing the starter switch, the relay holding winding is ac-
tive and current flows also through the series
connection of pick-up winding and electric motor. The
engaging solenoid picks up and moves the free-
wheeling with the pinion forward via the engaging le-
ver and the engaging spring. In case of a favourable
position of the pinion to the ring gear a tooth of the pin-
ion will directly engage in a tooth gap. In this case the
pinion will engage over the entire length of the screw
path, until the contact bridge in the engaging relay
touches the relay contacts. The starter motor is no
switched on. However, if the pinion does not directly Fig. 2 Switching position during engagement
find a tooth gap, the ring gear will block any further en-
gaging movement. The engaging lever in this case
compresses the engaging spring and the main contact
closes, even though the pinion and the ring gear are
not engaged. The electric motor keeps rotating the
pinion in front of the ring gear face, until a pinion tooth
gap matches a tooth on the ring gear and the preload-
ed engaging spring moves pinion and free-wheeling
forward. When switching the relay winding off, the re-
turn spring forces the relay armature and the pinion
with free-wheeling back to rest position. This disen-
gagement is supported by the steep thread.
Magnetic switch
The magnetic switch is normally arranged directly
above the starter. Fig. 3 Switching position during starting
With the starter switch switched on, both the pickup 1 Ground
winding and the holding winding are energized and 2 Battery
shift the iron core in axial direction. With a lever this
iron core pulls the starter pinion towards the engine 3 Starter switch
flywheel. 4 Pull-in winding
Once the gears are engaged the starter current is ap- 5 Holding winding
plied to the back through a large cross-section. At the 6 Exciter winding
same time the pickup winding is shorted via the starter 7 Restoring spring
current and thus switched off as a measure to reduce
8 Driver
the load on the energy household.
9 Pinion
10 Flywheel
008 911 71 BOMAG 149

7.13 Electric starter
Trouble shooting "Starter" Testing and measuring the electric starter

The most frequent fault is definitely a fully discharged
battery. i Note
If the starter rotates too slowly, either the brushes The highest current flows when the starter is blocked!
are partly worn off, or parts of the exciter or armature (Short circuit current in starter). This is the case when
winding is shorted. In some cases oxidized electric the pinion is engaged and the starter has the duty to
contacts or a soiled ground connection causing ex- accelerate the flywheel to starting speed.
tremely high voltage losses in the overall starter sys-
tem are the cause of problems. Function test with starter installed
If the starter only emits a clicking sound,- either
● Initiate the starting process and measure the volt-
the magnetic switch is defect / soiled (dismantle and age on the pickup solenoid switch (50a). At least
clean))- the main contacts on the magnetic switch are 10.8 Volt should be applied.
worn off / soiled (scrape off carefully with a file and ● When operating the starter switch the magnetic
clean)- the starter motor is defective / soiled (remove switch must engage in the flywheel ring gear (no-
armature and clean), cover cleaned, moveable parts ticeable clicking sound) and release the starting
with grease. current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
Frequently a jammed return mechanism is the reason
this does not happen even though voltage is ap-
for a starter failure.
plied, replace the magnetic switch.
Occasionally worn contacts are found on the magnetic
return switch Function tests with disassembled starter
Defects on the actual starter motor including pinion
and carbon brushes are very rare. !Caution
With a trouble shooting chart the faults in the starter Before removing the starter you must disconnect
system can be narrowed down. The starter system the ground cable from the minus pole of the bat-
can only work when many conditions are fulfilled at tery while the ignition is switched off.
the same time. ● Check the wear on the carbon brushes and their
●
Immobilizer deactivated? contact pressure.
●
Ignition switch OK? ● Check the collector, it must not have electrical con-
●
Travel lever in correct position? tact with the rotor shaft.
●
Emergency stop not actuated? ● Check the drive pinion for excessive wear.
●
Battery sufficiently charged? ● The return mechanism should not be tight, if neces-
●
Battery poles OK? sary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
●
Main battery fuse OK?
● Measure the resistance of the magnetic switch main
●
Main battery switch closed?
contact in disengaged condition. Maximum value
●
Main starter cable (terminal 30) OK? 0.2 OHM Ω.
●
Starter control cable (terminal 50) OK, voltage
drop?
●
Ground cable OK?
● Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
●
the experience of the specialist
●
the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.
150 BOMAG 008 911 71

Telemecanique switch 7.14
7.14 Telemecanique switch
Example of terminal designations
Fig. 1 Terminal designations

●
Normally open contact 23 located on block 2
●
●
Normally closed contact 12 located on block 1
●
Normally closed contact 11 located on block 1
●
●
●
●
●
●
i Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.
008 911 71 BOMAG 151

7.14 Telemecanique switch
Disassembly
Fig. 2 Disassembly
● Lift up the interlock (5).
Fig. 4 Pulling out the front element

● Lift up the interlock (2) and pull out the front element
(3).
Fig. 3 Folding down the switch block
● Fold down the switch block (4).
● Loosen screw (1).
152 BOMAG 008 911 71

Telemecanique switch 7.14
Assembly
Fig. 5 Assembly
● Insert the front element (3) into the bore in the con-
trol panel.
Fig. 7 Assemble the switch block

● Clip on the switch block (4).
Fig. 6 Observe the marks.

i Note
Hook in the switch block at the bottom first (Fig. 7).
● Clip the fastening adapter (6) onto the front element
(3).
i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
●
Tighten the screw (1) with a tightening torque of 0.6
Nm.
008 911 71 BOMAG 153

7.15 Inductive proximity switches
7.15 Inductive proximity switches NPN circuitry
General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 10 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.
Working principle
Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 11
This stray field leaks out from the active area of the Proximity switches are used as breaking or making
proximity switch. If metal or non-ferrous metal enters contacts. Depending on the design the switching dis-
into the response range energy is absorbed. The os- tances are 2 or 4 mm. The maximum amperage is 300
cillator is thus dampened and the resulting change in mA.
current consumption is evaluated. The LED (Fig. 11) lights up, when the initiator has de-
tected metal in its stray field.
PNP circuitry
Fig. 9 PNP circuitry

On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
154 BOMAG 008 911 71

Angle sensor with current output 7.16
7.16 Angle sensor with current out-
put
Fig. 1 Sensor
The the function of the angle sensor (Fig. 1) is based
on the so-called "Hall-Effect". Named after the Ameri-
can physicist E.H. Hall. Due to the fact that moving
electrons are deflected in a magnetic field, a voltage
transverse to the flow direction of the primary current
can be expected on a current conducting conductor in
the magnetic field. Since the electrons are deflected in
Fig. 12 Circuit diagram, making contact
transverse direction by the magnetic field, they must
The circuit diagram (Fig. 12) shows a proximity switch enrich on the one side and reduce on the opposite
with normally open contact. side. If a very thin circuit board is now subjected to a
Brown = voltage supply current that is uniformly distributed across its cross
section, no voltage will be measured between two
Blue = ground supply
points A and B, which have an identical distance to the
Black = switching output current supply lines and are connected by a highly
The initiator switches the relay (K05) sensitive galvanometer. When generating a magnetic
field vertical to the circuit board, voltage will be
present between A and B and a current will flow
through the galvanometer connected to these points.
This is referred to as "Hall-Effect". The cause for this
effect is the warping of the originally parallel electron
orbits in the board by the magnetic field.
008 911 71 BOMAG 155

7.17 Plug connectors
7.17 Plug connectors

Duties and requirements
Electric plug connectors must provide a reliable con-
nection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
● Vibration acceleration
●
Temperature fluctuations, high and low tempera-
tures
● Dampness
Fig. 2 Connection diagram ● Micro movements of the contact with resulting fric-
The angle sensor has 3 electric connections (Fig. 2). tion corrosion.
Ub, supply voltage (+ 8.5 Volt) These loads may increase the transition resistances
Gnd, ground of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
Out, output current 4-20 mA. cuits in neighbouring lines. Electric plug connectors
● at -35° = 4 mA output current must therefore have the following properties:
●
at 0° = 12 mA output current ●
Low transition resistances of the conductive parts.
● at +35° = 20 mA output current. ●
High insulation strength between conductive parts
with different voltage potentials.
●
Excellent leak tightness against water and mois-
ture.
156 BOMAG 008 911 71

Deutsch plug, series DT and DTM 7.18
7.18 Deutsch plug, series DT and DT Series
DTM
General
Plug connectors DT and DTM have a wedge to hold
the pins and sockets in their position. This wedge can
be removed and replaced, without having to cut any
leads.
Fig. 1 DT plug connection
Fig. 3 Crimp connections
Fig. 2 DT Series
Caution
!
Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Fig. 3 Sectional drawing
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
●
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.
008 911 71 BOMAG 157

7.18 Deutsch plug, series DT and DTM
Installing DT contacts
Fig. 4
● Insert the contacts through the rubber grommet until
they click into place.
● Insert the orange wedge in direction of arrow.
Caution
!

nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
Use the same method when assembling the socket.
158 BOMAG 008 911 71

Disassembling DT contacts
Fig. 5
● Pull the orange wedge out with long nose pliers.
●
Slightly pull the lead and unlock the interlocking
hook with a screw driver.
● Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
008 911 71 BOMAG 159

DTM Series
Fig. 1 DTM plug connection
Fig. 2 DTM Series
Fig. 3 Sectional drawing
160 BOMAG 008 911 71

Installing DTM contacts
Fig. 4
●
Insert the contacts through the rubber grommet until
they click into place.
●
Insert the orange wedge, until it clicks into place.
Caution
!

nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
008 911 71 BOMAG 161

Disassembling DTM contacts
Fig. 5
● Pull the orange wedge (interlock) out with long nose
pliers.
● Slightly pull the lead and unlock the interlocking
hook with a screw driver.
● Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
162 BOMAG 008 911 71

Plugs and terminals in spring clamping technology 7.19
7.19 Plugs and terminals in spring ventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.
clamping technology
! Caution
General
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!
Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration
resistant and maintenance-free connection of all con-
Connecting terminal for quick repairs
Fig. 2 That's how it works

The connecting clamp clamps up to 3 or 5 stripped
fine conductors of 0.08 mm² to 4 mm², single or multi-
ple strand up to 2.5 mm². And this even without tools
(Fig. 3).
That's how it works

● Strip 9-10 mm of the lead. Fig. 3 Connecting clamp
● Open the actuating lever and insert the strand.

● Return the actuating lever to initial position.
!Caution
nals must withstand a pulling force of 45 N with-
out any difficulties.
008 911 71 BOMAG 163

7.19 Plugs and terminals in spring clamping technology
Series clamp
Fig. 4 That's how it works
That's how it works

● Insert a screw driver into the actuating opening until
it bottoms.
● Strip 9-10 mm of the lead and insert it into the
clamp.
● Pull out the screw driver.
!Caution
Measuring signals
On these terminal blocks the bridge slot is most suita-
ble for tapping off and measuring signals. Here you
may directly insert a 4 mm test adapter (see special
tools for electrics) for connecting a measuring lead.
This test adapter is standard in the central electrics of
heavy equipment machines.
Fig. 5 Test adapter
164 BOMAG 008 911 71

Plugs and terminals in spring clamping technology 7.19
X-COM System for universal system wiring, ever since it was intro-
The X-COM-SYSTEM, a synthesis of plug connector duced in 1997. All the familiar series clamping func-
and series clamp, has grown up to a construction kit tions have thus become pluggable.
X-COM plug clamp
Fig. 6 That's how it works Measuring signals

That's how it works
●
Insert a screw driver into the actuating opening until
it bottoms.
●
Strip 9-10 mm of the lead and insert it into the plug.
●
Pull out the screw driver.
!Caution
Fig. 8 X-COM plug plugged onto the series clamp
Fig. 7 X-COM plug with measuring cable

● The most reliable measurements on the plug can be
made when using the measuring and connecting
cable with 2mm plug (see special tools for
electrics).
008 911 71 BOMAG 165

7.19 Plugs and terminals in spring clamping technology
166 BOMAG 008 911 71

8 Special tools, electrics
008 911 71 BOMAG 167

8.1 Special tools, electrics

Measuring equipment
14. Electric test case
Fig. 9
15. Multimeter
Fig. 10
16. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

17. Test prod red, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.
Fig. 11
18. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

19. Test prod red, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.
Fig. 12
168 BOMAG 008 911 71

Special tools, electrics 8.1
20. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.

high flexible design, black, length 1 m.

high flexible design, black, length 2 m.

Fig. 13 high flexible design, red, length 0.5 m.

high flexible design, red, length 1 m.

high flexible design, red, length 2 m.

26. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, black, length 300 mm.

sign, black, length 600 mm.

sign, red, length 300 mm.
Fig. 14
sign, red, length 600 mm.

30. Transition plug connector, with 4 mm plug on one
side and 2 mm socket on the other, insulated de-
sign
Fig. 15
008 911 71 BOMAG 169

31. Magnetic coil tester
Fig. 16
32. Clip-on measuring instrument
Fig. 17
33. Battery - generator tester
Fig. 18
Spring clamps (Wago or Weidmüller)
34. Cranked screwdriver (Fig. 19) to open spring
clamps (Fig. 20).
Fig. 19
170 BOMAG 008 911 71

35. Testing adapter to measure the signals from the
series spring clamps (Wago).
Fig. 20
Deutsch contacts
36. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).
Fig. 21
37. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
Fig. 22
38. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
Fig. 23
008 911 71 BOMAG 171

39. Disassembly tool for Deutsch contacts of series

HDP.
AWG 20, BOMAG part-no.: 079 900 78
Fig. 24
ITT contacts
40. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 25
41. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 26
42. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.
Fig. 27
172 BOMAG 008 911 71

Schaltbau contacts
43. Disassembly tool for Schaltbau contacts of series
M1, M2.
Fig. 28
44. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.
Fig. 29
FCI Burndy contacts
45. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO
Fig. 30
AMP contacts
46. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).
Fig. 31
008 911 71 BOMAG 173

47. Crimping pliers for AMP-contacts of series SU-

PER-SEAL with connecting cross-section 0.75 -
1.25 mm2.
Fig. 32
48. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).
Fig. 33
TON with connecting cross-section AWG 14 - 10.
Fig. 34
TON with connecting cross-section AWG 16 - 14
and AWG 18.
Fig. 35
174 BOMAG 008 911 71

51. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77
Fig. 36
Universal tools
52. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.
Fig. 37
53. Precision pressing pliers for non-insulated flat
male and female connectors0.5 - 6,0 mm2.
Fig. 38
Measuring adapter
54. Current measurement adapter for Hirschmann
plugs.
Fig. 39
008 911 71 BOMAG 175

55. Voltage measurement adapter for Deutsch plugs,

8-piece (2 to 12 pole).
Fig. 40
56. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.
Fig. 41
176 BOMAG 008 911 71

9 Machine related electrics
008 911 71 BOMAG 177

178 BOMAG 008 911 71
9.1 Machine related electrics
008 911 71 BOMAG 179

180 BOMAG 008 911 71

Machine related electrics 9.1
Service Training
Electrics
Single Drum Rollers – 4
P/N 00809703 Version 3.29
Version/Status: V3.29 / 13.11.07 Page 1 of 84

Author: Seis,MASH,LOEW / TE/TES
008 911 71 BOMAG 181

Service Training WZ-4 from Version DH
Table of contents
1 Confirmation of changes................................................................................................5
1.1 Document..............................................................................................................................5
1.2 Software................................................................................................................................6
2 Displayed monitoring activities with fault reactions ...................................................7

3 The diagnostics system .................................................................................................9
3.1 Display functions .................................................................................................................9
3.2 General facts and operation ...............................................................................................9

3.2.1 Calling up service mode .....................................................................................................9
3.2.2 Entering input codes.........................................................................................................10
3.3 Fault log – display and delete...........................................................................................12
3.3.1 Showing stored faults .......................................................................................................12
3.3.2 Delete all stored faults......................................................................................................12
3.4 Delete engine control error log ........................................................................................13
3.4.1 Deleting logged engine errors ..........................................................................................13
3.4.2 Deleting active engine faults ............................................................................................13
4 Settings and queries.....................................................................................................14

4.1 Setting the machine type ..................................................................................................14
4.2 Driving against the closed brake .....................................................................................17
4.3 Teaching the travel direction sensor ...............................................................................17
4.4 Automatic detection of surge currents in travel system ...............................................17
4.5 Changing the steering unit on BVC-4 machines ............................................................19
4.6 Teaching the electronic end stops of the steering angle sensor (BVC) ......................20
4.7 Automatic detection of surge currents on steering valves (BVC)................................22

4.7.1 Reading out actual surge current values ..........................................................................23
4.8 "Trimming" the speed measurement...............................................................................23
4.8.1 Quick overview.................................................................................................................23
4.8.2 Explanation ......................................................................................................................23
4.9 Calibrating the speed detection (calibration of wheel diameter)..................................24
4.9.1 Quick overview.................................................................................................................24
4.9.2 Explanation ......................................................................................................................24
4.10 Activating/deactivating the vibration control..................................................................25
4.10.1 Quick overview.................................................................................................................25
4.11 Activating/deactivating the attachment plates ...............................................................25
4.11.1 Quick overview.................................................................................................................25
4.12 Setting the vibration motor type.......................................................................................26
4.12.1 Table of vibration motor types ..........................................................................................26
4.12.2 Table of pulse numbers....................................................................................................27

182 BOMAG 008 911 71

5 Replacement of components .......................................................................................28

5.1 How to proceed when replacing components?..............................................................28
5.2 Replacement of an ESX-control .......................................................................................28
5.3 Replacement of a travel pump / axle drive motor / drum drive motor..........................28
5.4 Replacement of a steering valve (BVC) ...........................................................................28
5.5 Replacement of a steering angle sensor.........................................................................28
5.6 How to proceed when replacing a front / rear axle sensors? .......................................28
5.7 Component replacement without adjustment procedure..............................................29
6 Description of the signals on the ESX-control...........................................................30

7 Description of signals on the data collector ..............................................................35
8 Description of signals on the travel lever...................................................................37
9 Descriptions of signals on the LC - Display ...............................................................39
10 Description of Signals on DIOS-Module .....................................................................40
11 Fault codes of the ESX control ....................................................................................41
11.1 Overview .............................................................................................................................41
11.2 Description of fault reactions ...........................................................................................42
11.3 Note codes..........................................................................................................................43
11.4 Detailed description of fault codes and their possible causes....................................45

11.4.1 General ............................................................................................................................45
11.4.2 Brake................................................................................................................................46
11.4.3 Travel lever ......................................................................................................................46
11.4.4 Travel speed range selector switch ..................................................................................48
11.4.5 Travel system...................................................................................................................48
11.4.6 Steering............................................................................................................................52
11.4.7 Driver's seat arm rest sensor............................................................................................54
11.4.8 Vibration ...........................................................................................................................55
11.4.9 Attachment plates ............................................................................................................58
11.4.10 Diesel engine ...................................................................................................................59
11.4.11 Diesel engine EMR...........................................................................................................59
11.4.12 Miscellaneous ..................................................................................................................62
11.4.13 Machine type....................................................................................................................64
11.4.14 Optional functions ............................................................................................................64
12 Input Codes for ESX Control........................................................................................65

12.1 Fault log ..............................................................................................................................65
12.2 Value displays ....................................................................................................................65

12.2.1 General ............................................................................................................................65
12.2.2 Brake................................................................................................................................65
12.2.3 Travel lever / driving .........................................................................................................66
12.2.4 Travel speed range selector switch ..................................................................................66
12.2.5 Travel pump: Travel direction forward ..............................................................................67
12.2.6 Travel pump: Travel direction reverse ..............................................................................67
12.2.7 Travel motor front (drum) .................................................................................................68
12.2.8 Travel motor rear (wheel axle)..........................................................................................68

008 911 71 BOMAG 183

12.2.9 Shut-down of drives..........................................................................................................68

12.2.10 Adaptation values for speed regulation ............................................................................69
12.2.11 Travel pressure sensor.....................................................................................................69
12.2.12 Inclination sensor .............................................................................................................69
12.2.13 Travel condition values.....................................................................................................69
12.2.14 Calibrating the wheel diameter .........................................................................................70
12.2.15 Speed limitation................................................................................................................70
12.2.16 Arm rest contact ...............................................................................................................70
12.2.17 Adoption values traction control .......................................................................................71
12.2.18 Steering: Steering valve ...................................................................................................71
12.2.19 Steering: Angle sensor in articulated joint ........................................................................71
12.2.20 Steering: Steering wheel ..................................................................................................72
12.2.21 Vibration ...........................................................................................................................72
12.2.22 Vibration (up to version 3.24 ) ..........................................................................................72
Vibration control; Vario and low amplitude circular exciter (from version 3.25 ) .................................73
Vibration control; high amplitude circular exciter (from version 3.25 ) ................................................73
12.2.23 Attachment plates, option (only BW213 BVC) ..................................................................74
12.2.24 Engine ..............................................................................................................................75
12.2.25 Hydraulics ........................................................................................................................75
12.3 Test settings .......................................................................................................................76
12.3.1 Brake................................................................................................................................76
12.3.2 Disable electric supply to wheel and drum drive motors (switch off).................................76
12.4 Settings / Teach / Emergency functions..........................................................................77
12.4.1 Changing the machine code.............................................................................................77
12.4.2 Automatic detection of surge currents in travel system ....................................................77
12.4.3 Speed detection, trimming of measuring values...............................................................77
12.4.4 Speed detection, teaching of distance pulses ..................................................................77
12.4.5 Detection of wheel rotation ...............................................................................................78
12.4.6 Steering: Automatic detection of surge currents on steering valve...................................79
12.4.7 Steering: Determining the steering stops .........................................................................79
12.4.8 Steering: Emergency function ..........................................................................................79
12.4.9 Steering: Other functions..................................................................................................79
12.4.10 Setting the vibration motor type........................................................................................79
12.4.11 Vibration: Travel speed dependent vibration lock.............................................................80
12.4.12 Vibration: Enable frequency setting..................................................................................80
12.4.13 Attachment plates (only circular exciter): Activating/deactivating the attachment plates
option 80
12.4.14 Plates: Preventing reversing with plates lowered .............................................................80
13 Terminology in connection with ESX..........................................................................81

184 BOMAG 008 911 71

1 Confirmation of changes
1.1 Document
No. Date Description of changes resp.

2.01 23.04.2004 Creation of version 1.00 Werner
2.02 06.05.2004 Revision, teach functions Fondel
2.03 11.05.2004 Revision, supplements version 1.01 Seis
2.04 24.06.2004 Revision, supplements to version 1.02
2.05 23.01.2005 Revision, supplement to software versions from 2.00 MASH
2.06 29.04.2005 Revision, supplement to software versions from 2.06 MASH
2.07 22.05.2005 Error code description 5121 changed. Löw
3.01 16.03.2006 Supplements with respect to TIER3 engines. Fault treatment. Löw
3.02 11.08.2006 List of "selected fault reactions" corrected Löw
Documentation of error codes revised
List of machine types changed
3.03 13.11.2006 Fault codes 5127 and 5136 added. Löw
26.01.2007 Machine types of new Tier 3 machines supplemented. Vogt
21.02.2007 Fault description for steering supplemented. MASH
22.02.2007 Note for code list added MASH
3.23 22.10.2007 Input codes 3070 to 3072 to activate/deactivate the towed plate MASH
option for circular exciter machines added.

008 911 71 BOMAG 185

1.2 Software
Ver. Date Description of changes resp.

1.03 02.09.2004 Surge currents travel system teach function changed Schroeder,
Known faults Fondel
Revision of error codes
Deactivation of electric steering on BVC machines
How to proceed when replacing components?
2.00 16.12.2004 List of error codes extended Schroeder
Fondel
MASH
2.02 08.03.2005 Adaptive adaptation of gradability. Display codes for the fac- MASH
tors "Front top" 1500 and "Tail top" 1501
Input code to shut down the speed dependent Vib-limitation
(3047..3049).
Error message (8440..8443) for invalid BabyBoard equipment
of the ESX-travel control.
Overspeed protection for wheel drives (axle and drum drives)
2.06 29.04.2005 Input codes (1158/1159) for manual adaptation of axle speed MASH
recording.
Input codes to record the pulse frequency of the drives:
Recording of speeds (1160..1169)
Adapted tank characteristic.
Change of speed limitation for operation with plates.
2.07 22.05.2005 Tank characteristic values changed. MASH
2.16 22.02.2006 Explanation concerning error messages steering supple- MASH

3.00 mented.
2.18 10.03.2006 Supplements with respect to TIER3 engines. MASH

3.01 Fault treatment extended. Löw
Description of "known faults" extended.
2.19 20.03.2006 Fault correction travel pressure monitoring. MASH

3.02 Löw
3.04 18.05.2006 Fault monitoring steering wheel revised MASH
3.05 10.07.2006 Problem with start-up of new controls eliminated Löw
3.05 26.07.2006 Optimized CANopen functionality MASH

Fault treatment for steering changed
(faults 2200 and 2201)
Rotary speed (vibration frequency) control and
fault monitoring changed
3.29 04.10.2006 Implementation of circular exciter machines with plate com- MASH
pactors.

186 BOMAG 008 911 71

2 Displayed monitoring activities with fault reactions
Reaction Symbol in fault mes- Warning Warning Engine stop

sage display
Code output Code output Code output
Signal without buzzer with buzzer with buzzer
Engine oil pressure

(from EMR) 5100 5101
5112 5112
Coolant temperature
(from EMR)
5100 5101
5116 5116
Coolant level
5024 5025
after 5s after 10s
Engine air filter
5026 5027
after 5s after 2min.
ASC
Various error causes and reaction times.
See error codes
Hydraulic oil filter
5502 5503
after 5s after 2min.
Water separator in
fuel filter 5028 5029
TIER II Engines after 5s after 2min.
Water separator in
fuel filter 5100
TIER III Engines
5119
Seat contact
1300
Arm rest
2300

008 911 71 BOMAG 187

Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Effect: Cause:
Display remains dark, no voltage PIN in display plug X 28 bent
Error code 5100, 5140 and engine does not re- Switch the ignition off and on and restart the ma-
spond to full speed switch or travel lever chine immediately.
After switching on the display shows "Error code Code 8224 is no error code, but a software fault in
8224" the display software, which has been rectified in
display firmware version 1.36 and higher
The display shows various engine faults (Code Faulty assessment of engine faults in the EMR3
51xx), even though neither code 5100 nor 5101 is control unit. Remedy: Delete active and passive
displayed. engine faults
(see 3.4 Delete engine control error log)

188 BOMAG 008 911 71

3 The diagnostics system

The machine is equipped with a diagnostics system consisting of display unit (LCD) and button-type
input unit (in the travel lever) to report machine faults, display measuring values and to set parame-
ters.
3.1 Display functions
The field t in the LC-Display shows the following diagnostic readings:
Type of indication Flashing Flashing "d" Flashing "d" Comment

warning tri- Of the fields
angle next to the
warning tri-
angle
Fault message
* * *
Warning
* *
Note
* *
Display, measuring Values ranging from
values 0 0 0 0 ...9 9 9 9 to be called up via
input codes
Parameter setting Values ranging from
0 0 0 0 ...9 9 9 9 to be called up via
input codes
Negative display values are identified by a "Minus sign".
If several faults are detected, the displayed fault codes will change in a 3 second cycle.
3.2 General facts and operation
The following chapter describes the operation of the LC display via travel lever buttons.
3.2.1 Calling up service mode

For this purpose the display must be switched via input mode to service mode. Dies erfolgt über die
beiden gelben Infotasten „INFO 1“ und „INFO 2“ an der Fahrhebelrückseite. Navigation in input and
service mode takes place via the green and blue buttons on the front of the travel lever.
Werte ändern Navigieren

INFO 1 Taste (grün) (blau)
(gelb)
INFO 2 Taste
(gelb) Werte ändern
(grün)
Navigieren
(blau)
Version/Status: V3.29 / 13.11.07 Functions of ESX Control Page 9 of 84
008 911 71 BOMAG 189

The travel lever must be in locked braking position in order to activate input mode!Input mode
is switched on by simultaneously pressing both INFO – buttons over a period of approx. 3 seconds.
3.2.2 Entering input codes

Input mode starts with flashing of the left hand digit. Here service code9 9 9 9 provides the possibility
to change to the service mode. The green buttons can be used to increase or reduce the values of the
corresponding digit. By operating one of the blue buttons one can jump to the next (left or right) digit.
Once the last right hand digit has been entered the code will be transferred to the control by pressing
the right hand blue button once again.
If the access code has been entered correctly, the "Spanner" symbol is displayed and the first input
digit flashes again. Individual operating states of the machine can now be interrogated by transferring
the input code to the control (as described above).
When operating both INFO buttons again for approx. 3 seconds, another input code can be entered.
The input of code "0 0 0 0 " or switching of the ignition quits the service mode.
If the travel lever is shifted out of the brake lock while in service mode, all machine functions will be-
come active, with the exception of the LC-display, which remains in service mode and continues to
display the operating values requested last.

190 BOMAG 008 911 71

Normalmodus (Fahrhebel in Bremsraste!)

Aufruf optionaler Anzeigen über INFO - Taste 1
und INFO - Taste 2
„Eingabe“ - Modus:
Umschaltung Displayfunktion
Einstellungen Display
Betätigen INFO 1
+ INFO 2 ca. 3s
Plattenverstellung inaktiv!
Bet. INFO 1 +
Eingabe
INFO 2 ca. 3s
Zugangangscode
oder Fahrhebel
9999
aus Bremsr.
„Service“- Modus:
CODE - Eingabe „0000" oder Eingabe Diagnosecodes
Zündung aus
Fehlerspeicher abrufen / löschen
Maschinentypen umstellen
Plattenverstellung inaktiv!
Fahrhebel aus Bremsraste:

Diagnosemodus im Vordergrund aktiv!

008 911 71 BOMAG 191

3.3 Fault log – display and delete
3.3.1 Showing stored faults

This function is only valid from software version 1.10!
Switch on function "Show stored faults":

Enter code number 0 7 0 0 ( !WITHOUT service code 9999). This code number enables the func-
tion „Show stored faults“.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX, the display will show "- - - - - "
Switch off function "Show stored faults":

Enter code number 0 7 0 1 ( !WITHOUT service code 9999). This code number disables the func-
tion „Show stored faults“.
Note: Apart from the stored faults the current faults are also displayed.
Note: This function can only be activated / deactivated when the travel lever is locked
in the brake gate. (Æ Input mode)
3.3.2 Delete all stored faults

Execute the function „Delete all stored faults“:

The engine must not be running!
Enter code number 0 7 1 0 ( !WITHOUT service code 9999).
Switch the ignition off and on again.
All stored faults are now deleted.
Note: The stored faults can only be deleted when the engine is not running.

192 BOMAG 008 911 71

3.4 Delete engine control error log
3.4.1 Deleting logged engine errors

This function is only valid from software version 2.18 or 3.01 respectively!
Execute the function "Delete all logged faults in engine control unit":
Service code 9 9 9 9 .
Enter code number 0 7 6 0 .
All stored engine faults are now deleted.
3.4.2 Deleting active engine faults

This function is only valid from software version 2.18 or 3.01 respectively!
Execute the function "Delete all logged faults in engine control unit":
Service code 9 9 9 9 .
Enter code number 0 7 6 1 .
All active engine faults are now deleted.

008 911 71 BOMAG 193

4 Settings and queries
4.1 Setting the machine type

Since the same control software is used for all single drum rollers of generation DH-4 (with electroni-
cally controlled engines), the control must be matched to the machine in which it is actually installed
(setting the machine type).
This is necessary during first time commissioning as well as in case of a spare parts replacement.
This type setting is necessary, because different machine types/variants can have different parameter
sets, e.g. different wheel or axle drive motors (different numbers of pulses) or electrically different
hydraulic components (valve spools), or may be equipped with attachment plates or other optional
equipment.
For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module when switching the ignition on. It can also be checked by entering code 0720.
The following machine types can be adjusted:
Machine type First serial number Last serial number Code Available from versi-
on
Standard1 - - 7200 1.00
177 DH 101 582 21 1001 XXX XXX XX XXXX 7201 1.00

177 PDH 101 582 22 1001 XXX XXX XX XXXX 7202 1.00
179 DH 101 582 24 1001 XXX XXX XX XXXX 7203 1.00
213 DH 101 582 51 1001 XXX XXX XX XXXX 7205 1.00
213 DH 101 583 14 1001 XXX XXX XX XXXX
214 DH 101 582 58 1001 XXX XXX XX XXXX
214 DH 101 583 19 1001 XXX XXX XX XXXX
213 PDH 101 583 15 1001 XXX XXX XX XXXX
216 DH-4 101 582 60 1001 XXX XXX XX XXXX 7209 1.00
216 DH-4 101 582 64 1001 XXX XXX XX XXXX
216 PDH-4 101 582 61 1001 XXX XXX XX XXXX 7210 1.00
216 PDH-4 101 582 65 1001 XXX XXX XX XXXX
219 DH-4 101 582 70 1001 XXX XXX XX XXXX 7211 1.00
219 DH-4 101 582 77 1001 XXX XXX XX XXXX
219 PDH-4 101 582 78 1001 XXX XXX XX XXXX
226 DH-4 147kW 101 582 80 1001 XXX XXX XX XXXX 7213 1.00
226 DH-4 150kW 101 582 88 1001 XXX XXX XX XXXX
226 PDH-4 147kW 101 582 81 1001 XXX XXX XX XXXX 7214 1.00
226 PDH-4 150kW 101 582 89 1001 XXX XXX XX XXXX
226 DH-4 174kW 101 582 83 1001 XXX XXX XX XXXX 7215 1.00
226 PDH 174kW 101 582 84 1001 XXX XXX XX XXXX 7216 1.00
1
The standard machine type does not represent a real machine, but is the initial point for not yet set controls
during initial commissioning or after replacing a control.

194 BOMAG 008 911 71

177 BVC 101 582 23 1001 XXX XXX XX XXXX 7250 1.00
213 BVC 101 582 53 1001 101 582 53 1082 7251 1.00
up to engineering status
01.12.05
213 BVC plates 101 582 54 1001 101 582 54 1038 7252 1.00
up to engineering status
01.12.05
226 BVC 147kW 101 582 82 1001 XXX XXX XX XXXX 7253 1.00
226 BVC 150kW 101 582 86 1001 XXX XXX XX XXXX
226 BVC 174kW 101 582 85 1001 XXX XXX XX XXXX 7254 1.00
from engineering status
01.12.05
101 583 16 1001 XXX XXX XX XXXX
213 BVC 101 582 12 1001 XXX XXX XX XXXX
Variocontrol
213 BVC plates 101 582 54 1039 XXX XXX XX XXXX 7256 3.00
from engineering status
01.12.05
101 583 06 1001 XXX XXX XX XXXX
213 BVC plates 101 582 13 1001 XXX XXX XX XXXX
Variocontrol +
EXAMPLE: Machine code for BW 219 PDH-4: 7212
Note:
Parameter adjustments can only be performed when the engine is not running.
This function can only be activated / deactivated when the travel lever is locked in the
brake gate. (ÆInput mode)
Procedure for initial commissioning of a control:
The control has been installed into the machine.

Switch the ignition on. Approx. 4 seconds after switching on the word
C O D E will appear for 3 seconds. After this the display changes and shows code 7000.
Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes.
Confirm the selection with the Arrow Right key.
After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for
approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not
switch the ignition off during this time!
After this switch the ignition off and on again to accept the configuration.
After this the normal display will appear again.
The following applies for a correction of the machine type code after it has been set.
Enter code number 9 9 9 9 (activation of service mode)

Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.
The display module now permanently shows the code 7 2 0 0 .
Select the machine code from the table above and confirm it with the Arrow Right key. After oper-
ating the Arrow Right key the control switches automatically off and on again.
After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for
approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not
switch the ignition off during this time!

008 911 71 BOMAG 195

After this switch the ignition off and on again to accept the configuration.
After this the normal display will appear again.
Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!
New controls are delivered with the default machine type setting 7 2 0 0 . This
does not enable to drive or steer the machine. It only serves the purpose of
commissioning.

196 BOMAG 008 911 71


After entering the code number 0 5 0 0 the brake will not be released. If the travel lever is in this con-
dition shifted out of the brake gate and moved to any travel direction, the travel pumps will be trig-
gered according to the chosen travel direction. At the same time a warning (fault code 0 5 0 0 ) ap-
pears on the display and the warning buzzer is triggered, in order to keep the operator informed about
the condition. The brake control light in the LC-display remains activated.
In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or
switch the ignition off. After entering code number 0 5 0 1 the function is aborted and OK is
displayed as confirmation for 5 seconds. After this the code needs to be entered again.
4.3 Teaching the travel direction sensor

Teaching of the travel direction sensor is required for initial commissioning and after the replacement
of a travel motor. Perform the following sequence
Turn the speed range selector switch to "MAX"
Shift the travel lever slowly out of neutral, until a travel speed of approx. 1 km/h is indicated.
If one or both travel direction sensors detected a counteracting direction the error codes 1106
and/or 1116 will appear after approx. one machine length. Otherwise no error code will be dis-
played. The travel direction detection is now automatically set.
However, should one of the two error codes appear, this must be caused by a sensor fault.
4.4 Automatic detection of surge currents in travel system

For a sensitive and exact function of the travel system the surge currents in the travel system must be
determined for both travel directions. The surge currents are automatically determined after entering a
code number, so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and
after the replacement of the ESX-control.
The measurement is identical for both travel directions: After entering the respective code number the
current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250mA..
After each current increase the system waits for 3 seconds. If a considerable drum movement is
measured during the waiting time, the surge current is reached. In order to enhance the measuring
result this measurement is performed three times. The final surge current is the mean value of these
three measurements. This surge current is automatically stored and is valid from the next start of the
machine.
Before the measurement you should strictly make sure that the machine is parked on level ground and
has a sufficient distance for movement to front and back, because the machine will move to the re-
spective direction when performing the measurement.
Attention! First set the machine to input mode (code 9 9 9 9 ). It must be strictly assured that the
speed sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code
number 1 1 0 6 at the display module. This code can be used to display the number path pulses from
the speed sensor. The displayed value must change when the machine is driven.

008 911 71 BOMAG 197

If this value does not change even though the machine is moving, the measurement must not
be performed!
The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not
be detected. (See also: „Resetting the surge currents in the travel system”)
Attention!
During the measurement the machine will move when the surge current is reached!
Do not leave the machine while the measurement is progressing!
During the measurement keep an eye on your environment!
To stop the machine reset the travel lever to neutral position!
The automatic measurement of the travel system surge currents is performed as follows:
The speed selection switch must be in position ECO.
If necessary enter code number 9 9 9 9 to access the service mode.
Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents
in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This
code number must be entered to be able to perform the following steps. From this point the ma-
chine can no longer be operated with the travel lever! The travel lever will only be in func-
tion again after the teach function has been completed or the machine has been restarted.
The measurements (forward/reverse) must be started by entering a code number. The code num-
ber required to teach the travel direction is as follows:
Determination of control surge currents 1 0 9 1
After the input of the above code number the display shows " F O R E ". Shifting the travel lever
forward starts the first surge current measurement for forward travel.
During the measurement the actual current is displayed (display value = current in mA).
Once the surge current measurement is finished the display will show the reading O K for a pe-
riod of 5 seconds.
After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward
to start the surge current measurement in reverse.
After completion of the measuring process in reverse the display will show O K again.
The travel lever must now be returned to braking position.
Once both surge currents have been learned correctly and the travel lever is in "braking position",
the display shows the reading "D O N E", the values are saved and the function is completed.
Now the machine can be operated again with the travel lever. The new surge current values for the
travel system are valid from the next start.
The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.
The following procedure applies for software versions 1.07 and 1.08:
The automatic measurement of the travel system surge currents is performed as follows:
The seat must be adjusted for travel direction forward!
The speed selection switch must be in position ECO.
If necessary enter code number 9 9 9 9 to access the service mode.
Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents
in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This
code number must be entered to be able to perform the following steps.

198 BOMAG 008 911 71

From this point the machine can no longer be operated with the travel lever! The travel lever
will only be in function again after the teach function has been completed or the machine
has been restarted.
Both measurements (forward/reverse) must be started by entering a code number. The code num-
bers for both travel directions are:
Determine surge current for control forward 1 0 9 1

Determine surge current for control reverse 1 0 9 2
After entering one of the above code numbers the measurement will only start after moving the
travel lever to the respective travel direction. ATTENTION:The
ASC fault indicator light will come on during the teach process. In this case this is of no relevance.
The warning will disappear when restarting the machine.
Teaching is required for both travel directions.
When returning the travel lever to neutral position after the two measurements, the display will
show O K for 3 seconds and the averaged values will be saved.
Once both surge currents have been measured the machine can be operated again with the travel
lever. The new surge current values for the travel system are valid from the next start.
The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.
4.5 Changing the steering unit on BVC-4 machines

Availability: From version 1.09
By standard all BVC-4 machines (code 725x) are equipped with electric steering. For machines with
the Hydraulic Steering Option the steering mode (steering unit) in the travel control must be switched
over (electric steering disabled):
Enter code number 9999 (activation of service mode)

Enter code number 2060. This code number activates the function "Adjusting the steering unit“.
The following code numbers are available to activate the assembled steering unit.
Hydraulic steering 2062

Electric steering 2061
The display shows O K
Attention: The steering unit can only be changed when the engine is not running!

008 911 71 BOMAG 199

4.6 Teaching the electronic end stops of the steering angle sensor (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: During the measurement the machine should be parked on level ground.
The drum should be standing on old rubber tires or a metal plate.
Specify the engine speed -> travel lever out of braking position = neutral position
(Not while entering a code).
To prevent the steering from moving all the way to the mechanical stops of the steering cylinder it is
necessary to determine a defined safety distance to these end stops.
Enter code number 9 9 9 9 to access the service mode.

Enter code number 2 0 1 0 to activate the mode "Teach steering stops".
Return the travel lever to neutral position (no braking function, but to relieve the machine of
strain). The display shows the standardized steering position (0..1000 right ... left).
Now turn the electric steering wheel clockwise, until the mechanical stop is reached The displayed
value should be in the range of 100..300. Then shift the travel lever to braking position and enter
code number 2 0 1 2 (press both Info-buttons first to access the input mode). In case of accep-
tance the value 2 2 2 2 will appear for a moment.In case of a fault the value 9 9 9 9 upon accep-
tance (see below).
Return the travel lever to neutral position (no braking function, but to relieve the machine of
strain). The display shows the standardized steering position (0..1000 right ... left).
Now turn the electric steering wheel anti-clockwise, until the mechanical stop is reached The dis-
played value should be in the range of 700..900. Then shift the travel lever to braking position and
enter code number 2 0 1 3 (press both Info-buttons first to access the input mode). In case of ac-
ceptance the value 3 3 3 3 will appear for a moment. In case of a fault the value 9 9 9 9 upon ac-
ceptance (see below).
To leave the mode the machine must be switched off or code 2 0 1 1 must be entered.
Possible error causes (code 9 9 9 9 ) :
- Incorrect connection of hoses -> have checked by engineer -> correct.

- Connecting fault on potentiometer -> have checked by an electrician -> correct.
- Potentiometer faulty -> replace the potentiometer.

200 BOMAG 008 911 71

START
Machine on level
d
Tires or metal
plate under drum
Machine on level
d
Enter 9999
Enter 2010
Travel lever in
neutral position
Turn steering wheel

CLOCKWISE, until STOP
is reached
(noise from pressure
relief valve, cylinder fully
Travel lever in
braking position
Display Display
Enter 2012 shows shows
2222 9999
Travel lever in
neutral position
Turn steering wheel

ANTI-CLOCKWISE, until
STOP is reached
(noise from pressure
relief valve, cylinder fully
Travel lever in
braking position
Display Display
Enter 2013 shows shows
3333 9999
Switch the ignition

off and on again. OR Enter 2011
FINISHED

008 911 71 BOMAG 201

4.7 Automatic detection of surge currents on steering valves (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: Perform this function only AFTER

"Teaching the electronic end stops of the steering angle sensor"
.
During the measurement the machine should be parked on level ground.

Before the measurement both drums should be steered to straight ahead position.
The travel motor must be moved out of braking position -> raised idle speed!
To enable a sensitive and exact function of the steering the surge currents of the two control solenoids
and both steering valves must be measured. The surge currents are automatically adjusted after en-
tering a code number, so that no electric meter is required.
The surge currents must only be adjusted during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and
after the replacement of the ESX-control.
The measurement is identical for both solenoids:
Example BW 177 BVC:

After entering the respective code numbers the current is increased by the control solenoid in steps of
5 mA, starting from 650mA.. After each increasing step the system waits for 2 seconds. If a change in
drum angle is measured after the waiting time, the surge current is reached. In order to enhance the
measuring result this measurement is performed three times. The final surge current is the mean
value of these three measurements. This surge current is automatically stored and is valid from the
next start of the machine.
For all other machine types the same procedure is used, however, currents and times will vary.
Before the measurement you must strictly make sure that the steering system is „bled“, because an air
cushion in the steering cylinders would have a negative effect on the measurement and therefore on
the steering performance of the machine. Sufficient bleeding is achieved by performing a few quick
steering movements at full engine speed.
The automatic measurement of the steering valve surge currents is performed as follows:
The engine must be operated in ECO-mode!
Enter code number 9 9 9 9 to access the service mode.
Travel lever in neutral position (Brake must be released!)
Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of
steering valve surge currents"; the display now shows the reading 0 0 0 0 with the first digit flash-
ing.
Now code number 2 0 0 1 must be entered.
After entering one of the above mentioned code numbers the measurement of the surge current
will start immediately.
The drum is thereby first steered to the right and then to the left.
During the measurement the actual valve current is displayed (display value in mA).
Attention! During the measurement the drum cannot be steered ! The steering wheel has no
effect.
During the measurement the machine should not be driven !
Once the measurement is completed the display value OK will appear for 3 seconds, after this the
code number 0000 is displayed with the first digit flashing, the next measurement can be started.
The new surge current values are valid from the next start.

202 BOMAG 008 911 71

4.7.1 Reading out actual surge current values
Surge current values currently saved in the control can be read out with the following
input codes.
The values should not differ more than +/- 50!
Show surge current for left hand valve control 2 1 0 6

Show surge current for right hand valve control 2 1 0 8
In case of excessively differing surge currents you should first of all run a new teach procedure.
See also fault codes 2 2 0 0 and 2 2 0 1 !
4.8 "Trimming" the speed measurement
4.8.1 Quick overview

Enter 9 9 9 9 : Switch on service mode.
Enter 1 1 5 8 : Allow function "Trimming the speed measurement".
Enter 1 1 5 9 : Start function "Trimming the speed measurement".
Display shows: F O R E : Move the travel lever forward (or back).
Green button up = raise indicated speed (measuring value too low)
Green button down = reduce indicated speed (measuring value too high)
Travel lever in braking position: D O N E = FINISHED! Procedure finished.
4.8.2 Explanation
In order to adjust the speed display (LCD) e.g. to the BOMAG measuring system to reference tests
benches, the machine integrated travel speed detection may be "trimmed", i.e. adjusted.
For this purpose the input codes 1 1 5 8 (enable function) and 1 1 5 9 (start function) are used to
activate the function Speed detection, trimming of measuring values (chapter 12.4.3, page 77).
As a result, the travel speed measured by the machine appears in the LCD-Display.
With the green button on the travel lever an internal calibration value can now be changed to such an
extent, that the displayed speed corresponds with the actual travel speed.
ATTENTION! If the speed detection is extremely falsified because of operating errors, this can
lead to uncomfortable travel behaviour and a reduced ASR control quality.

008 911 71 BOMAG 203

4.9 Calibrating the speed detection (calibration of wheel diameter)

see also 12.2.14 Calibrating the wheel diameter

Enter 1 1 6 0 : Allow function "Calibrate the speed detection".
Enter 1 1 6 1 : Start function "Calibration of speed detection" for a 5m distance.
or enter 1 1 6 2 : For a 10m distance
Display shows: F O R E : Move the travel lever forward (or back).

Green button up = raise indicated speed (measuring value too low)
Green button down = reduce indicated speed (measuring value too high)
Travel lever in braking position: D O N E = FINISHED! Procedure finished.
Enter 1 1 6 8 : Load original value.

Enter 1 1 6 9 : Save the values.
4.9.2 Explanation
The function Speed detection, teaching of distance pulses offers the possibility to calibrate the inter-
nal calibration value of the speed detection..
For this purpose the input code 1 1 6 0 (enable function) and 1 1 6 1 - 1165 (start the
respective function) can be used to select a distance, which is then travelled with the machine (as
exact as possible).
During travel a numeric value is displayed.
The measurement is subsequently saved by means of the input code 1 1 6 9 and is now a valid crite-
rion for the speed detection.
With the input code 1 1 6 8 it is also possible to adjust the basic value for series machines ->
(1 1 6 0 - > 1 1 6 9 ).
ATTENTION! If the speed detection is extremely falsified because of operating errors, this can
lead to uncomfortable travel behaviour and a reduced ASR control quality.

204 BOMAG 008 911 71

4.10 Activating/deactivating the vibration control

Availability: From version 3.20 (design status 01.05.2007)
With design status 01.05.2007 machines with circular exciter (DH-4. Not BVC) were equipped with a
switch in the dashboard to adjust the nominal vibration frequency.
Machines with an older design status and without this switch need to be adjusted accordingly when
using the the currently valid travelling software.

see also 12.4.11 Vibration: Enable frequency setting

Enter 3 0 9 1 : Enable function "Switch over frequency setting".
Enter 3 0 9 2 : Activate frequency setting (machine with switch).
or
Enter 3 0 9 3 : Disable frequency setting (machine WITHOUT switch).
Viewing the current setting:

Enter 3 0 9 0 : View the current setting.
4.11 Activating/deactivating the attachment plates

Availability: From version 3.29 (design status 01.09.2007)
With design status 01.09.2007 the "attachment plate" option was released for machines with circular
exciter (DH-4. Not BVC).
ATTENTION: Machines with attachment plates are setup with the same software identification, as the
machines without plates (213 DH-4 = 213DH-4-plates = 7205)!

see also 12.4.13:
Attachment plates (only circular exciter): Activating/deactivating the attachment plates option

Enter 3 0 7 0 : Optional changeover enabled.
Enter 3 0 7 1 : Activate option "attachment plates").
or
Enter 3 0 7 2 : Disable option "attachment plates".

008 911 71 BOMAG 205

4.12 Setting the vibration motor type

Availability: From version 3.20 (design status 01.05.2007) or 3.21 (design status 01.06.2007)
Other vibration motors (type 2) were introduced as standard for machines (Code numbers 7205 to
7210)
from design status 01.05.2007 and for machines (Code numbers 7251, 7252, 7255, 7256) from design
status 01.06.2007.
Standard settings are shaded grey in the table (from design status 01.06.2007).
ATTENTION! If a machine with an older design status is furnished with the up-to-date travelling soft-
ware, the corresponding vibration motor type needs to be set (see 12.4.10).
Example:
BW213DH-4 (7205) with design status before 01.05.2007: -> 9 9 9 9 -> 3 0 3 1 -> 3 0 3 2 .
Check: -> 3 0 3 0 , display: 47 (see 4.12.2).
4.12.1 Table of vibration motor types
Vibration motor types

Machine Type1 Type 2 Type 3 Type 4 Type 5 Type 6 Type 7 Type 8
type code (3032) (3033) (3034) (3035) (3036) (3037) (3038) (3039)
7201 MMF025
7202 MMF025
7203 MMF025
7204 MMF025
7205 A2FM56 90M055
7206 A2FM56 90M055
7207 A2FM56 90M055
7208 A2FM56 90M055
7209 A2FM56 90M055
7210 A2FM56 90M055
7211 A2FM63
7212 A2FM63
7213 A2FM80
7214 A2FM80
7215 A2FM80
7216 A2FM80
7250 MMF025
7251 A2FM56 90M055
7252 A2FM56 90M055
7253 A2FM80
7254 A2FM80
7255 A2FM56 90M055
7256 A2FM56 90M055

206 BOMAG 008 911 71

4.12.2 Table of pulse numbers
For correct detection of the vibration frequency, the control must be aware of the number of pulses
(number of pulses per revolution) of the vibration motors. The pulse numbers are determined by the
vibration motor type.
The currently set pulse number can be read out with input code 3030.
Pulse numbers
Machine Type 1 Type 2 Type 3 Type 4 Type 5 Type 6 Type 7 Type 8
type code (3032) (3033) (3034) (3035) (3036) (3037) (3038) (3039)
7201 43
7202 43
7203 43
7204 43
7205 47 52
7206 47 52
7207 47 52
7208 47 52
7209 47 52
7210 47 52
7211 47
7212 47
7213 53
7214 53
7215 53
7216 53
7250 43
7251 47 52
7252 47 52
7253 53
7254 53
7255 47 52
7256 47 52

008 911 71 BOMAG 207

5 Replacement of components
5.1 How to proceed when replacing components?
Each machine is adjusted individually during initial commissioning. This adjustment or teaching proc-
ess is necessary to make sure that the travel and steering functions are almost identical on all ma-
chines. Background of these adjustment procedures are the tolerances of the components used, e.g.
hydraulic pump for travel system, proportional valves for steering, steering angle sensors and ESX
control. These tolerances apply for both mechanical as well as electrical functions and are unavoid-
able for manufacturing reasons.
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All
that is needed is this manual and a bit of time. By following the described procedure it is possible to
take a machine back into operation after the replacement of one of the components specified above
and to re-establish the usual functional quality, with almost any previous knowledge. Even an incor-
rectly or incompletely conducted teaching procedure can be repeated without problems as often as
necessary. At the first glance it seems to be at bit awkward to perform this adjustment work on every
machine, but this procedure enables the operation of all machines with the same operating software.
At the end of the day this considerably increases the spare parts availability.
5.2 Replacement of an ESX-control

Since the control stores all teach values of the machine, each teaching procedure must be performed
with the new control after a replacement.
Attention: Before performing one of the following steps, the machine type must first
be set (see chapter 3.3)!
When changing the machine type all previously made adjustments will be
lost!
Now the teach functions must be executed.
From DH
Automatic detection of travel system surge currents (see chapt. 3.6)
On BVC
Automatic detection of steering valve surge currents (see chapt. 3.7)
Teaching the electronic end stops of the steering angle sensor (see chapt. 3.8)
5.3 Replacement of a travel pump / axle drive motor / drum drive motor
Automatic detection of travel system surge currents (see chapt. 3.6)
5.4 Replacement of a steering valve (BVC)

Automatic detection of steering valve surge currents (BVC) (see chapt. 3.7)
5.5 Replacement of a steering angle sensor

Teaching the electric end stops of the steering angle sensor (see chapt. 3.8)
5.6 How to proceed when replacing a front / rear axle sensors?

Teaching the travel direction sensor

208 BOMAG 008 911 71

5.7 Component replacement without adjustment procedure
Which components can be replaced without a subsequent adjustment procedure?
Display
Data collector
Joystick
Electric steering wheel
Diesel engine
All switches in the dashboard
Vibration motor
Vibration pump
Note: A final function test of the complete machine is highly recom-

mended.

008 911 71 BOMAG 209

210
9.1
Service Training WZ – 4 Description of Signals on the ESX Control
6 Description of the signals on the ESX-control

Notes:
Wherever the value of 12V is mentioned in the following text, it refers to the current battery voltage
under due consideration of voltage drops in the lines.
ESX terminal Signal description Nominal values (voltage / current)

X35:1 AGND = Analogue ground: Ground potential for sensors (steering an- approx. 0 V measured against ground (terminal 31)
gle sensor, steering unit etc.)
X35:2 Output amplitude changeover active, i.e. high amplitude )approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. low amplitude ) 0V
X35:3 Output warning buzzer Warning buzzer active )approx. 12 V
Digital output (max. 2.5 A) Warning buzzer inactive ) 0V
X35:4 Interface RS 232 RxD, not used for normal operation. Measurement not possible!
X35:5 Interface RS 232 TxD, not used for normal operation. Measurement not possible!
X35:6 Not used ---
X35:7 Not used ---
BOMAG
X35:8 Not used ---
X35:9 Not used ---
X35:10 Not used ---
X35:11 Not used ---
X35:12 Input axle speed Signal changes between approx. 0V and approx. 12V, when machine is
Frequency input (0...0.70.5kHz) driving.
Frequency with travel speed m/min
Machine type:
XX m/min )approx.XX Hz
Machine type:
Machine type:
X35:13 Not used ---
Version/Status: V3.29 / 13.11.07 Description of Signals on ESX Control Page 30 of 84

Machine related electrics
008 911 71
008 911 71
X35:14 Not used ---
X35:15 Input seat contact switch Seat operated ) 0V
Digital input active high Seat not operated ) ?V
X35:16 Arm rest switch ---
X35:17 Input BTS brake (from travel lever) Brake released )approx. 12 V
Digital input active high Brake applied ) 0V
X35:18 Input steering sensor (S1/A) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned.

Frequency depends on speed of turning
X35:19 Input steering sensor (S1/B) Signal changes between approx. 0V and 12V, when steering wheel is
X35:20 Output steering left Steering left active )0.4.0.10.6 A
PWM digital output (max. 4 A) Steering left inactive ) 0A
X35:21 Output steering right Steering right active )0.4.0.10.6 A
PWM digital output (max. 4 A) Steering right inactive ) 0A
X35:22 Output vibration pump attachment plate permissible current range: approx. 0.0.10.2 A
PWM power output (max. 4A) Vibration pump active )0.6.0.10.2 A
BOMAG
Vibration pump not active ) 0A
X35:23 Voltage supply for sensors Nominal voltage = 8.5 V
This output supplies steering angle sensor and steering unit. Permissible range: approx. 7.65..90.35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override mode (emergency function).
X35:24 Output backup alarm Backup alarm inactive ) 0V
Digital output (max. 2.5 A) Backup alarm active )approx. 12 V
X35:25 Not used ---
X35:26 Interface CAN-Bus 1 Wire -, is used for communication with MESX,
data collector, LCD-display and BOP. Measurement not possible!
X35:27 Interface CAN-Bus 1 Wire +, is used for communication with MESX,
data collector, LCD-display and BOP. Measurement not possible!
X35:28 Input potential terminal 15 Control switched on )approx. 12 V
Digital input active high Control switched off )approx.2 V
This signal must be present, so that the control can work.
X35:29 Input steering angle sensor Position steering angle sensor (measured against AGND)
Analogue input / voltage input 0..8,5 V right hand stop ) 0.50.0.10.00 V

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212
9.1

straight ahead / neutral / middle ) ..V
left hand stop ) 6.80.0.80.70 V
X35:30 Input longitudinal inclination of machine Inclination of machine (measured against AGND)
Analogue input / voltage input 0..8,5 V -45° axle high ) 0.50.0.20.49 V
Neutral position ) 2.50 V
maximum down ) 2,51..4,50 V
X35:31 Input hydraulic pressure travel pump circuit 0 bar ) approx.4 mA
Analogue input (current input 4mA..20mA) from pressure sensor on 600 bar ) approx.20 mA
travel pump
X35:32 Not used ---
X35:33 Interface CAN-Bus 2 Wire -, is used to communicate with the travel
lever and engine EMR. Measurement not possible!
X35:34 Input drum speed Signal changes between approx. 0V and approx. 12V, when machine is
Frequency input (0...0.70.5kHz) driving.
Frequency with travel speed m/min
Machine type:
BOMAG
Machine type:
Machine type:
X35:35 Input vibration motor Frequency with vibration frequency in Hz
Frequency input (0....2,0kHz) Machine type:
Vib. frequency XX Hz )approx.XX Hz
Machine type:
Machine type:
X35:36 Input sense of rotation of vibration motor Sense of rotation forward )approx. 12 V

008 911 71
008 911 71
(currently not used) Sense of rotation backward )approx.2 V
Digital input active high
X35:37 Input sense of rotation of drum Sense of rotation forward )approx. 12 V
Digital input active high Sense of rotation backward )approx.2 V
X35:38 Input sense of rotation of axle Sense of rotation forward )approx. 12 V
Digital input active high Sense of rotation backward )approx.2 V
X35:39 Not used ---
X35:40 Input steering sensor (S2/A) Signal changes between approx. 0V and 12V, when steering wheel is
X35:41 Input steering sensor (S2/B) Signal changes between approx. 0V and 12V, when steering wheel is
X35:42 Output emergency steering Emergency steering active )approx. 12 V
Emergency steering inactive ) 0V
X35:43 Not used ---
X35:44 Not used ---
X35:45 Not used ---
BOMAG
X35:46 Output drum drive motor permissible current range: approx. 0.0.00.6 A
PWM power output (max. 4 A) Drum drive motor active )0.0.0.20.0 A
Drum drive motor not active ) 0A
X35:47 Output axle motor permissible current range: approx. 0.0.00.6 A
PWM power output (max. 4 A) Axle motor active )0.0.0.20.0 A
Axle motor not active ) 0A
X35:48 Output vibration pump permissible current range: approx. 0.0.00.6 A
PWM power output (max. 4A) Axle motor active )0.0.0.20.0 A
Axle motor not active ) 0A
X35:49 Output travel pump forward Travel forward active )0.0.0.20.0 A
PWM power output (max. 4 A) Travel forward inactive ) 0A
Sauer components with EDC

Travel forward active )18.0.80 mA
Travel forward inactive ) 0 mA
X35:50 Not used ---
X35:51 Not used ---

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214
9.1

X35:52 Not used ---
X35:53 Interface CAN-Bus 2 Wire +, is used to communicate with the travel
lever and engine EMR. Measurement not possible!
X35:54 Voltage supply for electronics (permanent voltage) Control running )approx. 12 V
Control not running ) 0V
X35:55 Ground connection electronics 0 V (measured against ground)
X35:56 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:61 Output brake Open brake )approx. 12 V
Digital output (max. 4 A) Close brake ) 0V
X35:62 Output blower coupling stage 2 (currently not used) Active )approx. 12 V
Digital output (max. 4 A) Inactive ) 0V
X35:63 Output blower coupling stage 3 (currently not used) Active )approx. 12 V
Digital output (max. 4 A) Inactive ) 0V
BOMAG
X35:64 Output travel pumps reverse Travel forward active )0.0.0.20.0 A
PWM power output (max. 4 A) Travel forward inactive ) 0A
Sauer components with EDC

Travel forward active )18.0.80 mA
Travel forward inactive ) 0 mA
X35:65 Test connection Baby Boards approx. 0 V

008 911 71
Service Training WZ – 4 Description of Signals on the Data Collector
008 911 71
7 Description of signals on the data collector
Notes:
Wherever the value of 12 V is mentioned in the following text, it refers to the current battery voltage
PIN data Signal description Nominal values (voltage / current)

collector
X26:1 Input indicator right Indicator right active )approx. 12 V
Digital input active high Indicator right inactive ) 0V
X26:2 Input indicator left Indicator left active )approx. 12 V
Digital input active high Indicator left inactive ) 0V
X26:3 Input engine running (D+) Engine running )approx. 12 V
Digital input active high Engine not running ) 0V
X26:4 Not used ---
X26:5 Input hydraulic oil filter differential pressure Filter clogged ) 0V
Digital input active low Filter OK ) ?V
X26:6 Not used ---
BOMAG
X26:7 Input air conditioning Air conditioning on )approx. 12 V
Digital input active high Air conditioning off ) 0V
X26:8 Input engine air filter Filter clogged ) 0V
Digital input active low Filter OK ) ?V
X26:9 Input background illumination Illumination on )approx. 12 V
Digital input active high Illumination off ) 0V
X26:10 Input coolant supply Coolant supply too low ) 0V
Digital input active low Sufficient coolant supply ) ?V
X26:11 Not used ---
X26:12 Ground connection 0V (measured against ground)
X27:1 Not used
X27:2 Input fuel level The voltage signal changes with the filling level in the fuel tank
Analog input Fuel tank empty ) ?? V
Fuel tank full ) ?? V
X27:3 Not used ---
X27:4 Voltage supply for monitoring of water separation (PIN X27:9) Voltage supply O.K. ) approx.12 V
Version/Status: V3.29 / 13.11.07 Description of Signals on Data Collector Page 35 of 84

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216
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Service Training WZ – 4 Description of Signals on the Data Collector
PIN data Signal description Nominal values (voltage / current)

collector
No voltage supply ) 0V
X27:6 Interface CAN-Bus 1 Wire +, is used for communication with MESX, Measurement not possible!
ESX, LCD-display and BOP.
X27:7 Interface CAN-Bus 1 Wire -, is used for communication with MESX, Measurement not possible!
ESX, LCD-display and BOP.
X27:8 Voltage supply (permanent voltage) Control running )approx. 12 V
Control not running ) 0V
X27:9 Input water separation If a sufficient amount of water has been separated, a low current flows
Current input over the over the contacts and the water in the separator bowl. This input
analyses this current.
No water separated ) I= 0A
Water separated ) I 0,03mA
X27:10 Not used ---
X27:11 Not used ---
X27:12 Not used ---
BOMAG
Version/Status: V3.29 / 13.11.07 Description of Signals on Data Collector Page 36 of 84
008 911 71
Service Training WZ – 4 Description of Signals on the Travel Lever
008 911 71
8 Description of signals on the travel lever
Notes:
PIN travel Signal description Nominal values (voltage / current)

lever
X23:1 Voltage supply (permanent voltage) Electronics functioning )approx. 12 V
Electronics not working ) 0V
X23:3 Output BTS brake Brake opens )approx. 12 V
Digital output (max. 4 A) Brake closes ) 0V
X23:4 Output BTS (not used)
Digital output (max. 4 A)
X23:5 Output voltage supply for additional analog evaluations Nominal voltage = approx. 5,0 V
This output supplies the 24-stage travel range selector switch. This Permissible range: approx. 4.8.0.50.2 V
voltage is required to connect and evaluate further analog switches to This voltage must be measured against AGND.
BOMAG
the travel lever.
X23:6 Interface CAN-Bus 2 Wire +, is used to communicate with ESX and Measurement not possible!
engine EMR.
X23:7 Interface CAN-Bus 2 Wire -, is used to communicate with ESX and Measurement not possible!
engine EMR.
X23:8 AGND = Analogue ground: Ground potential for additional analog approx. 0 V measured against ground (terminal 31)
evaluations
Reference to PIN X23:5
X23:9 Node address addressing 1 Connection to machine ground (0V)
X23:10 Node address addressing 2 Connection to machine ground (0V)
X23:11 Input travel stage selector switch The voltage signal changes with the adjusted travel speed range
Analog input Travel stage min. ) ?? V
Travel stage max. ) ?? V
X23:12 Not used ---
X24:1 Not used ---
X24:2 Input high amplitude High amplitude active )approx. 12 V
Version/Status: V3.29 / 13.11.07 Description of Signals on Travel Lever Page 37 of 84

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Service Training WZ – 4 Description of Signals on the Travel Lever
PIN travel Signal description Nominal values (voltage / current)

lever
Digital input active high High amplitude inactive ) 0V
X24:3 Input low amplitude Low amplitude active )approx. 12 V
Digital input active high Low amplitude inactive ) 0V
X24:4 Not used ---
X24:5 Not used ---
X24:6 Input arm rest left (not yet realized) ---
X24:7 Output voltage supply for additional digital evaluations Voltage supply active )approx. 12 V
This output supplies the amplitude selector switch. This voltage is re- Voltage supply inactive ) 0V
quired to connect and evaluate further digital switches to the travel
lever.
X24:8 Output voltage supply ground potential 0V (measured against ground)
In connection with PIN X24:7 this output enables the control of addi-
tional components (relays, displays etc.)
BOMAG
Version/Status: V3.29 / 13.11.07 Description of Signals on Travel Lever Page 38 of 84
008 911 71
Service Training WZ – 4 Description of Signals on the LC-Display
008 911 71
9 Descriptions of signals on the LC - Display
Notes:
PIN Display Signal description Nominal values (voltage / current)

X28:1 Voltage supply (permanent voltage "ignition on") Electronics functioning )approx. 12 V
X28:3 Interface CAN-Bus 1 Wire +, is used for communication with MESX, Measurement not possible!
ESX, data collector and BOP.
X28:4 Interface CAN-Bus 1 Wire -, is used for communication with MESX, Measurement not possible!
ESX, data collector and BOP.
X28:5 Voltage supply (permanent voltage "Battery +“ for RTC) Electronics functioning )approx. 12 V
X28:6 Not used ---
X29:1 Input lower frequency Adjustment active )approx. 12 V
Digital input active high Adjustment inactive ) 0V
BOMAG
X29:2 Input higher frequency Adjustment active )approx. 12 V
Digital input active high Adjustment inactive ) 0V
X29:3 Input engine speed high idle High idle active )approx. 12 V
Digital input active high High idle inactive ) 0V
X29:4 Input engine speed low idle Low idle active )approx. 12 V
Digital input active high Low idle inactive ) 0V
X29:5 Not used ---
X29:6 Not used ---
X29:7 Output voltage supply for additional digital evaluations Voltage supply active )approx. 12 V
This output supplies the engine speed switch and the switch for fre- Voltage supply inactive ) 0V
quency adjustment. This voltage is required to connect and evaluate
further digital switches to the LCD.
X29:8 Not used ---
Status: 13.11.07 Description of Signals on the LC-Display Page 39 of 84

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9.1
Service Training WZ – 4 Description of Signals on the DIOS Module
10 Description of Signals on DIOS-Module

(only for option with attachment plates)
DIOS terminal Signal description Nominal values (voltage / current)

X62:1 Interface CAN-Bus 1 Wire +, is used to communicate with the ESX- Measurement not possible!
control.
X62:2 Interface CAN-Bus 1 Wire -, is used to communicate with the ESX- Measurement not possible!
control.
X62:3 Voltage supply for electronics Ignition ON: )approx. 12 V
Ignition OFF: ) 0V
X62:4 Input proximity switch, plates middle Plates in middle position )approx. 12 V
Digital input active high Plates outside middle position ) 0V
X62:5 Output plates up Up active )approx. 12 V
Digital output (max. 4 A) Up inactive ) 0V
X62:6 Output plates down Down active )approx. 12 V
Digital output (max. 4 A) Down inactive ) 0V
X62:7 Output plates left Sliding to left active )approx. 12 V
Digital output (max. 4 A) Sliding to left inactive ) 0V
BOMAG
X62:8 Output plates right Sliding to right active )approx. 12 V
Digital output (max. 4 A) Sliding to right inactive ) 0V
X62:9 Voltage supply for outputs Ignition ON: )approx. 12 V
Ignition OFF: ) 0V
X62:10 Voltage supply for outputs Ignition ON: )approx. 12 V
Ignition OFF: ) 0V
X62:11 Ground connection 0 V measured against ground
X62:12 Input proximity switch, plates top Plates lifted above sensor ) 0V
Digital input active high Plates lowered below sensor )approx. 12 V
X62:13 Output plates float position 1 Float position active )approx. 12 V
Digital output (max. 4 A) Float position inactive ) 0V
X62:14 Output plates priority Priority active )approx. 12 V
Digital output (max. 4 A) Priority inactive ) 0V
X62:15 Output plates float position 2 Float position active )approx. 12 V
Digital output (max. 4 A) Float position inactive ) 0V
X62:16 Not used ---
Version/Status: V3.29 / 13.11.07 Description of Signals on the DIOS Module Page 40 of 84

008 911 71
Service Training Fault codes of the ESX control
11 Fault codes of the ESX control
11.1 Overview
Fault code Fault description
0000 - General faults / warnings / machine tests
0999
1000 - Fault in travel system
1999
2000 - Fault in steering system
2499
2500 - Fault in remote control
2999
3000 - Faults in work functions (vibration, attachment plates, rotor, chip
4499 spreader)
4500 - Fault in measuring systems
4999
5000 - Fault diesel engine
5499
5500 - Fault hydraulic system
5999
6000 - Fault anti-theft warning system, localization system, access sys-
6999 tem, time account, etc.
7000 - Input of machine codes
7499
7500 - Input of codes for measuring technology
7899
7900 - Operating hours, load spectrum, etc.
7999
8000 - Severe software error 1
8999
9000 - Errors of external IO-nodes (joystick, data collector, Dios module,
9999 LC-display, etc.) 1
1
These faults are not broken down hereunder!
Version/Status: V3.29 / 13.11.07 Fault Codes on ESX Control Page 41 of 84

008 911 71 BOMAG 221

222
9.1
Service Training WZ – 4 Description of Control Error Codes
11.2 Description of fault reactions

Fault reacti- Description of fault reaction
on
1 Warning.
Fault code is displayed.
2 Warning.
Audible signal
3 Function affected, the faulty function is replaced by an emergency function.

Audible signal
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
BOMAG
Audible signal
) the diesel engine is shut down.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
Audible signal
6 Severe fault. The function of the control can no longer be guaranteed.

) Control is switched off.
) the diesel engine is shut down, if possible.
The fault code is displayed, the signal light in the monitoring board is permanently on.
No audible signal!
Note: Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log!
Version/Status: V3.29 / 13.11.07 Description of Control Error Codes Page 42 of 84

008 911 71
008 911 71
11.3 Note codes
Notes are a special form of fault messages.

The display shows note codes in the same way as fault codes, however, these do not require any service action, because they are just notes on particular operating
states of the machine.
Note Fault description Possible causes Assignment Input

Code DH-4 BVC-4 code for
diagnose
1088 Travel pump valve surge currents The function "Teaching pump surge currents" for the travel pump has not
Surge currents for travel pump have NOT been learned. yet been executed. X X
See 4.4 Automatic detection of surge currents in travel system Î New machine/replacement of control
1500 Warning "Dangerous condition ASC" Due to counter-rotating drive units the machine was stopped and the brake
applied. X X
The brake can be released again after shifting the travel lever to braking
position, travel operation can be resumed.
2201 Steering logic Difference between steering wheel movement and This display is a Note, if steering at standstill is not possible. At standstill
steering movement too big -> machine has stopped! the steering forces may not be high enough. This is just a possible opera- X X
BOMAG
ting state.
2068 Valves steering pump surge currents The function "Teaching surge currents" for the electric steering has not yet
Surge currents for steering pump have NOT been learned. been executed. X X
See 4.7 Automatic detection of surge currents on steering valves Î New machine/replacement of control
(BVC)
(Only machine with electric steering)
2198 Electric steering, steering end stops The function "Teaching steering stops" for the electric steering has not yet
Teaching of steering stops for electric steering NOT yet executed. been executed. X X
See 4.6 Teaching the electronic end stops of the steering angle Î New machine/replacement of control
sensor (BVC)
2300 Arm rest raised The arm rest has been raised or the magnetic switch under the left hand
Î Machine does not pick up throttle and is braked to stop. arm rest is defective X
3060 Warning ! Attachment plate lowered and backward travel The attachment plates are lowered and an attempt is made to drive back- X
wards
5013 Diesel engine stalled various X X

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9.1
Note Fault description Possible causes Assignment Input

Code DH-4 BVC-4 code for
diagnose
BOMAG
008 911 71
008 911 71
11.4 Detailed description of fault codes and their possible causes
11.4.1 General
Fault Fault description Possible causes Terminal Assignment Input Fault
Code DH-4 BVC-4 code for reaction
diagnose
0500 Driving against brake – warning A corresponding input code has been entered
The function "Driving against brake" is activated X X 2
0502 Simulated engine run - warning A corresponding input code has been entered
The function "Simulated engine run" is activated X X 2
0504 Ant- Slip Control (ASC) deactivated - warning A corresponding input code has been entered
The function "Anti Slip Control (ASC)" is deactivated X X 2
0507 Drum drive deactivated - warning A corresponding input code has been entered
Test mode "Drum drive deactivated" was activated. X X 2
0508 Axle drive deactivated - warning A corresponding input code has been entered
Test mode "Axle drive deactivated" was activated. X X 2
0560 Overvoltage 8,5V Connection of voltage level to operating voltage, another voltage X35:23
BOMAG
The voltage level of the 8,5V range is impermissibly ex- potential or control defective X X 2
ceeded
(see signal description)
0561 Undervoltage 8,5V Connection of voltage level to ground, another voltage potential X35:23
The voltage level of the 8,5V range is impermissibly fallen or control defective X X 2
short of
562 Error "Voltage Override Relay" 2
The voltage level of the 8,5V range is... X X

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9.1
11.4.2 Brake
diagnose
1001 Brake valve line breakage ) The connecting line between output of control and X35:61
The required control power cannot be transmitted to the control solenoid is interrupted. X X 1001 6
control solenoid. ) The solenoid is defective
1002 Brake valve short circuit to ground ) The connecting cable has short circuit to ground X35:61
Signal outside the valid range (see signal description) ) Coil defective X X 1001 6
1003 Brake valve short circuit Ub ) The connecting cable has short circuit to battery voltage X35:61
Signal outside the valid range (see signal description) X X 1001 6
1004 Brake valve ) The connecting cable has short circuit to ground X35:61
Overheating of output driver in ESX ) Coil defective X X 1001 6
1005 BTS brake / plausibility (BTS=output driver) ) Hardware defect on travel lever X35:17
Plausibility conflict in evaluation of travel lever X- axis to ) Connection between ESX and travel lever interrupted X33:3 X X 5
the brake contact signal
BOMAG
11.4.3 Travel lever
diagnose
1025 Travel lever sum error X-axis Internal fault in travel lever -> Replace travel lever. CAN
Error in redundant evaluation of axis X X 3
1026 Travel lever cable breakage X-axis Cable breakage in travel lever -> Replace travel lever. CAN
Signal outside the valid range (see signal description) X X 3
1027 Travel lever parameterization X-axis Internal fault in travel lever -> Replace travel lever. CAN
X X 3
1028 Travel lever direction evaluation X-axis Internal fault in travel lever -> Replace travel lever. CAN
The direction of travel lever movement could not be de- X X 3
termined

008 911 71
008 911 71
diagnose
1029 Travel lever difference error X-axis Internal fault in travel lever -> Replace travel lever. CAN
Error in redundant evaluation of travel lever signal X X 3
1030 Travel lever software error X-axis Internal fault in travel lever -> Replace travel lever. CAN
Software does not work fault free X X 3

diagnose
1031 Travel lever sum error Y-axis Internal fault in travel lever -> Replace travel lever. CAN
Error in redundant evaluation of axis X X 3
1032 Travel lever cable breakage Y-axis Cable breakage in travel lever -> Replace travel lever. CAN
Signal outside the valid range (see signal description) X X 3
1033 Travel lever parameterization Y-axis Internal fault in travel lever -> Replace travel lever. CAN
X X 3
1034 Travel lever direction evaluation Y-axis Internal fault in travel lever -> Replace travel lever. CAN
The direction of travel lever movement could not be de- X X 3
BOMAG
termined
1035 Travel lever difference error Y-axis Internal fault in travel lever -> Replace travel lever. CAN
Error in redundant evaluation of travel lever signal X X 3
1036 Travel lever software error Y-axis Internal fault in travel lever -> Replace travel lever. CAN
Software does not work fault free X X 3

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9.1
11.4.4 Travel speed range selector switch

diagnose
1040 Travel range selector switch "Ground connection" Cable breakage in ground line, or X23:8
Signal outside the valid range (see signal description) Connecting cable between switch and ground connection has X X 1040 3
come loose
1041 Travel range selector switch "Supply connection" Cable breakage in connecting line, or X23:5
Signal outside the valid range (see signal description) The connecting cable between switch and supply line X X 1040 3
has come loose
1042 Travel speed range selector switch Higher contact resistances have possibly caused a faulty signal. X23:11
Signal outside the valid range (see signal description) The switch must be replaced. X X 1040 3
11.4.5 Travel system

diagnose
1070 Output travel pump forward The connecting line from the output of the control to the propor- X35:49
BOMAG
The required control power cannot be transmitted to the tional solenoid is interrupted or the proportional solenoid is X X 5
proportional solenoid. defective
-> Line interrupted/cable breakage.
1071 Fault of current regulator forward Faults in valve control Check wiring. X35:49
X X 5
1072 Fault of current regulator forward Faults in valve control Check wiring. X35:49
X X 5
1073 Output travel pump forward Short circuit of connecting line (control to proportional valve) to X35:49
Supply voltage UB applied to the output to the proportional voltage supply X X 5
valve.
1074 Output travel pump forward - Short circuit of connecting line (control to proportional valve) X35:49
Output to proportional valve shorted to ground. to machine frame or a ground cable. X X 5
- Proportional valve defective.
1075 Error in teaching the surge current forward Machine mechanically blocked X35:49
Travel system bypass valves out of adjustment X X 5

008 911 71
008 911 71
diagnose
1080 Output travel pumps reverse The connecting line from the output of the control to the propor- X35:64
The required control power cannot be transmitted to the tional solenoid is interrupted or the proportional solenoid is X X 5
) Line interrupted/cable breakage.
1081 Fault of current regulator reverse Faults in valve control Check wiring. X35:64
X X 5
1082 Fault of current regulator reverse Faults in valve control Check wiring. X35:64
X X 5
1083 Output travel pumps reverse Short circuit of connecting line (control to proportional valve) to X35:64
Supply voltage UB applied to the output to the proportional voltage supply X X 5
valve.
1084 Output travel pumps reverse - Short circuit of connecting line (control to proportional valve) X35:64
Output to proportional valve shorted to ground. to machine frame or a ground cable. X X 4
1085 Error in teaching the surge current reverse Machine mechanically blocked X35:64
Travel system bypass valves out of adjustment X X 3
BOMAG
1088 Travel pump surge currents Note, no fault! See 11.3 Note codes
Surge currents for travel pump have NOT been learned. X X 1
See 4.4

9.1
229
230
9.1

diagnose
1100 Output front travel motor The connecting line from the output of the control to the propor- X35:46 X X 4
The required control power cannot be transmitted to the tional solenoid is interrupted or the proportional solenoid is
Î Line interrupted/cable breakage.
1105 Speed sensor pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:34 X X 4
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor
1106 Direction signal pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:37 X X 4
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor
1107 Output front travel motor Short circuit of connecting line (control to proportional valve) to X35:46 X X 5
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1108 Output front travel motor - Short circuit of connecting line (control to proportional valve) X35:46 X X 4
Output to proportional valve shorted to ground. to machine frame or a ground cable.
1110 Output rear travel motor The connecting line from the output of the control to the propor- X35:47 X X 4
BOMAG
1115 Speed sensor pulses rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:12 X X 4
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor
1116 Speed sensor direction signal rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:38 X X 4
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor
1117 Output rear travel motor Short circuit of connecting line (control to proportional valve) to X35:47 X X 4
valve.
1118 Output rear travel motor - Short circuit of connecting line (control to proportional valve) X35:46 X X 4

008 911 71
008 911 71
diagnose
1140 Travel system pressure sensor "Signal" The connecting line between control output and pressure sensor X35:31 X X 1
The current signal is not transmitted (see signal specifica- is interrupted, or
tion The pressure sensor is defective
1141 Travel system pressure sensor "Signal range" The pressure sensor is defective X35:31 X X 1
The current signal is outside the valid range (see signal
specification)
1142 Travel system pressure sensor "no pressure" No pressure connection on sensor, or X35:31 X X 4
The electric signal indicates that the travel pressure is supply line blocked or
permanently missing. no travel pressure built up
1145 Inclination sensor "Supply connection" Cable breakage in connecting line, or X35:?? X X 3
Signal outside the valid range (see signal description) connecting cable between sensor and power supply has come ..
loose X35:30
1146 Inclination sensor "Ground connection" Cable breakage in ground line, or X35:1 X X 3
Signal outside the valid range (see signal description) Connecting cable between sensor and ground connection has
come loose
1300 Seat connect not occupied Cable breakage in signal line, or X35:15 X X 2
driver's seat not occupied (driver not seated!)
BOMAG
1500 Warning "Dangerous condition ASC" Note, no fault! See 11.3 Note codes X X 2

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232
9.1
11.4.6 Steering
diagnose
2000 Limp home steering valves active X 1
2040 Output steering valve right The connecting line from the output of the control to the propor- X35:20 X 4
2041 Output steering valve right Faults in valve control Check wiring. X35:20 X 4
Fault current regulator
2042 Output steering valve right Faults in valve control Check wiring. X35:20 X 4
2043 Output steering valve right Short circuit of connecting line (control to proportional valve) to X35:20 X 5
valve.
2044 Output steering valve right - Short circuit of connecting line (control to proportional valve) X35:20 X 4
BOMAG
2050 Output steering valve left The connecting line from the output of the control to the propor- X35:21 X 4
2051 Output steering valve left Faults in valve control Check wiring. X35:21 X 4
2052 Output steering valve left Faults in valve control Check wiring. X35:21 X 4
2053 Output steering valve left Short circuit of connecting line (control to proportional valve) to X35:21 X 5
valve.
2054 Output steering valve left - Short circuit of connecting line (control to proportional valve) X35:21 X 4
Proportional valve defective.

008 911 71
008 911 71
diagnose
2065 Error when teaching the surge current for the right Drum was not moved, maximum current was reached, steering is X35:20 X 4
hand valve blocked (e.g. articulation lock applied)
2066 Error when teaching the surge current for the left hand Drum was not moved, maximum current was reached X35:21 X 4
valve Steering is blocked (e.g. joint lock engaged)
2068 Valves steering pump surge currents Note, no fault! See 11.3 Note codes X 1
Surge currents for steering pump have NOT been learned.
See 4.7 Automatic detection of surge currents on steer-

ing valves (BVC)
2170 Steering valve (arm rest) "direction change" Wiring fault or steering sensor in left hand arm rest defective X35:18 X 4
X35:19
X35:40
X35:41
2171 Steering valve (arm rest) "Pulse coverage" Steering sensor in left hand arm rest defective. X35:18 X 4
High difference in measuring values between sensor 1 and X35:19
2 X35:40
X35:41
2172 Steering wheel (arm rest) "Sensor 1 pulse range" Check connecting line to steering sensor 1 or X35:18 X 4
The detected steering pulses on steering sensor 1 are replace the steering sensor in the left hand arm rest, if necessary X35:19
outside the valid range
BOMAG
2173 Steering wheel (arm rest) "Sensor 2 pulse range" Check the connecting lines to steering sensor 2, or replace the X35:40 X 4
The detected steering pulses on steering sensor 2 are steering sensor in the left hand arm rest, if required. X35:41
outside the valid range
2174 Steering wheel A45 (arm rest) "Sensor 1" Steering sensor in left hand arm rest defective. X35:18 X 4
X35:19
2175 Steering wheel A45 (arm rest) "Sensor 2" Steering sensor in left hand arm rest defective. X35:40 X 4
X35:41
2176 Steering wheel A45 (arm rest) "Sensor 1 cable break- Check the connecting lines to steering sensor 1, or replace the X35:18 X 4
age" steering sensor in the left hand arm rest, if required. X35:19
2177 Steering wheel A45 (arm rest) "Sensor 2 cable break- Check the connecting lines to steering sensor 2, or replace the X35:40 X 4
age" steering sensor in the left hand arm rest, if required. X35:41
2178 Steering wheel A45 (arm rest) "Sensor 1 sensor fault" Sensor fault. If this occurs frequently, change steering wheel. X 4
2179 Steering wheel A45 (arm rest) "Sensor 2 sensor fault" Sensor fault. If this occurs frequently, change steering wheel. X 4

9.1
233
234
9.1

diagnose
2190 Steering "steering angle sensor... initialization" Replace the control X 4
Internal control fault.
2191 Steering angle sensorB65 "Measuring value" Steering angle sensor on the articulated joint X35:29 X 4
2192 Steering angle sensor B65 "Supply cable breakage" Voltage supply line to steering angle sensor interrupted or X35:23 X 4
steering angle sensor on articulated joint defective
- Ground connection of signal line
2193 Steering angle sensor B65 "Ground cable breakage" Ground cable to the steering angle sensor interrupted, or X35:1 X 4
Steering angle sensor on the articulated joint defective.
2198 Electric steering, steering end stops Note, no fault! See 11.3 Note codes (X) 4
Teaching of steering stops for electric steering NOT yet
executed.
See 4.6 Teaching the electronic end stops of the steer-
ing angle sensor (BVC)
2200 Steering logic Difference between steering wheel move- Steering valve "jammed". No hydraulic oil supply.
ment and steering movement too big -> machine travelling! Surge currents have not been taught (correctly) see also 4.7
Automatic detection of surge currents on steering valves (BVC).
BOMAG
2201 Steering logic Difference between steering wheel move- Note, no fault! See 11.3 Note codes X 2
ment and steering movement too big -> machine has
stopped!
11.4.7 Driver's seat arm rest sensor

diagnose
2300 Information message! "Arm rest raised" Note, no fault! See 11.3 Note codes X35:16 X 2
-> Machine does not pick up throttle and remains
braked.
2301 Signal fault Cable breakage in magnetic switch signal line, or X35:16 X 2
Signal outside the valid range (see signal description) Magnetic switch under left hand arm rest defective
-> !!Machine can be driven normally!!
2302 Supply cable breakage Voltage supply line to magnetic switch interrupted or magnetic X35:16 X 4
-> !!Machine can be driven normally!! switch under left hand arm rest defective.
2303 Ground cable breakage Ground cable to the magnetic switch interrupted, or X35:16 X 4
-> !!Machine can be driven normally!! Magnetic switch under left hand arm rest defective

008 911 71
008 911 71
11.4.8 Vibration
diagnose
3000 Vibration sensor "No signal" Check connecting lines and plugs to the vibration sensor, or X35:35 X X 1
The sensor in the vibration motor does not pick up any replace the sensor in the vibration motor, if necessary.
pulses.
3001 Valve vibration pump (low amplitude on DH) Details in 3004 – 3008 X35:48 X X 1
General fault.
3002 Valve vibration pump (low amplitude on DH) System fault! Replace the control! X35:48 X X 1
Internal system fault.
3003 Valve vibration pump (low amplitude on DH) "Current Faults in control line, or X35:48 X X 1
range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3004 Valve vibration pump (low amplitude on DH) The connecting line between control output and proportional X35:48 X X 1
Line interruption solenoid is interrupted, or
The proportional solenoid is defective
changeover relay / bridge missing
3006 Valve vibration pump (low amplitude on DH) "Control Faults in connecting line, incorrect valve coil, or X35:48 X X 1
BOMAG
fault regulation down" Connection to another potential (e.g. operating voltage)
specification)
3007 Valve vibration pump (low amplitude on DH) "Control Faults in connecting line, incorrect valve coil, or X35:48 X X 1
fault regulation up" Connection to another potential (e.g. operating voltage)
specification)
3009 Valve vibration pump (low amplitude on DH) Short circuit of connecting line (control to proportional valve) to X35:48 X X 1
valve.
3010 Valve vibration pump (low amplitude on DH) - Short circuit of connecting line (control to proportional valve) X35:48 X X 1

9.1
235
236
9.1

diagnose
3011 Vibration adaptation control (low amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X X 2
"Frequency adaptation" Valve sticking/defective.
Adjustment range reached!
(see signal specification)
Upper adjustment range reached!
Lower adjustment range reached!
3014 Vibration frequency (low amplitude on DH) Vibrations frequency exceeded by more than 5Hz. X35:48 X X 4
Frequency/speed to high Emergency shut down to protect bearings.
After replacement of a vibration pump or peripheral equipment in
the vibration circuit this fault may occur as a result of unfavour-
able component tolerances.
In this case normal operation can be reached by multiple
activation of the vibration, after the fault has been rectified.
BOMAG
ATTENTION! It must be assured, that the fault has not be
caused by a faulty component (pump, control,
valve.
3021 Vibration pump valve (only DH: high amplitude) Details in 3014 – 3018 X35:48 X 1
General fault.
3022 Vibration pump valve (only DH: high amplitude) System fault! Replace the control! X35:48 X 1
3023 Vibration pump valve (only DH: high amplitude) "Current Faults in control line, or X35:48 X 1
range" Connection to another potential (e.g. operating voltage)
specification)
3024 Valve vibration pump "Cable breakage" The connecting line between control output and proportional X35:48 X 1
(only DH: high amplitude) solenoid is interrupted, or
Line interruption The proportional solenoid is defective

008 911 71
008 911 71
diagnose
3026 Vibration pump valve (only DH: high amplitude) Faults in connecting line, incorrect valve coil, or X35:48 X 1
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
specification)
3027 Vibration pump valve (only DH: high amplitude) Faults in connecting line, incorrect valve coil, or X35:48 X 1
"Control fault regulating down" Connection to another potential (e.g. operating voltage)

specification)
3029 Vibration pump valve (only DH: high amplitude) Short circuit of connecting line (control to proportional valve) to X35:48 X 2
valve.
3030 Vibration pump valve (only DH: high amplitude) - Short circuit of connecting line (control to proportional valve) X35:48 X 2
3031 Vibration adaptation control (only DH: high amplitude) Wear or damage in vibration system hydraulic circuit. X35:48 X 2
Frequency adaptation
Limits of adaptation range exceeded
BOMAG
Upper adjustment range reached!
Lower adjustment range reached!
3034 Vibration frequency (only DH: high amplitude) Vibrations frequency exceeded by more than 5Hz. X35:48 X 4
Frequency/speed to high Emergency shut down to protect bearings.
After replacement of a vibration pump or peripheral equipment in
the vibration circuit this fault may occur as a result of unfavour-
able component tolerances.
In this case normal operation can be reached by multiple
activation of the vibration, after the fault has been rectified.
ATTENTION! It must be assured, that the fault has not be
caused by a faulty component (pump, control,
valve.

9.1
237
238
9.1
11.4.9 Attachment plates

diagnose
3051 Vibration pump, plates, valve Details in 3052 – 3058, this fault always is connected with one of X35:22 X 1
General fault. the faults listed below
3052 Vibration pump, plates, valve "hysteresis" X35:22 X 1
3053 Vibration pump, plates, valve "current range" X35:22 X 1

specification)
3054 Vibration pump, plates, valve "Cable breakage" The connecting line between control output and proportional X35:22 X 1
Line interruption solenoid is interrupted, or
The proportional solenoid is defective
BOMAG
diagnose
3055 Vibration pump, plates, valve System fault! Replace the control! X35:22 X 1
3056 Vibration pump, plates, valve X35:22 X 1

"Control fault positive limit"
specification)
3057 Vibration pump, plates, valve X35:22 X 1
"Control fault negative limit"
specification)
3058 Vibration pump, plates, valve System fault! Replace the control! X35:22 X 1
3060 Warning ! Attachment plate lowered and backward Note, no fault! See 11.3 Note codes X 2
travel

008 911 71
008 911 71
11.4.10 Diesel engine
Code DH-4 BVC-4 code for Reaction
diagnose
5013 Diesel engine stalled Note, no fault! See 11.3 Note codes X X 1
5024 Diesel engine "Coolant level" warning Coolant level too low or sensor defective X26:10 X X 2
5025 Diesel engine "Coolant level" fault shut-down Coolant level too low or sensor defective X26:10 X X 5
5026 Diesel engine "Air filter" warning Air filter soiled or sensor defective X26:8 X X 2
5027 Diesel engine "Air filter" fault shut-down Air filter soiled or sensor defective X26:8 X X 5
5028 Water separator warning Water or other dirt in fuel filter X27:4 X X 2
X27:9
5029 Water separator fault shut-down Water or other dirt in fuel filter X27:4 X X 5
X27:9
11.4.11 Diesel engine EMR

diagnose
5100 Diesel engine EMR "Warning light" Collective warning X X 2
) see further fault code for more accurate fault diagnose
BOMAG
5101 Diesel engine EMR "red stop light" Collective message for engine shut down X X 2
5102 Diesel engine EMR has more than one logged fault. Collective message for engine shut down X X 2

9.1
239
240
9.1

diagnose
5110 Diesel engine EMR "Nominal speed value" ) CAN connection between ESX and EMR interrupted X X 2
) CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
) ESX without voltage supply
) Battery charge level too low
5111 Diesel engine EMR "Engine oil filling level" ) Engine oil filling level too low X X 2
5112 Diesel engine EMR "Oil pressure" ) Engine oil pressure too low X31:21 X X 2
5113 Diesel engine EMR "Charge air pressure" ) Charge air pressure too low X31:24 X X 2
5114 Diesel motor EMR "Temperature in intake line" ) Charge air temperature too high X31:4 X X 2
5116 Diesel engine EMR "Coolant temperature" ) Coolant temperature too high X31:9 X X 2
5117 Diesel engine EMR "Fuel temperature" ) Fuel temperature too high X X 2
5118 Diesel engine EMR "Engine speed" ) Speed sensor 1 or 2 defective X31:13 X X 2
) Connection between EMR and speed sensor 1 or 2 inter- X31:11
rupted
5119 Water separator (EMR3) Water or other dirt in fuel filter X X 2
BOMAG
5120 Diesel engine EMR "CAN communication" ) CAN connection between ESX and EMR interrupted X X 2
5121 Diesel engine EMR "CAN communication" ) CAN connection between ESX and EMR interrupted X X 5
) EMR without voltage supply.
5122 Diesel engine EMR "Nominal speed value" ) CAN connection between ESX and EMR interrupted X X 2
5123 Diesel engine EMR CAN communication ) CAN communication between EMR and ESX X30:12 X X 2
X30:13
X30:13
X30:13

008 911 71
008 911 71
5126 Diesel engine EMR CAN communication ) CAN communication between EMR and ESX.# X30:12 X X 2
Occurs also when the ESX travel control switches off for X30:13
longer than 5 seconds (LCD-display flickers) while the engine
is running.
BOMAG
9.1
241
242
9.1

diagnose
5127 Diesel engine EMR "Low pressure fuel pressure" ) Fuel pre-pressure too low (possibly filter clogged) X31:13 X X 2
X31:23
X31:40
5130 Diesel engine EMR "Oil pressure sensor" ) Sensor defective X31:20 X X 2
) Wire breakage in current path X31:21
X31:22
) Current path has short circuit to ground
5131 Diesel engine EMR "Charge air pressure sensor" ) Sensor defective X31:23 X X 2
X31:25
5132 Diesel engine EMR "Charge air temperature" ) Sensor defective X31:4 X X 2
X31:25
5133 Diesel engine EMR "Coolant temperature sensor" ) Sensor defective X31:8 X X 2
5134 Diesel engine EMR "Speed sensor" ) Speed sensor 1 or 2 defective X31:10 X X 2
X31:11
BOMAG
X31:12
X31:13
5135 Water separator (EMR2) Water or other dirt in fuel filter X X 2
5136 Diesel engine EMR "Fuel low pressure sensor" ) Sensor defective X31:13 X X 2
X31:40
5140 Diesel engine EMR "unknown fault" Fault diagnostics only possible with DEUTZ diagnostics tool X X 2
(SERDIA)
11.4.12 Miscellaneous
diagnose
5502 "Hydraulic oil filter" warning Hydraulic oil filter soiled or sensor defective X X 2
5503 "Hydraulic oil filter" fault shut-down Hydraulic oil filter soiled or sensor defective X X 5
5504 "Oil temperature" warning Hydraulic oil temperature too high or sensor defective X X 2
5005 "Oil temperature" fault shut-down Hydraulic oil temperature too high or sensor defective X X 5

008 911 71
008 911 71
BOMAG
9.1
243
244
9.1
11.4.13 Machine type

diagnose
7011 Warning "Change of machine type" Only change the machine type after applying appropriate meas- X X 6
This warning is displayed when the machine type is ures; e.g. conversion from D to PD (different rolling circumfer-
changed. ence of roller drum)
7012 "Conflict machine type" The machine type has been changed to such an extent, that the X X 4
This error message is displayed if the set machine does type parameters no longer match the basic parameters enter
not comply with the basic parameters of the machine. the correct machine code or one of the basic machine parame-
ters was changed (e.g. different axle)
11.4.14 Optional functions

diagnose
9400 Communication error travel control engine control ) Fault on CAN (2) line X34:C X X 4
) Travel lever defective X34:D
BOMAG
) Immobilizer not yet unlocked

008 911 71
Service Training WZ – 4 Description of Control Input Codes
008 911 71
12 Input Codes for ESX Control
Display and adjustment functions can generally only be accessed by entering "service code" 9999 beforehand!
12.1 Fault log

without service code!
Input code Description of display function Display values

0700 Function "Show stored faults“ activated Fault codes are displayed one after the other
0701 Function "Show stored faults“ deactivated 0000
0710 Delete stored faults once the fault log is deleted it is returned to 0000
12.2 Value displays
12.2.1 General
BOMAG
0555 Display of "machine control software version ( ESX)" e.g.: "1.13" for software version V 1.13
0556 Display of Firmware version "LCD Display" e.g. "1.36" for version 1.36
0557 Display of Firmware version "Data Collector" e.g. "1.11" for version 1.11
0720 Display of "Machine Code" The machine code is displayed (72xx) (see chapt. 3.6)
12.2.2 Brake
1001 Display of voltage at control output "Valve Brake" Display in V (e.g. 12.6 corresponds with 12,6V)
Version/Status: V3.29 / 13.11.07 Description of Control Input Codes Page 65 of 84

9.1
245
246
9.1
12.2.3 Travel lever / driving

1020 Display "Travel lever end positions" 100 = Forward
0 = Neutral
10 = Reverse
1000 = Left
10000 = Right
Combinations are possible, e.g. 1100 for forward
1021 Display "Values for axle forward reverse" 0..1000 = Forward
0..-1000 = Reverse
1022 Display "Values for axle right left" left -> - 1000..0..1000 -> right, i.e. brake gate
1025 Display "Travel lever actuating direction" 100 = Forward
0 = Neutral
1 = Reverse
1026 Display "Travel direction" 0 = Neutral
1 = Forward
2 = Reverse
BOMAG
1027 Display "Travel lever release" 0 = locked
1 = released
12.2.4 Travel speed range selector switch

1040 Display "Speed range / gear" Position of travel range selector switch from 1...24
1041 Display "Voltage value for speed range / gear" Stages 0..0.4 = 4
Stages 5..0.9 = 3
Stages 10..0.14 = 2
Stages 15..0.19 = 1
Stages 20...24 = 0

008 911 71
008 911 71
1042 Display "Voltage value for speed range / gear standardized" Stage 1 956 Stage 2 916 Stage 3 875
Stage 4 835 Stage 5 795 Stage 6 756

1044 Display "Speed range / gear" end value Stage 1 = 417 Stage 2 = 833 Stage 3 = 1‘250
Stage 4 = 1‘667 Stage 5 = 2‘089 Stage 6 = 2‘500
12.2.5 Travel pump: Travel direction forward
BOMAG
1070 Display "Actual current value travel pump forward" Display in mA (0..350..1300)
1071 Display "Nominal current value travel pump forward" Display in mA (0..350..1300)
1078 Initial current value (learned surge current) of the valve Display in mA (permitted range 350mA..600mA)
1079 Maximum current value (derived end current) of the valve Display in mA (permitted range 1,150mA.0.1400mA)
12.2.6 Travel pump: Travel direction reverse

1080 Display "Actual current value travel pump reverse" Display in mA (0.0.400..1300)
1081 Display "Nominal current value travel pump reverse" Display in mA (0.0.400..1300)
1088 Initial current value (learned surge current) of the valve Display in mA (permitted range 350mA..600mA)
1089 Maximum current value (derived end current) of the valve Display in mA (permitted range 1,150mA.0.1400mA)

9.1
247
248
9.1
12.2.7 Travel motor front (drum)

1100 Actual coil current Display in mA (0.0.600.0.1000)
1101 Coil current Nominal value Display in mA (0.0.600.0.1000)
1105 Travel speed Display in m/min
1106 Pulses of speed sensor Counts the pulses up to 99‘999 and starts again at 0
1107 Direction signal of speed sensor 2 = Forward
1 = Standstill and reverse
1108 Travel direction logics 1 = Forward
0 = Standstill
2 = Reverse
12.2.8 Travel motor rear (wheel axle)

1110 Actual coil current Display in mA (600..1000)
1111 Coil current Nominal value Display in mA (600..1000)
1115
BOMAG
Travel speed Display in m/min
1116 Pulses of speed sensor Counts the pulses up to 99‘999 and starts again at 0
1117 Direction signal of speed sensor 2 = Forward
1 = Standstill and reverse
1118 Travel direction logics 1 = Forward
0 = Standstill
2 = Reverse
12.2.9 Shut-down of drives1

1120 Enable shut-down (force max. displacement)
1121 Drum drive
1122 Wheel drive
1
Settings will not be saved. After shutting down the machine all drives are engaged again!

008 911 71
008 911 71
12.2.10 Adaptation values for speed regulation
1128 Pre-control factor forward travel 7000..10000
1129 Pre-control factor reverse travel 7000..10000
12.2.11 Travel pressure sensor


1140 Pressure in bar 0..600
1141 Raw measuring value (voltage in V) 0.0.5V
1142 Standardized measuring value 0..1000
1143 Function status (internal logic -> diagnose) 0, 1, 2
12.2.12 Inclination sensor

1145 Standardized measuring value –1000..0..1000. (0 = 0%)
1146 Raw measuring value (voltage in V) 0..8,5V (-> 0..1000)
1147 Standardized measuring tube value 0..8,5V = 0..1000
BOMAG
1148 Function status (internal logic -> diagnose) 0=Not initialized, 1=Normal operation, 2=Fault
12.2.13 Travel condition values

1150 Current travel speed (in km/h) 0,00..20,00

9.1
249
250
9.1
12.2.14 Calibrating the wheel diameter

See 4.9 Calibrating the speed detection
1160 Activate the function
1161 Travel a distance of 5m
1168 Setting of standard values
1169 Saving the measuring value.
Speed detection has been parameterized anew!
12.2.15 Speed limitation

1210 Current setting (in km/h) 0 = No limitation
BOMAG
6 = 6 Kmh
7 = 7 Kmh
8 = 8 Kmh
9 = 9 Kmh
10 = 10 Kmh
11 = 11 Kmh
12 = 12 Kmh
12.2.16 Arm rest contact

1300 Function status 1= arm rest up; 2= arm rest down
1301 Raw measuring value (voltage in V) Display in mV
1302 Travel operation status by arm rest contact 1= Driving permitted; 2= Driving disabled

008 911 71
008 911 71
12.2.17 Adoption values traction control
1500 Pre-control factor front 400..24000
1501 Pre-control factor rear 400..24000
12.2.18 Steering: Steering valve

2100 Display „Current setpoint right hand steering valve“ 0– 1200mA
2101 Display „Current actual value right hand steering valve“ Display in mA
2102 Display „Current setpoint left hand steering valve“ 0– 1200mA
2103 Display „Current actual value left hand steering valve“ Display in mA
2106 Display "Current min value (surge current) left hand steering valve" Display in mA
2107 Display „Current max value left hand steering valve“ Display in mA
2108 Display "Current min value (surge current) right hand steering valve" Display in mA
2109 Display „Current max value right hand steering valve“ Display in mA
BOMAG
12.2.19 Steering: Angle sensor in articulated joint
2110 Raw measuring value (voltage in V) 0...8,5VDC
- Middle position approx. 4,5V
- Steering left = lower voltage (approx. 2V..4,5V)
- Steering right = lower voltage (approx. 4,5V..4.7V)
2111 Standardized measuring value 0...1000 (left= high value (approx. 750), right = low value (ap-
prox. 220)
2112 Standardized actual steering angle position -1000...0...1000 (left = negative value, right positive value)

9.1
251
252
9.1
12.2.20 Steering: Steering wheel

2120 Standardized nominal steering angle position -1000...0...1000
2130 Steering wheel sensor 1 track 1 absolute pulses Number of total pulses
2132 Steering wheel sensor 1 total pulses of sensor
2133 Steering wheel sensor 1 sense of rotation 1=steering wheel steers to the right (clockwise); 2=steering
wheel steers to the left
2142 Steering wheel sensor 2 total pulses of sensor
2143 Steering wheel sensor 2 sense of rotation 1=steering wheel steers to the right (clockwise); 2=steering
wheel steers to the left
12.2.21 Vibration
BOMAG
3000 Display "Switch for vibration mode" Value DH4 BVC _
0 off off
1 low amplitude on
2 high amplitude ---
3001 Display "Status of vibration relay“ 0 = Relay K43 not switched
1 = Relay K43 switched
12.2.22 Vibration (up to version 3.24 )

3002 Display "Vibration pump valve current" Display value = mA
The display shows the actual pump current.
3003 Display "Vibration pump valve current" (high amplitude on DH) Display value = mA
3004 Actual working frequency (low amplitude on DH) Display value = Hz
3005 Actual working frequency (high amplitude on DH) Display value = Hz
3006 Actual control factor (low amplitude on DH) 2000 – 8000 (machine type dependent)

008 911 71
008 911 71
3007 Actual control factor (high amplitude on DH) 2000 – 8000 (machine type dependent)
3009 Actual Vario status (only BVC) -1 ... 7
Vibration control; Vario and low amplitude circular exciter (from version 3.25 )
3002 Display "Vibration pump valve current" (low amplitude on DH) Display value = mA

3003 Display "Vibration pump nominal valve current" (low amplitude on DH) Display value = mA
The display shows the nominal pump current.
3004 Actual working frequency (low amplitude on DH) Display value = Hz
3006 Actual control factor for frequency controller (low amplitude on DH) 2000 – 8000 (machine type dependent)
3007 Actual control factor valve flow controller (high amplitude on DH) 2000 – 8000 (machine type dependent)
3008 Actual fault counter valve flow controller (high amplitude on DH) 1000
Vibration control; high amplitude circular exciter (from version 3.25 )

BOMAG
3012 Display "Vibration pump valve current" Display value = mA
3013 Display "Vibration pump nominal valve current" Display value = mA
The display shows the nominal pump current.
3014 Current working frequency Display value = Hz
3016 Current control factor frequency controller 2000 – 8000 (machine type dependent)
3017 Current control factor valve current controller 2000 – 8000 (machine type dependent)
3018 Current fault counter valve current controller 1000

3030 Vibration motor number of pulses per revolution (vibration motor type 30 ... 60
dependent)
(see 4.12 „Setting the vibration motor type“)

9.1
253
254
9.1
12.2.23 Attachment plates, option (only BW213 BVC)

3050 Display "Attachment plates activated" OFF, i.e. software for plates switched off
ON, i.e. software for plates switched on
3051 Display "Sensor for height shut-down" OFF = Sensor has switched, senses metal, plates raised
ON = Sensor has not switched, senses no metal, plates low-
ered
3052 Display "Sensor for middle position" OFF = Sensor has not switched, senses no metal
ON = Sensor has switched, senses metal, plates in middle
3053 Display "Logic vibration On-Off“ OFF = Vibration switched off

ON = Vibration switched on
3054 Display "Switch for float position" OFF = Switch switched off
ON = Switch switched on
Attention! Float position is not always activated when switch is
in ON-position!
3055 Display "Contact plates coupled" OFF = Plates are not hydraulically connected with the machine
BOMAG
ON = Plates are connected with the machine
3056 Display "Potentiometer value frequency setting of plates" 0..1000 standard, 0 = min. frequency, 1000 = max. frequency
3057 Control status valve "move up" OFF = Output not triggered
(Pin 5 DIOS module) ON = Output triggered
3058 Control status valve "move down" OFF = Output not triggered
3059 Control status valve "retract sideways" OFF = Output not triggered
3060 Control status valve "extend sideways" OFF = Output not triggered
3061 Control status valve "floating position" OFF = Output not triggered
(Pin 13 + 15 DIOS module) ON = Output triggered
3062 Control status valve "Priority change-over" OFF = Output not triggered

008 911 71
008 911 71
12.2.24 Engine
5000 Actual speed (rpm) 0..3000
5001 Nominal speed (rpm) 0..3000
5010 Idle speed (EMR parameter) (rpm) 600..1000
5011 Maximum speed (EMR parameter) (rpm) 1600..3000
5024 Display "Status engine coolant level" 0= Coolant level OK

1= Coolant level too low
5026 Display "Status engine air filter" 0= Air filter OK
1= Air filter soiled
5028 Display "Status of water separator" 0= Water separator OK
1= Water or dirt in fuel filter
5050 Charge air pressure (in bar * 100) 0..300 -> 0..3bar
BOMAG
12.2.25 Hydraulics
5502 Display "Status hydraulic oil filter" 0= Hydraulic oil filter OK
1= Hydraulic oil filter contaminated

9.1
255
256
9.1
12.3 Test settings
12.3.1 Brake
0500 Activates the function "Driving against the closed brake" 500 and brake control light stays on when shifting the travel
lever out of the brake gate
0501 Deactivates the function "Driving against the closed brake" O K for 3seconds, then 0000
12.3.2 Disable electric supply to wheel and drum drive motors (switch off)
1120 Enable function
1121 Switch off function "Disable electric supply for drum drive motor"
Motor valve not energized. The motor should now swash to max. dis-
placement position.
1122 Function "Disable electric supply for drum drive motor"
BOMAG
Motor valve not energized. The motor should now swash to max. dis-
placement position.
1123 Function "Switch of power supply for drum drive motor TOGETHER
WITH wheel drive motor"
Motor valves not energized. The motors should now swash to max.
displacement position.
1124 Switch off function "Disable electric supply for drum drive motor"
The motor valve is max. energized. The motor should now swash to
min. displacement position.
1125 Function "Disable electric supply for wheel drive motor"
The motor valve is max. energized. The motor should now swash to
min. displacement position.
1126 Function "Switch on power supply for drum drive motor TOGETHER
WITH wheel drive motor"
Motor valves max. energized. The motors should now swash to min.

008 911 71
008 911 71
12.4 Settings / Teach / Emergency functions
12.4.1 Changing the machine code

7010 Change "Machine code" see chapter "Change machine code"
12.4.2 Automatic detection of surge currents in travel system

1090 Activate the function see chapt. "Teach travel system surge currents"
1091 Function "Determine surge currents forward" (only Vers.1.07 and see chapt. "Teach travel system surge currents"
1.08)
1092 Function "Determine surge currents reverse" (only Vers.1.07 and see chapt. "Teach travel system surge currents"
1.08)
12.4.3 Speed detection, trimming of measuring values
BOMAG
1158 Enable function
1159 Activate the function Pulses per 10m. 4000 - 15000
12.4.4 Speed detection, teaching of distance pulses

1160 Permit teach function
1161 Activate the function: Measurement over a travel distance of 5m Pulses read
1168 Reset to basic values "saved"
1169 Storing the learned values "saved"

9.1
257
258
9.1
12.4.5 Detection of wheel rotation

1200 Permit teach function
1201 Teach sense of rotation1 Raise travel speed over 10m/min
1
Only optional function! The logical sense of rotation is automatically adjusted
BOMAG
008 911 71
008 911 71
12.4.6 Steering: Automatic detection of surge currents on steering valve
2000 Activate function "Teach steering start current" see chapter 0
2001 Function "Teach steering start current" see chapter 0
12.4.7 Steering: Determining the steering stops

2010 Activate function "Teach steering stops" see chapter 4.6
2011 Deactivate function "Teach steering stops" 0000
2012 Function "Accept right hand steering stop" see chapter 4.6
2013 Function "Accept left hand steering stop" see chapter 4.6
12.4.8 Steering: Emergency function

2050 Steering with joystick buttons "OK". In case of steering wheel failure
2051 Steering with steering wheel (uncontrolled) "OK". In case of steering angle potentiometer failure
BOMAG
12.4.9 Steering: Other functions
2060 Activates function „Change steering unit“ see chapter 4.5
2061 Activate: Electric steering unit see chapter 4.5
2062 Activate: Hydraulic steering unit see chapter 4.5
12.4.10 Setting the vibration motor type

3030 View current setting of pulse numbers see chapter 4.12
3031 Activate function „Adjust vibration motor type“ see chapter 4.12
3032..30 Select vibration motor type 1..8. see chapter 4.12
39 Follow the selection table in 4.12.

9.1
259
260
9.1
12.4.11 Vibration: Travel speed dependent vibration lock

3047 Enable function "Changeover of travel speed dependent vibration
lock"
3048 Activate vibration lock from travel speed stage 12
3049 Disable vibration lock.
12.4.12 Vibration: Enable frequency setting

3090 View the current setting. 0, 1
3091 Enable function "Switch over frequency setting".
3092 Activate frequency setting (machine with switch).
3093 Disable frequency setting (machine WITHOUT switch).
BOMAG
12.4.13 Attachment plates (only circular exciter): Activating/deactivating the attachment plates option
3070 Enable optional changeover.
3071 Activate option "attachment plates".
3072 Disable option "attachment plates".
3075 Code "Plate adjustment without sensors" Attention – danger of collision! Use only in case of a sensor
fault!
3076 Code "Plate pump energized without plates attached" Only for initial commissioning!
12.4.14 Plates: Preventing reversing with plates lowered

3077 Activate function "Prevent reversing with plates lowered"
3078 Allow reversing with plates lowered.
3079 Prevent reversing with plates lowered.

008 911 71
Service Training WZ – 4
13 Terminology in connection with ESX

Short circuit
A direct, unwanted connection between two different cables or between machine and ca-
bles.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
torn (not necessarily visible from outside)
rubbed through
chafed mostly in connection with a short circuit to ground
Terminal, cable lug

loosened, slipped off
broken off,
corroded,
socket / plug faulty
Version/Status: V3.29 / 13.11.07 Terminology Page 81 of 84

008 911 71 BOMAG 261

Short circuit to ground

Line, terminal has direct connection to vehicle ground, often in connection with wire break-
age
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital, many states are permitted within a certain range. E.g. room tempera-
ture 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 to 300 ; valve
0% to 100% opened (proportional valve)

262 BOMAG 008 911 71

Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Closed loop control

Closed loop control is a process during which a value, the closed loop control value (e.g.
pressure), is continually measured and compared with a nominal value (guide value). The
result of this comparison will affect the closed loop control value, thereby adapting the closed
loop control value to the guide value.
This sequence occurs in a closed circuit, the co-called closed loop control circuit.
Marking Closed loop control Control

Operating path: closed open
(closed loop control circuit) (control chain)
Measurement and Value to be adjusted is meas- Values to be controlled
comparison of value to ured and compared. are not measured and
be adjusted: compared.
Reaction to faults (ge- Counteracts to all faults tar- Does not respond to un-
nerally): geting the system to be con- known faults
trolled.
Technical expense: Low effort: High expense if many
Measurement of the value to faults have to be consid-
be controlled, comparison of ered, low expense if not
nominal and actual value, faults occur.
power amplification
Performance in For unstable systems closed In unstable systems con-
unstable systems loop controls must be used. trols cannot be used.

008 911 71 BOMAG 263

Current and voltage measurement
Ohm’s law:
U =R∗I
U = Voltage
R = Resistance U
I = Current
I=
R
U
R=
I
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position for-
ward and reverse will cause an fault message, because this condition is normally not possi-
ble.
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional ana-
logue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
PWM – digital output

Certain outputs on the ESX are designed as so-called PWM – digital outputs. This means
that these outputs are special current outputs. Here it is possible to measure a current, but
no voltage. These outputs are used to trigger proportional valves.

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008 911 71 BOMAG 265

266 BOMAG 008 911 71

008 911 71 BOMAG 267

268 BOMAG 008 911 71

9.2 Electrics BEM (BOMAG Evib-meter)
008 911 71 BOMAG 269

BOMAG Evib-meter (BEM)
i Hinweis
The documentation "Service Training Electrics MESX" contains also the documentation BEM (BOMAG Evib-me-
ter).
The BOP (BOMAG Operation Panel) is only installed in connection with BVC machines, BEM-machines are
equipped wit display module. The display module is used for the output of fault codes and display values, as
well as for the input of code numbers.
270 BOMAG 008 911 71

Electrics BEM (BOMAG Evib-meter) 9.2
Service Training
Electrics
MESX
008 097 05 Version 4.00
Status: 05.06.2007 Page 1 of 59

Author: T.Löw / TE
Dateiname: p:\schulung\elektrik\wz\mesx_bvc\englisch\schulung elektrik mesx_v4.00_gb.doc
008 911 71 BOMAG 271

Service Training MESX
Table of contents
1 Document alteration list.....................................................................................................................3
2 Proof of software change MESX .......................................................................................................4
3 Proof of software change BOP..........................................................................................................6
4 Known faults......................................................................................................................................7
5 How to proceed when replacing components?.................................................................................8
5.1 How to proceed when replacing an ESX control? .....................................................................8
5.2 How to proceed when replacing a rear axle sensor? ................................................................8
5.3 Which components can be replaced without a subsequent adjustment procedure? ................8
5.4 List of machine types .................................................................................................................9
6 Possible adjustments on machines without BOP ...........................................................................12
6.1 Description of the Display Module ...........................................................................................12
6.2 Input of code numbers .............................................................................................................12
6.3 Changing the machine type (only via display module) ............................................................13
6.4 Inverting the direction signal (only via display module) ...........................................................14
6.5 Changing the bit rate (only with display module).....................................................................15
7 Adjustment/display possibilities on machines with BOP.................................................................16
7.1 Adjusting the machine type (BOP)...........................................................................................16
7.2 Inverting the direction signal via the BOP control terminal ......................................................18
7.3 Accessing the diagnostics menu .............................................................................................20
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof) ................. 22
7.3.2 Extended diagnose BVC machines ......................................................................................... 23
7.4 Changing the printout language...............................................................................................24
7.5 Setting the machine serial number ..........................................................................................26
7.6 Teaching distance pulses ........................................................................................................28
7.7 Activating the amplitude limitation (only BVC machines) ........................................................30
7.8 Changing the display mode (metric/imperial) ..........................................................................32
7.9 Switching the GPS Receiver Voltage Supply Mode ................................................................34
8 Possible settings on the BCM05mobile ..........................................................................................36
8.1 Reading the software version ..................................................................................................36
8.2 Changing the language............................................................................................................36
8.3 Changing the unit system (metric/imperial) .............................................................................36
9 Block diagram BEM.........................................................................................................................37
10 Block diagram BTMplus / VARIOCONTROL...............................................................................38
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile................................................39
12 Description of the signals on the ESX-control .............................................................................40
13 Fault codes of the ESX control ....................................................................................................45
13.1 Overview...............................................................................................................................45
13.2 Description of fault reactions ................................................................................................46
13.3 Detailed description of fault codes and their possible causes ............................................47
14 Input codes for ESX control (only via BEM display module) .......................................................51
14.1 Travel system .......................................................................................................................51
14.2 Vibration ...............................................................................................................................52
14.3 Light......................................................................................................................................52
14.4 Acceleration transducer........................................................................................................53
14.5 Diesel engine........................................................................................................................53
14.6 Setting the machine type......................................................................................................54
14.7 Parameter change................................................................................................................55
15 Terminology in connection with ESX...........................................................................................56
Status:05.06.2007 Page 2 of 59
Author: T.Löw / TE
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1 Document alteration list
Version Date Description of changes resp.

0.00 27.04.2004 Creation of version 1 Löw
1.00 05.05.2004 Î Block diagrams added Löw
Î Description of display module extended
Î "Proof of software change" added
1.01 23.07.2004 Î Description of BOP display pages added. Löw
2.00 31.08.04 Î Input code 4602 replaced by code 4606 Löw
Î Machine type BW219D added
3.00 15.10.2004 Î Item "How to proceed when replacing components?" added Löw
Î Description for ESX Pin 0:35 added
Î Description fault code 4601 and 4606 corrected
Î Description Software Version 3.00 added
3.01 14.02.2005 Î Description Code 7534 from version 3.00 added Löw,
Î Description Software change V3.01 added Horch
Î Description Code 7573 from version 3.01 added
Î Description of menus "Amplitude limitation" and "Imperial
display" added
Î Description Software Version up to 3.03 added
Î Terminal designation MESX changed from X0 to X44
Î Description of codes 7502, 7511, 7512, 7532, 7541, 7542,
7550, 7551, 7552, 7562, 7571, 7572, 7576 from version 3.03
added
Î Proof of "Software change" changed to "Software MESX"
Î Item "Proof of software change BOP" added
Î Item "Adjustment possibilities on BCM05mobile" added
Î Block diagram BTMplus / VARIOCONTROL and
BCM05mobile added
Î Serial numbers added to list of machine types
4.00 01.05.2007 Î Description of "GPS Mode" menu added Löw
Î Item "Change language" changed for BCM 05
Î Description fault code 4531 and 4532 extended
Î List of machine types extended
Author: T.Löw / TE
008 911 71 BOMAG 273

2 Proof of software change MESX

1.00 25.03.2004 Creation of version 1.00 Löw
1.01 05.04.2004 Î Printout modified Löw
Î Amplitude limitation for Automatic changed to 0.3 mm
Î Default setting in Automatic changed to "MAX"
1.02 13.04.2004 Î BW213 BVC implemented Löw
Î Printer control modified (Xon, Xoff protocol)
Î Software version and revision documented in printout
Î Finished criterion extended (weak spots of 2 m are tested)
Î Bmfsa code input for DH machines modified
1.03 05.05.2004 Î Learning mode for travel distance modified (value range Löw
check)
Î Finished criterion for polygonal drum deactivated
Î 2-stage jump information implemented
Î Self-latching of control during shut-down implemented
Î Saving of current adjustment values during shut-down
implemented.
Î Bmfsa code input for DH machines modified
Î BW211 D, BW213 D and BW213 DH implemented
Î Query for software version of BOP implemented
1.04 16.04.2004 Î BW226 BVC Polygon implemented Löw
Î Max. adjustment angle limited to 80°
Î Max. valve current for BW177 limited to 1000mA
1.05 26.07.2004 Î BW219DH and BW213 BVC Polygon implemented Löw
Î Termination criteria for while loops incorporated into Evib
calculation
2.00 31.08.2004 Î Number of machine variants extended to 25 (BW219D) Löw
Î Problem with sporadic SW crash eliminated
3.00 15.10.2004 Î Distance pulse changed to 10m for BW226 Löw
Î Amplitude limitation realized in automatic mode
Î Simulation mode realized
Î Changeover metric/imperial realized
Î minimum required BOP version changed to 3.00 (always
the same version as MESX)
3.01 16.11.2004 Î The ESC-key does not abort the printout, it only resets the Löw
measurement
Î Machine variant BW226BVC added
3.02 01.12.2004 Î Machine type BW216D activated Löw
Î Completion report for BW226BVC with smooth drum
activated
3.03 14.02.2005 Î Designation on printout modified (RC; DI) Löw
Î Default setting for amplitude limitation set to "inactive".
Î Machine types 177PDH, 179DH, 179PDH, 213PDH,
214DH, 214PDH 216D, 216DH,216PDH, 219PDH, 226DH,
226PDH, 226BVC RC" enabled.
Î Controller settings for BW213BVC and BW226BVC
optimized with respect to pressure peaks
Î Minimum speed for swivelling of of exciter changed to 0.18
km/h => Build-up of the machine with vibration at standstill
is thereby avoided
3.04 10.05.2005 Î Vibration detection for BW177DH/PDH and BW179DH/PDH Löw

corrected
3.05 19.05.2005 Î Phase response correction acceleration transducer Löw
activated
Î "Flash Request" activated
Author: T.Löw / TE
274 BOMAG 008 911 71


4.00 01.05.2005 Î Languages Slovakian, Slovenian, Czech, Romanian added Löw
Î Function "vCheckMMISoftwareVersion" corrected
Î Teach mode for distance via BCM implemented
Î Triggering of a relay for GPS receiver voltage supply
implemented
Î GPS mode changed: Off and ON now independent from
engine run, Automatic depending on engine run!
Î Setting of work number in serial number has been realized
Î ATTENTION: Signal distribution for CAN message
MMI_CONFIG_DATA_2 0x156 was changed!!!
Î new machine types:211PD, 213PD, 216PD, 219PD + "low
cost" designs:
177D40,1777DHC,177D_40,177DHC,177PDHC,177PDH_
40,179DHC,179PDHC,211D_40,211PD_40,213D_40,213D
HC,213PDHC,213PD_40,214DHC,214PDHC,216DHC,216
PDHC,212D_40,212PD_40
Î Pulse numbers changed to 10m for BW219D
Î VM classes taken from V3.90, VM class is sent to BCM
Author: T.Löw / TE
008 911 71 BOMAG 275

3 Proof of software change BOP

1.00 25.03.2004 first software version for series production Löw
1.01 13.04.2004 Revision of BVC diagnostics screen Löw
1.02 23.04.2004 2-stage jump information (yellow and red) Löw
3.00 15.10.2004 Î Realization of imperial display Löw

Î Simulation mode implemented on BOP
Î New TN 582 701 92
3.01 24.1.2005 Î Part-No. changed to 58 701 93 Löw

Î Designation "ESX" replaced by "MESX" and "BOP" by
"BOP"
3.02 10.02.2005 Î Amplitude bar graph in imperial display mode corrected Löw
4.00 01.05.2007 Î Flags for all EU-languages and additionally Japan and Löw
China stored in OPUS
Î Page for changing over GPS Receiver Mode implemented
Î Triggering for fault LED in BVC diagnostics page 2
activated
Author: T.Löw / TE
276 BOMAG 008 911 71

4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Behaviour of machine Possible cause
During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kbit
reading "ct0" => see "Setting the bit rate"
Author: T.Löw / TE
008 911 71 BOMAG 277

5 How to proceed when replacing components?

Each machine is adjusted individually during initial commissioning. This is mainly accomplished by
setting the correct machine type (see "5.4 List of machine types", or "7.1 Adjusting the machine type
(BOP)").
The following chapter describes the necessary adjustments to the control when replacing individual
components in the measuring system.
5.1 How to proceed when replacing an ESX control?
Attention: A machine must not be operated with a wrong type setting,

because in such a case the correct function of the control cannot
be assured!
You should therefore set the machine type first! see "5.4 List of
machine types, or "7.1 Adjusting the machine type (BOP)").
After setting the machine type check the following items:
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
Set the machine serial number (only on machines with BOP), see: 7.5
Set the printer language (only machines with printer), see: 7.4
5.2 How to proceed when replacing a rear axle sensor?
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
5.3 Which components can be replaced without a subsequent

adjustment procedure?
BOP
Acceleration transducer
Valve block for exciter adjustment
Printer
Bmfsa display module
All switches in the dashboard
Note: A final function test of the complete machine is highly

recommended.
Author: T.Löw / TE
278 BOMAG 008 911 71

5.4 List of machine types

Since the same control is used for all single drum rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
type adjustment is necessary, because the machines have e.g. different axle loads or different drum
widths, which requires the calculation of measuring values to be adapted. The adjustment procedure
is described under items "6.3 Changing the machine type (only via display module)" or "7.1 Adjusting
the machine type (BOP)".
The following machine types can be adjusted:
Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
211 D 101 582 40 1001 XXX XXX XX XXXX 7520 1.03
101 582 41 1001
101 583 09 1001
211 PD 101 582 45 1001 XXX XXX XX XXXX 7529 4.00
101 583 10 1001
213 D 101 582 50 1001 XXX XXX XX XXXX 7530 1.03
101 583 08 1001
213 DH 101 582 51 1001 XXX XXX XX XXXX 7531 1.03
101 583 14 1001
213 PD 101 582 46 1001 XXX XXX XX XXXX 7539 4.00
101 583 13 1001
101 583 16 1001
213 BVC plates 101 582 54 1001 XXX XXX XX XXXX 7534 3.00
101 583 06 1001
213 BVC DI 101 582 53 1001 XXX XXX XX XXXX 7535 1.05
101 583 16 1001
214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03
101 583 19 1001
101 583 20 1001
216 D 101 582 62 1001 XXX XXX XX XXXX 7550 3.03
101 583 23 1001
216 DH 101 582 60 1001 XXX XXX XX XXXX 7551 3.03
101 582 64 1001
216 PD 101 582 63 1001 XXX XXX XX XXXX 7559 4.00
101 583 24 1001
101 582 65 1001
219 D 101 582 72 1001 XXX XXX XX XXXX 7560 2.00
101 582 10 1001
219 DH 101 582 70 1001 XXX XXX XX XXXX 7561 1.05
101 582 77 1001
219 PD 101 582 73 1001 XXX XXX XX XXXX 7569 4.00
101 582 11 1001
101 582 78 1001
Author: T.Löw / TE
008 911 71 BOMAG 279

version
226 DH 101 582 80 1001 XXX XXX XX XXXX 7571 3.03
101 582 83 1001
101 582 88 1001
101 582 84 1001
101 582 89 1001
101 582 85 1001
101 582 86 1001
226 BVC DI 101 582 82 1001 XXX XXX XX XXXX 7575 1.04
101 582 85 1001
101 582 86 1001
226 BVC RC 101 582 82 1001 XXX XXX XX XXXX 7576 3.03
101 582 85 1001
101 582 86 1001
version
VARIOCONTROL 101 582 12 1001 XXX XXX XX XXXX 7537 4.00
VARIOCONTROL+ 101 582 13 1001 XXX XXX XX XXXX 7538 4.00
version
177 D-40 101 582 26 1001 XXX XXX XX XXXX 7600 4.00
177 DH-40 101 582 27 1001
177 DHC-4 101 582 00 1001 XXX XXX XX XXXX 7601 4.00
177 PDHC-4 101 582 01 1001 XXX XXX XX XXXX 7602 4.00
211 D-40 101 583 02 1001 XXX XXX XX XXXX 7620 4.00
101 583 25 1001
211 PD-40 101 583 03 1001 XXX XXX XX XXXX 7629 4.00
101 583 26 1001
212 D-40 101 582 43 1001 XXX XXX XX XXXX 7680 4.00
212 PD-40 101 583 48 1001 XXX XXX XX XXXX 7689 4.00
213 D-40 101 582 44 1001 XXX XXX XX XXXX 7630 4.00
101 582 55 1001
101 583 07 1001
213 DH-40 101 582 56 1001
101 583 11 1001
101 583 12 1001
213 PD-40 101 582 49 1001 XXX XXX XX XXXX 7639 4.00
213 PDH-40 101 582 57 1001
101 583 17 1001
101 583 18 1001
101 583 21 1001
Status:05.06.2007 Page 10 of 59
Author: T.Löw / TE
280 BOMAG 008 911 71

101 583 22 1001
Status:05.06.2007 Page 11 of 59
Author: T.Löw / TE
008 911 71 BOMAG 281

6 Possible adjustments on machines without BOP
6.1 Description of the Display Module
Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP the settings are made via the BOP!
(See item 7 "Adjustment/display possibilities on machines with BOP")
The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.
Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 …9 9 9 9 are possible. Higher
values lead to the display "- - - - ", negative values are indicated by the "minus dot" lighting up (see
illustration).
sign
057 667 72
15/54
The following description describes the input of code numbers.
6.2 Input of code numbers

For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
)The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
1. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure 9
is displayed and the left hand key (F1) is pressed again, the display will return to the value .
2. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.
Status: 05.06.2007 Functions of the ESX control Page 12 of 59

Author: T.Löw / TE
282 BOMAG 008 911 71

6.3 Changing the machine type (only via display module)

For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module of the central electrics when switching the ignition on. It can also be checked at any
time by entering code 7000.
Setting the machine type requires the following sequence:
Note: Parameter adjustments can only be performed when the engine is not running!
Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type".
Select and enter the machine from the table above.
The display module now permanently shows the entered code. (e.g. 7 5 3 3 )
Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control initiates a restart, the display module shows the new
machine type for approx. 3 seconds.
After this the newly adjusted machine type will be displayed for approx. 3 seconds.
Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!
New controls are delivered with the default machine type setting 7 5 0 0 .

Author: T.Löw / TE
008 911 71 BOMAG 283

6.4 Inverting the direction signal (only via display module)

Depending on the installation position, the axle sensor used delivers a 12 V output signal in forward and
reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.
Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.
Enter code number 7 6 0 1 . This code number inverts the direction signal.
The display module now permanently shows the code 0 0 0 1 (signal inverted), or the code 0 0 0 0
(signal not inverted).
In succession the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 14 "Input codes for ESX control").

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6.5 Changing the bit rate (only with display module)

The multi-function display can be operated with different CAN transmission speeds. For operation in
our machines the bit rate must be set to 125 kBit/s. The bit rate is changed as follows:
Hold both keys (F1 and F2) of the multi-function display depressed and switch on the ignition.
) The currently set bit rate is displayed, e.g. 0 1 0 0 .
The bit rate can now be changed in fixed steps by pressing the right hand key (F2). Hold the key
depressed until the display reads 0 1 2 5 .
By pressing the left hand key (F1) the bit rate is accepted and the display changes back to the
normal display mode.

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7 Adjustment/display possibilities on machines with BOP
7.1 Adjusting the machine type (BOP)

Setting the machine type requires the following sequence:
Press key "?" to open the screen page "MENU". The following screen is displayed:
Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:

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The desired machine type can be selected by pressing the keys "F11" and "F12". (see "List of
machine types" under item "Item 5.4 "List of machine types" ).
After selecting the desired machine type press key "F14", until the symbol (F14) lights green for
confirmation (approx. 4s).
When releasing the key the start screen will automatically be displayed and the control will initiate a restart.
BOP and MESX are now adjusted to the new machine type.

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7.2 Inverting the direction signal via the BOP control terminal
Depending on the installation position, the axle sensor used delivers a 12V output signal in forward
and reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the travel direction correspond with the actual travel direction.
Press key "F1" to open the screen page "Invert direction signal". The following screen is
displayed:

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The direction signal can now be inverted or not inverted by pressing key "F5" ("Invert = 1" or
"Invert = 0").
After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
Press "ESC" to leave the page.
Check on the printout or in the diagnostics menu whether the travel direction has been correctly detected.

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7.3 Accessing the diagnostics menu

Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:

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If an actual error is present the corresponding error code will be displayed in the field "Actual Errors".
By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see
below).

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7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,

BTMprof)
4.23 V Ubv: actual voltage front acceleration transducer
4.24 V Ubh: actual voltage rear acceleration transducer
98 % Small Ampl: Triggering of solenoid valve for low amplitude in percent
0 % Big Ampl: Triggering of solenoid valve for high amplitude in percent
Direction: Status MESX input travel direction (LED on = 12 V)
Lights: Status MESX input light detection (LED on = 12 V)
MD+ Status MESX input MD+ (detection engine running) (LED on = 12 V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses detected by the MESX (10 cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

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7.3.2 Extended diagnose BVC machines
4.25 V Uexciter: actual voltage of exciter position potentiometer
4.23 V Ubv: actual voltage front acceleration transducer
4.24 V Ubh: actual voltage rear acceleration transducer
98 % Ampl: Triggering of solenoid valve for vibration valve in percent
Direction: Status MESX input travel direction (LED on = 12 V)
Lights: Status MESX input light detection (LED on = 12 V)
MD+ Status MESX input MD+ (detection engine running) (LED on = 12 V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses detected by the MESX (10 cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

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7.4 Changing the printout language

Press key "F6" to open the screen page "Printout language". The following screen is displayed:

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The desired printout language can be selected by pressing the keys "F11" and "F12".
After selecting the desired language press key "F14" to save the setting. The symbol (F14) lights
green for a moment as a sign of confirmation.

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7.5 Setting the machine serial number

Press key "F7" to open the screen page "Serial number". The following screen is displayed:

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The desired printout language can be selected by pressing the keys "F11" and "F12".
After the adjustment press key"F14" to save the setting. The symbol (F14) lights green for a

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7.6 Teaching distance pulses

The distance pulses for the different machine types are already set by default after adjusting the
correct machine type. However, due to slippage on the rear axle the recorded distance measurement
may deviate from the actually travelled distance. In this case the distances pulses can be adjusted
accordingly.
Note: An adaptation of the distance pulses is only possible within a range of +/- 10%
of the preset value.
Press key "F8" to open the screen page "Distance pulses". The following screen is displayed:

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Pressing the key "F5" starts the teach mode. The following symbol appears:
Drive a distance of 10 m length in forward and press the key "F6" at the end. The following symbol
appears:
After the end of the measuring travel press key "F14" to save the adjustment. The following
symbol appears:
Note: If the following symbol is displayed after the end of the travel distance the
measured distance pulses are not in the range of +/- 10% of the preset value.
Saving is in this case not possible! The measurement must be repeated!

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7.7 Activating the amplitude limitation (only BVC machines)

Press key "F3" to open the screen page "Amplitude limitation". The following screen is displayed:

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The limitation can now be activated or deactivated by pressing key "F5" ("Limit = 1" or "Limit = 0").

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7.8 Changing the display mode (metric/imperial)

Press key "F4" to open the screen page "Display mode". The following screen is displayed:

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The imperial display (mph, °F, etc.) can now be activated or deactivated by pressing key "F5"
("Imperial = 1" or "Imperial = 0").

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7.9 Switching the GPS Receiver Voltage Supply Mode

Press key "F14" to open the screen page "GPS Mode". The following screen is displayed:

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This function enables the GPS Receiver Power Supply to be controlled via MESX, so that the receiver
can be switched on and off in a defined way.
The GPS Mode can now be changed over by pressing the "F5"-key:
"0" OFF GPS Receiver always switched off

"1" ON GPS Receiver switched on as soon as the ignition is switched on.
"2" AUTO GPS Receiver switched on as soon as the BCM transmits data to MESX

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8 Possible settings on the BCM05mobile

Insert the BCM05mobile into the holder and close the clamp. Switch on the ignition and subsequently
the BCM05mobile by holding the yellow switch on the right depressed for approx. 1-2 seconds; wait
and confirm the time dialog.
For functions beyond the following description, please refer to the BCM05 user manual.
8.1 Reading the software version

Select "Configuration" at the right hand edge of the window.
The software currently installed in the BCM05mobile is displayed at the top left under the name BOMAG.
8.2 Changing the language
Note: This function is only available from software version 1.37!
Select "Configuration" at the right hand edge of the window.

Press the field "Language". A list with the available languages pops up. Choose the desired language
and confirm with "Select".
8.3 Changing the unit system (metric/imperial)

Open the service window: press the top switch of the three switches at the right hand edge of the
touch screen "Configuration" for about 5 seconds, until a roller symbol appears under the software
version number at the left hand side of the display. Release the "Configuration" switch and press the
symbol within 3 seconds. The touch screens now shows 4 switches near the right hand edge and
select the bottom switch "Service".
Note: After this setting the service window must be closed to avoid unauthorized
access. Press "Close window" at the bottom right in the service window.
Shift the switch in the "Unit" field to the desired position.

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Service Training MESX Block diagram
008 911 71
9 Block diagram BEM
Electrics BEM (BOMAG Evib-meter)
BOMAG
commande
Status: 05.06.2007 Block diagram Page 37 of 59

Author: T. Löw / TE
9.2
307
308
9.2
10 Block diagram BTMplus / VARIOCONTROL
printer
BOMAG
commande

008 911 71
008 911 71
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile
BCM 05
(mobile device
with card reader)

USB CAN
interface
BOMAG
Printer
commandes

9.2
309
310
9.2
Service Training MESX Description of signals
12 Description of the signals on the ESX-control

Notes:
1. Wherever the value of 12 V is mentioned in the following text, it refers to the current battery
voltage under due consideration of voltage drops in the lines.

X44:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X44:2
X44:3 Output Evib Display PWM signal (100Hz): ) approx. 0..6 V

PWM (max. 2.5 A)
X44:4 Interface RS 232 RxD, used for printer control. Measurement not possible!
X44:5 Interface RS 232 TxD, used for printer control. Measurement not possible!
X44:6
BOMAG
X44:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
Open circuit voltage (vibration off): ) 4,2..4,3 V

Analogue input / voltage input 0..8,5 V
X44:8
X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analogue input / voltage input 0..8,5 V Bottom stop ) approx. 2,2 V
Neutral position ) approx. 4,25 V
Top stop ) approx. 6,6 V
Status: 05.06.2007 Description of signals Page 40 of 59

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X44:10
X44:11
X44:12
X44:13
X44:14
X44:15 Input vibration 1 On Vibration on: ) >6V

Digital input active high Vibration off: )approx.0 V
X44:16 Input button START (option) Button depressed: ) 12 V

Digital input active high Button not depressed ) 2V
X44:17 Input button STOP (option) Button depressed: ) 12 V
X44:18 Input button PRINT (option) Button depressed: ) 12 V
BOMAG
X44:19 Input button CLEAR (option) Button depressed: ) 12 V
X44:20
X44:21
X44:22
X44:23 Output voltage supply for sensors Nominal voltage = 8,5 V

This output supplies steering joystick, travel speed range switch, etc. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override mode (emergency function).
X44:24

9.2
311
312
9.2

X44:25
X44:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:28 Input potential terminal 15 Control switched on ) 12 V

Digital input active high Control switched off ) approx.2 V
This signal must be present, so that the control can work.
X44:29 Input acceleration transducer VV/VL15g Acceleration signal (measured against AGND)

X44:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)
BOMAG
X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

X44:32
X44:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X44:34
X44:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on
machine type.

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X44:36
X44:37 Input D+ generator Engine running / engine is started ) 12 V

Digital input active high Engine stopped ) 0V
X44:38 Input vibration 2 On Vibration on: ) >6V
Digital input active high Vibration off: ) approx.0 V
X44:39
X44:40
X44:41
X44:42
X44:43
X44:44
BOMAG
X44:45
X44:46 Output valve 1 front permissible current range: approx. 0..1,5 A

PWM digital output (max. 4 A)
X44:47 Output valve 2 front permissible current range: approx. 0..1,5 A
PWM digital output (max. 4 A)
X44:48
X44:49
X44:50
X44:51
X44:52

9.2
313
314
9.2

X44:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. Measurement not possible!
X44:54 Voltage supply for electronics Emergency stop not actuated ) 12 V
Emergency stop actuated ) 0V
X44:55 Ground connection electronics 0 V measured against ground
X44:56 Voltage supply for outputs approx. 12 V measured against ground
X44:61
BOMAG
X44:62
X44:63
X44:64
X44:65 Mouse port Baby Boards approx. 0 V

008 911 71
Service Training Fault codes of the ESX control
13 Fault codes of the ESX control
13.1 Overview
Fault code Fault description

4501 - Position controller (exciter potentiometer, valves)
4540
4601 - Acceleration transducer
4620
8000 - Internal software errors
8250
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316
9.2
Service Training MESX Description of fault codes of the ESX control
13.2 Description of fault reactions
Fault reaction Description of fault reaction

1 Warning.
Signal light in BOP (option) lights in 5 second intervals.
2 Function affected, the faulty function is replaced by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
BOMAG
) the diesel engine is shut down.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
Error code is displayed.
Signal light in BOP (option) lights permanently.
Note: Errors with error reaction 1 are only warning messages and are NOT stored in the error log!
Status: 05.06.2007 Fault Code Description ESX Control Page 46 of 59

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13.3 Detailed description of fault codes and their possible causes
Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
4 5 0 1 Input exciter potentiometer front ) Wire breakage in current path X44:09 5
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse FM ? has tripped or wire breakage in voltage supply
current path
) Potentiometer defective
4 5 0 2 Input exciter potentiometer front ) Current path has connection to +12 V / +8,5 V X44:09 5
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective
BOMAG
9.2
317
318
9.2

diagnose
4 5 2 1 Output proportional solenoid front ) Current path has short circuit to voltage supply X44:46 2
Valve for exciter up ) Current path has non-permitted connection to another current
Output current too low. path
) Current path is interrupted
4 5 2 2 Output proportional solenoid front ) Current path has short circuit to ground X44:46 2
Valve for exciter up ) Current path has non-permitted connection to another current
Output current too high. path
4 5 2 3 Output proportional solenoid front ) Current path is interrupted X44:46 2

Valve for exciter up ) Current path has impermissible connection to another current
Fault when calibrating the valve path / ground
4 5 2 6 Output proportional solenoid front ) Current path has short circuit to voltage supply X44:47 2
Valve for exciter down ) Current path has non-permitted connection to another current
BOMAG
Output current too low. path
) Current path is interrupted
4 5 2 7 Output proportional solenoid front ) Current path has short circuit to ground X44:47 2
Valve for exciter down ) Current path has non-permitted connection to another current
Output current too high. path
4 5 2 8 Output proportional solenoid front ) Current path is interrupted X44:47 2

Valve for exciter down ) Current path has impermissible connection to another current
Fault when calibrating the valve path / ground

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diagnose
4 5 3 1 Position controller positive limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low
4 5 3 2 Position controller negative limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low
4 6 0 1 Input acceleration transducer 1 ) Current path has no connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X44:31
BOMAG
4 6 0 2 Input acceleration transducer 1 ) Current path has connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is above the ) Current path not connected to ground or
4 6 0 6 Input acceleration transducer 2 ) Current path has no connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is below the ) Current path connected to ground or
4 6 0 7 Input acceleration transducer 2 ) Current path has connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is above the ) Current path not connected to ground or

9.2
319
320
9.2

diagnose
8 0 0 0 Error message "Incorrect BOP Software - - 2
version" The software version of the BOP is too
old, i.e. various functions cannot be displayed.
This fault cannot be repaired on the machine.
The BOP needs to be replaced.
8 0 0 1 Fault message "severe software fault in control" - - - 5
- This fault cannot be repaired on the machine.
8 9 9 9 The control must be immediately replaced.
9 0 0 0 Error message "Communication via CAN bus ) Wire breakage in CAN bus lines X44:26 - 2
- disturbed" ) Short circuit between CAN bus lines X44:27-
9 1 9 9 The modules controlled via the CAN bus cannot ) One or both CAN bus line(s) has (have) connection to 12V or
be addressed by the main control (ESX). The ground
respective machine functions are not available
9 2 0 0 Fault message "Severe internal fault in control" - - - 5
BOMAG
- The control has automatically switched off. This
9 9 9 9 fault cannot be rectified on the machine. The
control must be immediately replaced.
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X44:26 - -
control. ) Short circuit between CAN bus lines X44:27
) One or both CAN bus line(s) has (have) connection to 12V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)

008 911 71
Service Training MESX Description of Control Input Codes
008 911 71
14 Input codes for ESX control (only via BEM display module)
14.1 Travel system

1000 Transducer for travel direction 0000 ) 0V
Show status of transducer. 0001 ) 12 V
1001 Travel direction 1000 ) Forward travel detected

Displays the travel direction derived by the control from the 0000 ) Neutral position
"transducer for travel direction". 000I ) Reverse travel detected
1002 Transducer for distance pulses Display value = travel distance in 10 cm

The distances pulses summarized since starting the machine are
displayed. If the machine has travel a longer distance in reverse than
in forward, the value will be negative.
1003 Travel speed Display value = max. speed in km/h
BOMAG
Shows the actual speed.
1010 Parameter "Show distance pulses per 10m" Depending on the selected machine type, e.g. 5896 for
Eeprom Parameter is displayed BW177 BVC
1011 Parameter "Invert travel direction" 0000 ) Direction signal is not inverted
Eeprom Parameter is displayed 000I ) Direction signal is inverted
Status: 05.06.2007 Description of Control Input Codes Page 51 of 59

9.2
321
322
9.2
14.2 Vibration

3000 Vibration status general 0000 ) Vibration OFF
The status of vibration is displayed. 0001 ) Vibration ON
3001 Vibrations status low amplitude 0000 ) Vibration OFF
The vibration status for low amplitude is displayed. 0001 ) Vibration ON
3002 Vibrations status high amplitude 0000 ) Vibration OFF
The vibration status for high amplitude is displayed. 0001 ) Vibration ON
14.3 Light

3010 Input light switch 0000 ) Light OFF
The status of the lighting is displayed. 0001 ) Light ON
BOMAG
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008 911 71
14.4 Acceleration transducer

4601 Acceleration transducer 1 Display value = voltage in V
Shows the voltage of transducer 1.
4606 Acceleration transducer 2 Display value = voltage in V
Shows the voltage of transducer 2.
14.5 Diesel engine

5000 Input MD+ 0000 ) Engine OFF

Show status of diesel engine. 0001 ) Engine ON
BOMAG
9.2
323
324
9.2
14.6 Setting the machine type

7000 Shows the adjusted machine type
7010 Switches on function „Set machine type“
7011 Confirms entered machine type
7500..7699 Pre-select machine type
BOMAG
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14.7 Parameter change

7600 Switch on function "Invert travel direction" Display value 7 6 0 0
7601 Inverts the actually adjusted travel direction see adjustment instructions
BOMAG
9.2
325
15 Terminology in connection with ESX

Short circuit
A direct, unwanted connection between two different cables or between machine and
cables.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
torn (not necessarily visible from outside)
chafed
chafed mostly in connection with a short circuit to ground
Terminal, cable lug

loosened, slipped off
broken off,
corroded,
socket / plug faulty
Status: 05.06.2007 Terminology Page 56 of 59

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326 BOMAG 008 911 71

Short circuit to ground

Line, terminal has direct connection to vehicle ground, often in connection with wire breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)
Status: 01.04.2005 General terminology Page 57 of 59

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008 911 71 BOMAG 327

Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
disturbance
variable (z)
input (w) a Output (y)

Controll distance
Closed loop control

Closed loop control is a process during which a value, the closed loop control value (e.g.
pressure), is continually measured and compared with a nominal value (guide value). The
result of this comparison will affect the closed loop control value, thereby adapting the closed
loop control value to the guide value.
This sequence occurs in a closed circuit, the co-called closed loop control circuit.
disturbance
variable (z)
input (w) + e u Output (y)

Controll distance
-
Marking Closed loop control Control

Operating path: closed open
(closed loop control circuit) (control chain)
Measurement and Value to be adjusted is Values to be controlled
comparison of value to measured and compared. are not measured and
be adjusted: compared.
Reaction to faults Counteracts to all faults Does not respond to
(generally): targeting the system to be unknown faults
controlled.
Technical expense: Low effort: High expense if many
Measurement of the value to faults have to be
be controlled, comparison of considered, low expense
nominal and actual value, if not faults occur.
power amplification
Performance in For unstable systems closed In unstable systems
unstable systems loop controls must be used. controls cannot be used.
Status: 05.06.2007 Terminology Page 58 of 59

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Current and voltage measurement
Ohm’s law:
U =R∗I
U = Voltage
R = Resistance U
I = Current
I=
R
U
R=
I
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position
forward and reverse will cause an fault message, because this condition is normally not
possible.
Override / emergency operation

In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 34, "")
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
PWM – digital output

Certain outputs on the ESX are designed as so-called PWM – digital outputs. This means
that these outputs are special current outputs. Here it is possible to measure a current, but
no voltage. These outputs are used to trigger proportional valves.
Status: 01.04.2005 General terminology Page 59 of 59

Author: T.Löw / TE
008 911 71 BOMAG 329

330 BOMAG 008 911 71

10 Service Training
008 911 71 BOMAG 331

332 BOMAG 008 911 71
10.1 Service Training Machine
008 911 71 BOMAG 333

334 BOMAG 008 911 71

Service Training Machine 10.1
008 911 71 BOMAG 335

Service Training
Table of contents
Foreword A1
Documentation A2
General A3
New developments A5
Travel system E1
Travel pump E3
Control E7
Charge pressure relief valve E8
High pressure relief valve E9
Pressure override E11
Axle drive motor E14
Drum drive motor E17
Test and adjustment points, travel system E19
Trouble shooting travel system E27
BW 213 / 214 DH / PDH -4
336 BOMAG 008 911 71

Service Training
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Vibration motor F8
Drum F11
Test and adjustment points, vibration system F13
Trouble shooting vibration F15
Steering G1
Charge pump G2
Steering pump G3
Steering valve G5
Articulated joint G7
Measuring and adjustment points G9
Trouble shooting steering G10
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Foreword and novelties
Reliable construction equipment is of greatest advantage for all parties involved:
• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
• in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
• for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
• the location of components in the machine eases maintenance work,
• the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
• the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
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Documentation
For valid BOMAG single drum roller serie -4 :
BW 213 DH-4
with serialnumber of the machine: 58314, 58315
BW 214 DH-4
with serialnumber of the machine: 58319, 58320
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
1. Operating and maintenance instructions

2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
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General
The new single drum rollers serie -4 from BOMAG are essentially further developments of their
predecessors, the machines of product range serie -3.
These machines have been successfully and reliably used for years on construction sites all over the
world, especially in earth construction and on sanitary landfill sites.
High compaction power and excellent traction are characteristics, which are of utmost importance for
this type of machine.
All components installed in these machines are manufactured in series production and are subjected to
stringent quality tests. This guarantees a high level of reliability and safety.
As with many other BOMAG products, and here especially with the large single drum rollers of the new
generation, we have decided to use the same successful drive concept with diesel engine (water cooled)
and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the
engine directly to drum, drive wheels and steering.
The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by
slow running radial piston motors.
On construction machines the work place of the operator is of utmost importance. Under such working
conditions the health and safety of the operator must be the greatest concern.
The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be
individually adjusted for every operator, even for his weight.
All control elements and gauges are within the reach and in the sight of the operator.
A monitoring display with light emitting diodes and clear pictograms informs the operator about any
operating faults. The operator is therefore always informed about the present condition of the machine.
The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens,
as well as a heated rear windscreen, offers clear vision to all sides.
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Important characteristics of the new generation of single drum rollers are
• strong ROPS/FOPS according to SAE-standard
• wear free service brake by closed hydrostatic travel circuits
• disc brakes in axle and drum drive motor serve as parking and emergency brakes
• high stability due to low centre of gravity and the use of an articulated joint
• operating safety due to the use of monitoring boards for all important system data
• automatic engine shut-down at too engine temperature, too low hydraulic oil level (when reaching the
lowest permissible level the engine will be shut down after 20 seconds) and too low engine oil
pressure.
The new single drum roller serie -4 are well designed down to the smallest detail, so that they can meet
the toughest demands on large scale construction sites all over the world.
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Service Training
Novelties
The multi-function travel lever and the display
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Control, operation, data collector,
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Service Training
Diesel engine with EMR
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Service Training
Travel System
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Travel system
15
Charge pressure filter

Charging
from
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Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

diagram
10 Travel pump, electr.- prop. 90R075 10
12 Drum drive motor electr.-prop. 12
51C110
13 Axle drive motor, electr.-prop. 13
51D110
14 Axle 14
15 Reduction gear CR 31
The travel system of the single drum rollers is a closed hydraulic circuit and consists
mainly of:
• travel pump with control and safety elements,
• Drum drive motor with reduction gear;
• axle drive motor,
• charge pump (also for vibration circuit),
• hydraulic oil filter (in charge circuit),
• hydraulic oil cooler with thermostat
• hydraulic lines.
Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump. The travel pump is the first pump section, flanged directly to the flywheel side
of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to 425 bar (Δp = 400 bar between low and high
pressure sides).
A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (Δp between the two sides of the closed
circuit). Leakage in the individual components of the circuit are replaced by the charge circuit through
the boost check valves in the travel pump.
The charge pump inside the vibration pump draws hydraulic oil out of the tank and delivers it through
the hydraulic oil filter to the boost check valves in travel and vibration pump. The return flow from the
steering system also flows through the hydraulic oil filter and is then available for the closed circuit
charging system. The charge circuit also provides the oil for the control functions in the closed circuits
for travel and vibration drive and to release the parking brakes.
Both travel motors and the travel and vibration pumps are electrically proportionately controlled.
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Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
4
1 2
Charging

diagram
1 Travel pump, electr.- prop. 90R075 10
2 Charge pressure relief valve
3 Control, electr.-prop.
4 Multi-function valve
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The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.
7 1
6
5
Fig. 1: Travel pump
1 Electric prop. control 5 Cylinder block

2 Drive shaft 6 Valve plate
3 Swash plate bearing 7 Control piston
4 Pistons with slipper pads
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
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Cross-sectional view of travel pump
2
4
5
1 3
9
10
8
11
Fig. 2: Cross-sectional view of travel pump
1 Retainer for swash plate 7 Swash plate bearing

2 Sliding block 8 Swash plate guide
3 Control piston 9 Swash plate
4 Servo arm 10 Swashing lever
5 Servo valve
6 Feedback device
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View of the rotating group
4 3
5
Fig. 3: Travel pump, view of the rotating group
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
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Description of function
2 3 4 5 6
1
8 6 7
Fig. 4: Function of travel pump
1 Drive shaft 5 Cylinder block

2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump (only in vibration pump)
4 Pistons with slipper pads 8 Valve plate
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
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When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
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Tandem pump, connections and adjustment points
38
Thermostat
housing
Fig. 5: Connections and adjustment points
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1 Rear vibration pump connecting plate, turned by 90° !!!
2 Proportional solenoid (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6 Pump flange
7 Port L, leak oil to vibration pump
8 Electr.-prop. control (travel pump)
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 not on EP-pumps
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 Charge pump (only in vibration pump)
19 Port L2, (connection to vibration pump)
20 not on EP-pumps
21 Filter block for charge circuit
22 Multi-function valve 400 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 400 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (fixed setting 40 bar)
26 Filter block for charge circuit
27 Port L1, leak oil port to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
Thermostat housing:
32 Port C, from solenoid valve for brake/speed range selection
33 Leak oil port D, leak oil from axle drive motor
34 Leak oil port A, leak oil from travel pump
35 Leak oil port G, leak oil from drum drive motor
36 Leak oil port F, leak oil from vibration motor
37 Leak oil port B, leak oil to oil cooler
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servo control
The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal
from the proportional valve into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the
swashing direction (flow direction of the pressure fluid).
The flow quantity delivered by the variable displacement pump is proportional to the value of the input
signal from the proportional valve. A mechanical feedback device ensures the fixed correlation between
the proportional valve input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder
Control piston
Sliding block
Servo arm
Control piston in pump
Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:
• when shutting the engine down,
• if the pressure in the charge circuit drops below a certain value.
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Multi-function valves
High pressure limitation
Pumps of series 90 are equipped with a follower valve, which activates a pressure override and a
pressure relief valve, one after the other.
1 2
3
A
6 5
B
4
Fig. 6: Multi-function valves
1 to the control 6 Drive shaft

2 Multi-function valve 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Port A
5 Pilot pressure relief valve B Port B
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
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In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override
works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the
high pressure relief valve is higher than the pressure level of the pressure override. The high pressure
relief valves will only respond if the pressure override is not able to swash the pump back quick enough
in case of sudden pressure peaks.
2 3
4
5
1
6
9 7
8
10
11
Fig. 7: Multi-function valve, details
1 Reducing fitting 7 Check valve

2 Hydraulic by-pass piston 8 Pressure limitation
3 Spring plate 9 Spring
4 Spring 10 By-pass housing
5 High pressure relief valve 10 By-pass sleeve
6 Valve seat
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
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Charge pressure relief valve
The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).
The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps, the speed range
selection and to operate the multi-disc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both
sides of the closed circuit are identical (charge pressure).
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Axle drive motor
The axle drive motor is a swash plate controlled Sauer-Danfoss axial piston motor of series 51 D 110
with an electrical proportional control for variable displacement.
HD-Pump Brake valve
Charge pressure
5
4
2
Leak
oil
HD-Pump
Fig. 1Hydraulic diagram, axle drive motor
1 Motor drive
2 Control piston
3 Proportional control with proportional solenoid
4 Flushing valve with flushing pressure limitation valve
5 Axle with brake
6) Rotary speed sensor (flange sensor)
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.
5 7 8
6
9
11
10
4
2
Fig. 2: Axle drive motor,
1 Control piston 7 Cylinder block

2 Flushing valve 8 Universal joint
3 Proportional control 9 Output shaft
4 Spindle with ball 10 Output shaft bearing
5 Qmin-screw 11 Working piston
6 Valve plate
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Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
Control
The motor is electric-proportionally controlled.
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment.
The front travel motor (drum drive) also is an axial travel motor 51C110
from Sauer-Danfoss.
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Flushing valve
Fig. 8Cross-section of flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valves are integrated in the axle drive motor, or on DH/PDH machines, also in the drum
drive motor. In case of a pressure increase in one of the two sides of the closed circuit the flushing valves
have the function to flush a certain quantity of oil out of the low pressure side.
The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).
If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral
position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows
through a thermostat valve back to the tank. The flushed out oil quantity is immediately replaced by oil
entering from the charge circuit through the corresponding boost check valve (part of the multi-function
valve).
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.
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Manual releasing of brake on axle drive
For manual releasing of the brakes on the rear axle you should proceed as follows:
Fig. 9: Manual releasing of rear axle brakes
• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
• Turn the brake releasing screw (2) in against the stop.
• To release the brake tighten the screw for max. 1 complete turn.
Attention!
Turn the screws on both sides in uniformly (alternately by 1/4 of a turn)
• Repeat this procedure on the opposite side of the axle.
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Drum drive motor 51C110 with reduction gear CR 31
The drums on the DH-4 and PDH-4 versions are driven by a swash plate operated Sauer axial piston
motor 51C110. This motor is almost identical with the rear axle motor. Another detailed description at
this point is therefore not necessary.
2
3 4
1
10 8
9
Fig. 10: Reduction gear CR 31
1 Travel motor 6 Sun gear

2 Tapered roller bearing 7 Planet carrier
3 Spur wheel 8 Brake discs
4 Hollow wheel 9 Mechanical seal
5 Planet wheel 10 Brake piston
This motor is a fast rotating hydraulic motor. Since the output speed of this motor is much too high to
drive the drum, a reduction gear reduces the output speed to the actually required drum drive speed.
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Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake. When moving
the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards
zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the
machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also
return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill.
However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause
creeping of the machine when it is parked on a slope with the engine running, the machine is additionally
equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever in
neutral position the multi-disc brakes will close and the machine can be parked on slopes with the
engine running and without the risk of creeping.
However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized
condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is
interrupted and the oil from the brake housings flows as leak oil back into the tank.
If the brake solenoid valve is supplied with current while the engine is running and the brake is open,
the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the
brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake
discs.
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Manual drum drive brake release (in the reduction gear)
Brake releasing device
in operation position
Brake releasing device in

position “brake manually
released”
For manual brake release both screws on the drum drive reduction gear (marked with arrow) must be
turned in uniformly, until the drum is able to rotate freely.
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Travel circuit with drum drive motor 51C110 and CR 31 (position of
components)
2
9
Travel lever
forward
3
8
4
7 5
n
6 ti o
ec 1 Travel pump
l dir 2 Vibration pump
a ve
Tr 3 Hydraulic oil filter
4 Rear axle
High pressure 5 Axle drive motor
6 Reduction gear
Low pressure
7 Drum drive motor
Charge pressure 8 Hydraulic oil tank
Leak oil 9 Travel lever
Fig. 11: Travel circuit with 51 C 110 and CR 31
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Brake control BW 213 (with Sauer motor 51C110 and CR 31)
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
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Test and adjustment points, travel system
Charge pressure filter and travel pump

diagram
1 charge oil filter 07
2 Charge oil filter pressure differential B21 Δp 3,5 bar
switch
3 Pressure test port, charge pressure MA 26+/-3 bar
4 Travel pump - pressure test port 10 / A / MD max. 426 bar
Travel pressure forward
5 Test port travel pump forward A 10 / A
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Travel pump
2
2
3
1
1

diagram
1 Travel pump - pressure test port 10 / B / MC max.426 bar
Travel pressure reverse
2 Prop. solenoid travel forward Bl.004 / Y17 / X16 12V / 0,4-1,2 A
3 Prop. solenoid travel reverse Bl.004 / Y16 / X15 12V / 0,4-1,2 A
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Travel and vibration pump

diagram
1 Test port travel pump reverse B 10 / B
2 Pressure test port, charge pressure MA 26+/-3 bar
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Travel motor (drum drive)
3 4
5
2 1
3
2
4 1

diagram
1 Pressure travel forward 12 - A
2 Pressure travel reverse 12 - B
3 Port X X1 approx. 26bar
4 Prop. solenoid Y30 12V / 0,4-1,2 A
5 Speed flange sensor PPU B59
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Travel motor (axle drive)
2
1
3
5

diagram
1 Prop. solenoid Y 31 12V / 0,4-1,2 A
2 Port X X1 approx. 26bar
3 Travel pressure sensor B 112 26 -426 bar
4 High pressure travel pump forward 13 - B
and further to drum drive motor
5 High pressure travel pump reverse 13 - A
and further to drum drive motor
6 Speed sensor (flange sensor) B 60
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Speed sensor and travel pressure sensor
NEW : Speed flange sensors in both travel motors and a travel

pressure sensor at the front left hand side under the operator's platform!

diagram
1 Speed flange sensor PPU axle B60
motor
1 Speed flange sensor PPU drum B59
drive motor
2 Travel pressure sensor in frame, B112
front left under operator's platform
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Brake valve
3 4
1

diagram
1 Brake valve Y 04 08 0V closed 12V
open
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Travel lever
Multi-function travel lever
For a detailed description of the travel lever buttons

please refer to the page on "Electrics" (Service Training Electrics)
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Trouble shooting
The display shows the fault codes
For a detailed description of how to read out fault codes and the display
All electric faults are mainly shown by the display
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
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Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
Maschine fährt mit Fahrhebel in Stellung 'Neutral'

Max.Fahrgeschwindigkeit wird nicht erreicht
Maschine fährt nur in eine Fahrtrichtung
Maschine fährt nicht (vor und zurück)
FEHLERSUCHE FAHRANTRIEB
Hydrauliköl wird zu heiss

BW 213/214 DH/PDH-4
SYMPTOME
MÖGLICHE URSACHEN
Bremsventil (elektrisch/mechanisch/hydraulisch) 1
Bremse Achse/Bandagenmotor (mechanisch/hydraulisch) 2 2 3
Fahrpropverstellung /defekt/Verkabelung 1
Speisepumpe / Speisedruckbegrenzungsventil(e)
2 3
verschmutzt/defekt
Pumpenansteuerung (Servoverstellung) 2 1 2 3
Druckabschneidung/ Hochdruckbegrenzung Fahrpumpe
3 2 3 3
verschmutzt/verstellt/defekt
Fahrhebel 1 2
Nullage Fahrpumpe 3 3
Fahrpumpe(n) defekt 3 3 2
Stellventil Fahrmotoren (elektrisch / mechanisch / hydraulisch) 1 2
Spülventil Fahrmotoren hängt 3
Fahrmotor(en) defekt 3 3
Hydraulikölkühler verschmutzt (intern/extern) 1
Thermostat (Hydraulik) verschmutzt/verklemmt/defekt 2
Kupplung Dieselmotor-Pumpe 2
Dieselmotor 1
Drehzahl-Flanschsensoren im Fahrmotor (Verkabelung) 1 1 2
FEHLERSUCHE
BW 213 / 214 DH / PDH-4

- E 34 -
008 911 71 BOMAG 379

Service Training
Vibration
3
4

diagram
1 Vibration pump 75 cm³ 11
2 Integrated charge pump 17 cm³
3 Multi-function valves with high
pressure limitation and boost check
valve function
4 Proportional control
BW 213 / 214 DH / PDH -4 -F1-
380 BOMAG 008 911 71

Service Training
diagram
5 Vibration motor with flushing valve 15
The vibration system on these single drum rollers works with different frequencies and tow amplitudes.
This enables perfect adaptation of the machine to various types of soil and different applications.
The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.
The main components of this circuit are
vibration pump,
Vibration motor
and the pressure resistant hydraulic hoses.
Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the
diesel engine.
By operation of a proportional valve the pilot oil is guided to one of the control piston sides. This actuates
the pump from neutral position to one of the two possible maximum displacement positions.
When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the vibration motors will change.
Since the engine speed is variable in "Position AUTO", the pump displacement must always be
proportionately adapted in order to maintain the vibration frequency at a constant level.
The vibration motor output shaft is joined with the exciter shaft in the drum via a Bowex coupling. The
rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically
suspended drums.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights.
BW 213 / 214 DH / PDH -4 -F2-
008 911 71 BOMAG 381

Service Training
Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.
Basic weight + change-over weight = high amplitude
Basic weight - change-over weight = low amplitude
The displacement of the pump may be different to both flow directions. This results in different exciter
shaft speeds for the different senses of rotation of the motor.
The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled
with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.
Sense of rotation of exciter shaft
BW 213 / 214 DH / PDH -4 -F3-
382 BOMAG 008 911 71

Service Training
Vibration pump
The vibration pump is a swash-plate controlled axial piston pump with variable displacement of type 90
R 075 EP from Sauer-Danfoss. The pump is fitted with all control and safety elements needed for
operation in a closed hydraulic circuit.
5 4
2 6 3

diagram
1 Vibration pump 75 cm³ 11
2 Integrated charge pump 17 cm³
3 Multi-function valves with high
pressure limitation and boost check
valve function
4 Prop. solenoids X 6 and X 7
5 servo control
6 Safety valve in charge circuit
BW 213 / 214 DH / PDH -4 -F4-
008 911 71 BOMAG 383

Service Training
Function
1 2
5 4 3
Cross-section of vibration pump
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
BW 213 / 214 DH / PDH -4 -F5-
384 BOMAG 008 911 71

Service Training
1
2
5
4 3
Cross-section of vibration pump
1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve
BW 213 / 214 DH / PDH -4 -F6-
008 911 71 BOMAG 385

Service Training
The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.
The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.
During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.
Control
The electro-hydraulic displacement control converts the electric proportional input signal into a load
controlling output signal.
The vibration pump has an integrated charge pump, an internal gear pump with a displacement of 17
cm³ per revolution
The vibration pump is equipped with an integrated charge pressure relief valve, which is set to a
pressure of 40 bar. This valve only has a safety function in the charge circuit.
BW 213 / 214 DH / PDH -4 -F7-
386 BOMAG 008 911 71

Service Training
Multi-function valve
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.
1 From the charge pump
2 Closed circuit
3 High pressure relief valve with integrated boost check valve
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 426 bar
(pressure difference between high and low pressure side = 400 bar + charge pressure = 26 bar).
The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit.
BW 213 / 214 DH / PDH -4 -F8-
008 911 71 BOMAG 387

Service Training
Vibration motor
The vibration motor is a Bosch-Rexroth axial piston motor of series A2FM 56 with fixed displacement in
bent axle design. Since the motor can be subjected to pressure from both sides, it is most suitable for
the use in closed hydraulic circuits.
BW 213 / 214 DH / PDH -4 -F9-
388 BOMAG 008 911 71

Service Training
When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 426 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).
Hard ground = High operating pressure
Loose ground = Low operating pressure
A MA
3 1
B MB
Circuit diagram of vibration motor
1 Vibration motor
2 Flushing valve
BW 213 / 214 DH / PDH -4 - F 10 -
008 911 71 BOMAG 389

Service Training
Flushing valve
The vibration motor is equipped with an integrated flushing valve. This flushing valve is located inside
the bolted on connecting block. When switching the vibration on a pressure difference will appear
between the two sides of the closed circuit. The higher pressure moves the valve spool of the flushing
valve against the neutral setting spring, so that oil can flow out of the low pressure side.
1
A
Flushing valve
1 Flushing spool
The flushing valve is fitted with a downstream 16 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.
BW 213 / 214 DH / PDH -4 - F 11 -
390 BOMAG 008 911 71

Service Training
Speed sensor
The fixed displacement vibration motor A2FM56 is equipped with a Bosch-Rexroth speed sensor
HDD1L16 or HDD2L16 with an installation depth of 16 mm, which uses the Hall-effect.
Fixed displacement motor

A2FM56
Connection in wiring diagram, vibration speed sensor B16 on page 006
BW 213 / 214 DH / PDH -4 - F 12 -
008 911 71 BOMAG 391

Service Training
Drum
4
14
5 9
7 13
6
10
3 8 11
12
Fig. 1 Cross-section of drum
1 Drum shell 8 Change-over weight

2 Vibration bearing 9 Coupling vibr.-motor – vibrator shaft
3 Basic weight 10 Travel bearing
4 Vibrator housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing
BW 213 / 214 DH / PDH -4 - F 13 -
392 BOMAG 008 911 71

Service Training
Test and adjustment points, vibration system
Vibration pump
7 8
6 6 72
1
8
6 5
7
5 1
5 4
3 4 1
2
3
4 2 3
diagram
1 Pressure test port, vibration 11 - B - ME Starting pressure
pressure low amplitude 330 -400 bar
2 Pressure test port, vibration 11 - A - MF Starting pressure
pressure high amplitude 330 -400 bar
3 High pressure port low amplitude 11 - B max. 426 bar
4 High pressure port high amplitude 11 - A max. 426 bar
5 Multi-function valve with high 11 - B
pressure limitation low amplitude
6 Multi-function valve with high 11 - A
pressure limitation high amplitude
7 Solenoid valve, low amplitude Y07 / X 8 11 - B 12V / 0,4 - 1,2A
8 Solenoid valve, high amplitude Y07 / X 7 11 - A 12V / 0,4 - 1,2A
BW 213 / 214 DH / PDH -4 - F 14 -
008 911 71 BOMAG 393

Service Training
Vibration motor
5 3
1
1 2
2
4
3
2 31

diagram
1 High pressure port high amplitude 15 - A
2 High pressure port, low amplitude 15 - B
3 Flushing valve 15
4 Leakage and flushing 15 - L1 approx. 2.5 l..
Flushing quantity
BW 213 / 214 DH / PDH -4 - F 15 -
394 BOMAG 008 911 71

Service Training

diagram
1 Speed-sensor B 16 15
BW 213 / 214 DH / PDH -4 - F 16 -
008 911 71 BOMAG 395

Service Training
Trouble shooting
BW 213 / 214 DH / PDH -4 - F 17 -
396 BOMAG 008 911 71

Service Training
Procedure:
Erregerwellendrehzahl nicht korrekt

Keine Vibration (Speisedruck OK)
Vibration nur in einer Amplitude
FEHLERSUCHE VIBRATION
BW 213/214 DH/PDH-4
SYMPTOME
MÖGLICHE URSACHEN
Vibrationschalter (Amplitudenvorwahl) 1 1
Fahrhebel, Taster Vibration (an/aus), Verkabelung 1
Elektrik defekt / Verkabelung 2 2
Pumpenansteuerung (elektrisch / hydraulisch) 1 1
Druckabschneidung/ Hochdruckbegrenzung Vibrationspumpe
2
verschmutzt/verstellt/defekt
Speisepumpe / Speisedruckbegrenzungsventil
2
verschmutzt/defekt
Frequenzeinstellung Vibrationspumpe 2
Vibrationspumpe defekt 2 2
Kupplung zwischen Dieselmotor und Fahrpumpe defekt
Erregerwellenlager defekt 3
Vibrationsmotorkupplung defekt 2
Vibrationsmotor defekt 2 1
Dieselmotor 1 1 1
Drehzahlsensor (Verkabelung) 1 1 1
Spülventil Vibmotor hängt 2
FEHLERSUCHE
BW 213 / 214 DH / PDH -4 - F 18 -
008 911 71 BOMAG 397

Service Training
Steering
Single drum rollers of series BW 213 / 214 DH-4 are equipped with a hydrostatically operated articulated
steering system.
The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.
to charge
system
1
7
6
5
3
2
4
from steering pump
Fig. 1Steering hydraulics
1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (Δp =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
BW 213 / 214 DH / PDH -4 -G1-
398 BOMAG 008 911 71

Service Training
Charge pump
The charge pump for travel circuit and vibration works also as steering pump The pump is an external
gear pump with fixed displacement.
The oil flow generated by the charge pump is joined together with the return flow from the steering valve
before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration
pump.
BW 213 / 214 DH / PDH -4 -G2-
008 911 71 BOMAG 399

Service Training
Steering pump
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.
9 9 6 1 7
8
2
4 5
Fig. 2Steering pump
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
BW 213 / 214 DH / PDH -4 -G3-
400 BOMAG 008 911 71

Service Training
Working principle of the gear pumps
The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.
The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.
When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.
For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.
This pressure field is always under the actual system pressure.
BW 213 / 214 DH / PDH -4 -G4-
008 911 71 BOMAG 401

Service Training
Steering valve
The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.
9 2
5
8
Fig. 3Cross-sectional view of steering valve
1 Neutral setting springs

2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Check valve
9 Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump. The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.
BW 213 / 214 DH / PDH -4 -G5-
402 BOMAG 008 911 71

Service Training
240 bar
Δp = 175 bar
240 bar
0,5 bar
Fig. 4Steering valve, hydraulic diagram
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.
The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.
A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.
BW 213 / 214 DH / PDH -4 -G6-
008 911 71 BOMAG 403

Service Training
Articulated joint
Front and rear frames of the single drum rollers BW 177 D-4 are connected by an oscillating articulated
joint. This ensures that drum and wheels are at all times in contact with the ground, even when driving
extreme curves.
Fig. 5Articulated joint
BW 213 / 214 DH / PDH -4 -G7-
404 BOMAG 008 911 71

Service Training
The rear console is tightly bolted to the rear frame.
The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.
The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.
The steering cylinder anchor point is welded to the front console.
When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.
All bearings on the articulated joint are maintenance free and do not require any lubrication.
Notes on assembly:
When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.
Please follow the instructions in the repair manual for the articulated joint.
BW 213 / 214 DH / PDH -4 -G8-
008 911 71 BOMAG 405

Service Training
Test and adjustment points steering points
3 4
1
2
2
Steering pump

diagram
1 Steering pump (and charge pump) 09
2 Steering pressure test port MB 200 +/-10 bar
BW 213 / 214 DH / PDH -4 -G9-
406 BOMAG 008 911 71

Service Training
Vibration and noise damper
The damper is located in the steering/charge circuit directly after the steering and charge pump.
It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.
The damper is mounted to the front plate of the rear frame, between both steering cylinders.
BW 213 / 214 DH / PDH -4 - G 10 -
008 911 71 BOMAG 407

Service Training
Trouble shooting
BW 213 / 214 DH / PDH -4 - G 11 -
408 BOMAG 008 911 71

Service Training
Procedure:
FEHLERSUCHE LENKUNG
BW 213/214 DH/PDH-4
Endanschläge werden nicht erreicht
Lenkung schwergängig
Keine Lenkfunktion
SYMPTOME
MÖGLICHE URSACHEN
Lenkorbitrol 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
BW 213 / 214 DH / PDH -4 - G 12 -
008 911 71 BOMAG 409

410 BOMAG 008 911 71

11 Engine
008 911 71 BOMAG 411

11.1 Diesel engine
11.1 Diesel engine The engines are characterized by the following posi-
tive features:
Series 4 single drum rollers are powered by 4 or 6 cyl- ● compact design
inder Deutz diesel engines type TCD 2013 or a 6-cyl- ● low noise level
inder engine TCD 2012.
● almost vibration free operation
The engines are water cooled in-line engines with
EMR3 electronics.
● low fuel consumption
The engines are mainly designed in two-valve tech-
● low exhaust emission EPA/COM IIl
nology with turbo charging and intercooler. They are ● high power density
highly compact and come with a Deutz-Common-Rail ● excellent access to all service locations.
injection system, called DCR in short. ● high reliability
All engines are designed with exhaust gas recircula- ● low running costs,
tion and thus reach emission values complying with
EPA/ COM/ Tier/ stage lll
● long lifetime
Fig. 1 Deutz diesel engine TCD 2012 and 2013
412 BOMAG 008 911 71

Engine description TCD 2012 11.2
11.2 Engine description TCD 2012
Fig. 1 Deutz diesel engine TCD 2012, right hand side 13 Flywheel or (transmission connection SAE)
14 Crankcase ventilation valve
1 Lubrication oil filling neck 15 Transport device
2 Combustion air inlet 16 Charge air line
3 Cover 17 Fuel control unit
4 Fan
5 Generator
6 Fuel lift pump
7 Idler pulley
8 Lubrication oil cooler
9 Fuel filter
10 Replaceable lubrication oil filter
11 Lubrication oil sump
12 Possible installation of hydraulic pump or com-
pressor (optional)
008 911 71 BOMAG 413

11.2 Engine description TCD 2012
Fig. 2 Deutz diesel engine TCD 2012, left hand side
1 Exhaust manifold
2 Exhaust turbo charger
3 Lubrication oil filling neck (optional)
4 Engine mounts
5 Lubrication oil return line from exhaust gas turbo
charger
6 Relay (starter)
7 Ribbed V-belt
8 Coolant inlet
9 Coolant outlet
10 Coolant pump
11 Connection cabin heater ort compensation line
414 BOMAG 008 911 71

Engine description TCD 2013, 4 and 6 cylinder 11.3
11.3 Engine description TCD 2013,
4 and 6 cylinder
Fig. 1 Deutz diesel engine TCD 2013 L04 2V, right hand side 14 Fuel control unit
15 High pressure pump
1 Combustion air inlet (possibility to install a heating 16 Crankcase ventilation valve
flange, optionally) 17 Injector
2 Connection cabin heater ort compensation line 18 Lubrication oil filling neck
3 Fan
4 Generator
5 Belt pulley on crankshaft
6 V-belt
7 Fuel lift pump drive
8 Fuel filter
11 Possible installation of hydraulic pump or com-
pressor (optional)
12 Lubrication oil return line crankcase ventilation
13 Central plug (for engine control)
008 911 71 BOMAG 415

11.3 Engine description TCD 2013, 4 and 6 cylinder
Fig. 2 Deutz diesel engine TCD 2013 L04 V2, left hand side
1 Lubrication oil filling neck (optional)

2 Transmission connection (SAE)
3 Engine mounts
4 Lubrication oil drain plug
6 Starter motor
7 Lubrication oil return line from exhaust gas turbo
charger
9 Coolant inlet
10 Charge air connection to intercooler
11 Coolant outlet
12 Exhaust manifold
13 Charge air line
14 Transport device
416 BOMAG 008 911 71

Engine description TCD 2013, 4 and 6 cylinder 11.3
Fig. 3 Deutz diesel engine TCD 2013 L06 2V, right hand side 17 Crankcase ventilation valve
18 Injector
1 Combustion air inlet
2 Lubrication oil filling neck
3 Transport device
4 Fan hub
5 Generator
7 Fuel filter
9 Oil dipstick
10 Lubrication oil drain plug
11 Oil return line crankcase ventilation
12 Engine mounts
13 Transmission connection (SAE)
14 Central plug (for engine control)
16 Rail
008 911 71 BOMAG 417

11.3 Engine description TCD 2013, 4 and 6 cylinder
Fig. 4 Deutz diesel engine TCD 2013 L06 2V, left hand side

2 Exhaust manifold
3 Starter motor
4 Lubrication oil flow to exhaust turbo charger
5 Coolant drain plug
6 Coolant inlet
7 Ribbed V-belt
8 Fan hub
9 Idler pulley
10 Connection cabin heater ort compensation line
11 Ventilation line to compensation tank
12 Coolant line from engine to radiator
418 BOMAG 008 911 71

Lubrication oil circuit TCD 2012 / 2013 11.4
11.4 Lubrication oil circuit TCD
2012 / 2013
25 26 23 22 18 12
12
123 19 20 21 17 15 11
12
8 7 6
5
24
27 1
1
1 14 13 16 10 9 4 2 3
Fig. 1 Lubrication oil diagram 17 Piston cooling nozzle with pressure maintaining
valve
1 Lubrication oil sump 18 Plunger with rocker arm pulse lubrication
2 Lubrication oil suction pipe 19 Push rod, lubrication oil supply for rocker arm lu-
brication
3 Lubrication oil pump
20 Rocker arm
4 Pressure relief valve
21 Return line to lubrication oil sump
22 Lubrication oil flow to exhaust turbo charger
6 Return flow check valve (only on 2012)
7 By-pass valve
24 Return line from compressor / hydraulic pump to
8 By-pass valve lubrication oil filter
crankcase
9 Pressure control valve
25 Compressor or hydraulic pump
26 Lubrication oil line to crankshaft and camshaft,
11 Main lubrication oil lines compressor / hydraulic pump
12 Internally switched exhaust gas recirculation 27 Return flow from exhaust turbo charger
13 Crankshaft bearings
14 Conrod bearings
15 Camshaft bearings
16 Line to spray nozzle
008 911 71 BOMAG 419

11.5 Coolant circuit TCD 2012 / 2013
11.5 Coolant circuit TCD 2012 /

2013
Fig. 1 Fuel diagram
1 Coolant outlet on radiator

2 Thermostat
3 Coolant - supply to water pump
4 Coolant pump
6 Cylinder cooling
7 Cylinder liner / head cooling
8 Coolant flow to heater
9 Cabin heater (optional)
10 Coolant to thermostat
11 Connection for cabin heater
12 Compensation line
13 Ventilation line to compensation tank
14 Coolant outlet to radiator
15 Compensation tank
16 Compensation line to heat exchanger
420 BOMAG 008 911 71

Fuel system TCD 2012 / 2013 11.6
11.6 Fuel system TCD 2012 / 2013
Fig. 1 Coolant diagram 12 Fuel return flow on cylinder head

13 Fuel return line to fuel tank
1 Fuel tank A= minimum distance 500 mm 14 Fuel lines from fuel control unit to high pressure
2 Fuel pre-filter with pre-pressure pumping possibil- pumps and rail
ity to fill the low pressure section (provided by cus- 15 Fuel lift pump 2013
tomer)
3 Line to fuel lift pump
4 Fuel lift pump
5 Fuel filter
6 Fuel supply line to fuel control unit
7 Rail
9 Fuel supply line to injector
10 Injector
11 FCU (Fuel Control Unit)
008 911 71 BOMAG 421

Fuel pre-filter
Fig. 2 Fuel pre-filter
1 Fuel supply to pump

2 Fuel return flow from FCU (Fuel Control Unit)
3 Manual fuel pump with bayonet lock to lock and
unlock
4 Thermostat valve with shut-down lever
5 Filter cartridge
6 Possibility to connect an electric water level sen-
sor
7 Drain tap
8 Water collecting bowl
9 Fuel inlet from fuel tank
10 Fuel return flow to fuel tank
A Electric water level sensor
422 BOMAG 008 911 71

Fuel system TCD 2012 / 2013 11.6
TCD 2013 Fuel filter system
5
2
2
11 13
4
4
Fig. 3 TCD 2013 Fuel system

1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter min. 3µm
4 Input fuel control unit
5 Fuel low pressure sensor
008 911 71 BOMAG 423

TCD 2012 Fuel filter system
2
2
2
5
4
1 1
1
4 3 4
Fig. 4 TCD 2012 Fuel system

1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter min. 3µm
4 Input fuel control unit
5 Fuel low pressure sensor
424 BOMAG 008 911 71

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 11.7
11.7 Deutz Common Rail (DCR) in- tion solely controlled by mapping is only possible un-
der this condition. Injection timing and injection
jection system for TCD 2012 / quantity are controlled by the engine electronics. The
2013 electric signals control an electrically operated valve
per cylinder, which is integrated in the injection noz-
The diesel engines type TCD 2012 and 2013 are zle. The short distances between valve and injection
equipped with a "Deutz Common Rail" injection sys- nozzle result in short pressure rise times, which has a
tem, DCR in short. positive effect on the combustion process and its con-
The English term "Common Rail" indicates that the trol. Various types of injection van be realized, e.g.
system is based on a common rail. It describes the pre-injection, main injection and post-injection. These
use of a common high pressure fuel line with corre- are freely controllable, in dependence on the control
sponding branches to supply all cylinders with fuel. unit.
The "Common Rail" injection is an injection system for The electric control is accomplished by the electronic
combustion engines, in which a high pressure pump control unit (EDC16) with EMR3, in dependence on
pressurizes the fuel to a high pressure level. The pres- the operating parameters. The system is capable of
surized fuel fills a piping system, which is permanently providing a wide range of limp-home functions, should
under pressure while the engine is running. any of the sensors fail. This ensures a reliable and
safe completion of travel and work.
The general idea is the total isolation of the pressure
generation from the actual injection process. An injec-
Overview of electronic diesel fuel control
Sensors Control unit (EMR3) Actuators

Injector
Rail
Pump
Fig. 1 TCD 2012 and 2013
008 911 71 BOMAG 425

11.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013
10
8
7
5
11
9
4 1
12
Fig. 2 Schematic of the Deutz Common Rail System "DCR" Under normal conditions the rail pressure is be-
tween 300 and 1350 bar
1 Fuel filter high pressure The PRV is set to 1600 bar
2 Fuel low pressure sensor (5-7bar) B145
If the PRV is defective or always open, the pres-
3 High pressure pumps
sure in the rail will only build up to max. 700 bar.
4 Fuel lift pump
5 Rail (high pressure pipe up to 1600 bar) The rail pressure must be at least 1.5 bar to start
the diesel engine
6 PRV (max. rail pressure limitation 1600bar)
7 Rail pressure sensor (B145) The fuel low pressure sensor is located after the
fuel filter and the pressure is normally between 5
8 Injectors (B148)
and 7 bar.
9 FCU Fuel Control Unit (Y137)
10 Engine control EDC16 - EMR3 The solenoid valve of the Fuel Control Unit (FCU)
is dead, open towards the tank.
11 Fuel filter with water separator
12 Hand pump The voltage applied to the injectors is normally
approx. 40 V.
426 BOMAG 008 911 71

FCU Fuel Control Unit (Y137)
electric connection
Fig. 3 Fuel Control Unit FCU
Two high pressure pumps
High pressure
Low
pressure
High pressu
pumps
Fig. 4 High pressure pump
008 911 71 BOMAG 427

Injector ( Y148 )
electric connections
Return flow
Armature group
Nozzle
Supply
Fig. 5 Injector
Wiring diagram page 4
Engine control EDC16 - EMR3
FCUFCU
Fig. 6 Excerpt from the wiring diagram
428 BOMAG 008 911 71

TCD 2013
5
7 6
2
4
1 3
Fig. 7 TCD 2013
1 Fuel pre-filter
2 Hand pump
3 Fuel filter
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3
008 911 71 BOMAG 429

TCD 2012
2 5
6
7
4
2
4
5 1
6
Fig. 8 Diesel engine TCD 2012
1 Rail pressure sensor (B93)

2 Rail pressure PRV
3 Fuel filter
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3
430 BOMAG 008 911 71

Sensors TCD 2012 / 2013 11.8
11.8 Sensors TCD 2012 / 2013
Diagnostics interface
10
Serdia connection
Fig. 1 Sensors TCD 2013
1 Fuel control unit (FCU)

2 Coolant temperature sensor
3 Sensor for charge air temperature and charge air
pressure
4 Possibility to connect a control unit
5 Engine control unit
6 Rotary speed sensor for crankshaft
7 Rail pressure sensor
8 Optional oil level sensor
9 Oil pressure sensor
10 Fuel pressure sensor
11 Rotary speed sensor for camshaft
12 Central plug for engine control
008 911 71 BOMAG 431

11.8 Sensors TCD 2012 / 2013
Fig. 2 Sensors TCD 2013
Fig. 3 Wiring loom TCD 2013
432 BOMAG 008 911 71

Sensors TCD 2012 / 2013 11.8
Camshaft speed sensor, B114
● Inductive sensor
● Determination of TDC
● Limp-home function in case of crankshaft sensor
failure
Crankshaft speed sensor, B130

● Inductive sensor
● Exact determination of engine speed
● Limp-home function in case of camshaft sensor fail-
ure
Charge pressure sensor, B133

● Pressure sensor
● Avoidance of smoke development
● Adaptation of injection pump in case of too low
charge pressure
● Determination of air mass for cylinder
Oil pressure sensor, B88

●
Pressure sensor
●
Monitors the oil pressure
●
Engine protection by switching of in case of too low
oil pressure
Charge air temperature sensor, B133

●
Temperature sensor
●
Temperature correction of air mass
●
Optimized injection quantity during cold start
Coolant temperature sensor, B113

●
Temperature sensor
●
Engine protection in case of excessive temperature
by reduction of injection quantity
●
Optimized injection quantity during cold start
Rail pressure sensor, B93

● Pressure sensor
● Monitoring the injection pressure)
Fuel low pressure sensor

●
Pressure sensor
●
Monitoring the inlet pressure approx. 5-7 bar
008 911 71 BOMAG 433

11.8 Sensors TCD 2012 / 2013
TCD 2012 Crankshaft speed sensor (B130)
Fig. 4 Crankshaft speed sensor TCD 2012 Adjustment measurement or sensor gap meas-
urement
1 Toothed disc on crankshaft
2 Speed sensor
Gap measurement C = 0,6mm +/- 0.5mm
Fig. 5 Crankshaft speed sensor
434 BOMAG 008 911 71

Sensors TCD 2012 / 2013 11.8
TCD 2013 Crankshaft speed sensor (B130)
Fig. 6 Crankshaft speed sensor TCD 2013 Adjustment measurement or sensor gap meas-
urement
1 Toothed disc on crankshaft
2 Speed sensor
Gap measurement C = 0,6mm +/- 0,1mm
Fig. 7 Crankshaft speed sensor
008 911 71 BOMAG 435

11.8 Sensors TCD 2012 / 2013
Camshaft speed sensor (B114)
Fig. 8 Camshaft speed sensor TCD 2012/2013 Adjustment measurement or sensor gap meas-
urement
1 Camshaft sprocket
2 Speed sensor
Gap measurement C = 1mm +/- 0.5mm
Fig. 9 Camshaft speed sensor
436 BOMAG 008 911 71

Sensors TCD 2012 / 2013 11.8
Measuring and testing
Camshaft Crankshaft
Fig. 10 Electric wiring diagram, page 004 Sensor test
Resistance measurement between Pin1 and Pin2 is
approx. 3.8 KOhm
If a magnetically conductive material is moved along a
sensor at a certain distance, a positive semi-wave
must be created on Pin 1, 2.
At a rotary speed of approx. 25 rpm there is a signal
voltage amplitude of at least 200mV from peak to
peak.
Fig. 11 Speed sensor
008 911 71 BOMAG 437

11.8 Sensors TCD 2012 / 2013
Combination sensor for charge air pressure and

charge air temperature (B133)
Fig. 12 TCD 2012
Fig. 13 TCD 2013
438 BOMAG 008 911 71

Sensors TCD 2012 / 2013 11.8
Pin
4 3 2 1
Fig. 14 Charge air pressure and temperature sensor Charge air temperature
Pin 2--- NTC-Temperature
Resistance R=2510 Ohm = 20°C
Resistance R=851 Ohm = 50°C
Charge air pressure

Pin4
0.5 Volt = 0 bar at 5 V feed voltage
4,5 Volt = 4 bar at 5 V feed voltage
Fig. 15 Electric wiring diagram, page 004
008 911 71 BOMAG 439

11.8 Sensors TCD 2012 / 2013
Oil pressure sensor (B88)
Fig. 16 TCD 2012
Fig. 17 TCD 2013
440 BOMAG 008 911 71

Sensors TCD 2012 / 2013 11.8
Fig. 18 Electric wiring diagram, page 004 Measurement

Pin 2 = Signal
Fig. 19 Assignment of connections
008 911 71 BOMAG 441

11.8 Sensors TCD 2012 / 2013
Coolant temperature senor (B113)
Fig. 20 TCD 2013 Measurement

Pin 1 = Signal
Resistance R=2500 Ohm = 20 °C
Resistance R=186 Ohm = 100 °C
442 BOMAG 008 911 71

Sensors TCD 2012 / 2013 11.8
Rail pressure senor (B93)
Fig. 22 TCD 2012 Measurement

Pin 2 = Signal
008 911 71 BOMAG 443

11.8 Sensors TCD 2012 / 2013
Fuel low pressure sensor (B145)
Fig. 24 TCD 2012
Fig. 25 TCD 2013
444 BOMAG 008 911 71

Sensors TCD 2012 / 2013 11.8
Fig. 26 Electric wiring diagram, page 004 Measurement

Pin 2 = Signal
Pin 2
Signal
Pin 4
Ground
Pin 1 +
Fig. 27 Connecting plug
008 911 71 BOMAG 445

11.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013
11.9 Engine control EDC16 with ● Working range 9-31 V

EMR 3 for TCD 2012 / 2013
● Engine start possible from 6 V
Control unit EDC 16 - EMR 3

● Operating voltage 12 V DC and 24 V DC
Connection Connection
Engine side Vehicle side
Fig. 1 EDC 16 - EMR 3 TCD 2012 and 1013
446 BOMAG 008 911 71

Engine control EDC16 with EMR 3 for TCD 2012 / 2013 11.9
EMR 3 - interface description

D 2.1 D 2.2
Pin 1-60 Pin 1-94
in wiring diagram in wiring diagram
Page 004 Page 004
X31:1 to X31:90 X30:1 to X30:94
Fig. 2 EMR 3 - connecting plug TCD 2012 and 2013
16
Fig. 3 Connecting plug EMR3
008 911 71 BOMAG 447

Interface on engine side X31:
448 BOMAG 008 911 71

Engine control EDC16 with EMR 3 for TCD 2012 / 2013 11.9
Interface on vehicle side X30:
008 911 71 BOMAG 449

Engine control EDC16 / EMR3
The EDC16 is located under the operator's stand
Fig. 6 EMR3-position in the machine under the operator's stand
450 BOMAG 008 911 71

Exhaust gas recirculation TCD 2012 / 2013 11.10
11.10Exhaust gas recirculation TCD
2012 / 2013
In order to be able to meet the exhaust gas stand-
ards EC and stage/Tier3, all engines are designed
with exhaust gas recirculation.
On 4-cylinder engines TCD 2012/2013 the exhaust

gas recirculation has been realized internally
through the intake valves, on 6-cylinders through
the exhaust valves. For this purpose the camshaft
has been manufactured with an additional cam for
short-term opening of the intake valve or exhaust
valve respectively.
Fig. 1 Exhaust/intake valve control TCD 2012 / 2013
008 911 71 BOMAG 451

11.11 Fault code monitoring with display TCD 2012 / 2013
11.11Fault code monitoring with

display TCD 2012 / 2013
Fig. 1 Display k yellow = lights when temperatures are low (pre-

heating for starting)
LCD display
l yellow = Charge control light, lights if the battery is
not being charged.
i Note Check V-belt, if necessary repair the
With the ignition switch in position I all gauges and in- generator.
struments are switched on for 3 seconds.
m red = Water separator in fuel pre-cleaner.
Toggling between the displays is described in the Lights when the water proportion in the
chapter "Operation". transparent section of the fuel filter
b = Fuel level gauge reaches the contacts.
c = Upper display field, shows either the time o = Fault code display
or the coolant temperature t red = The seat occupation monitoring system
e red = flashes if engine oil pressure too low, en- lights when the seat is not occupied. If
gine is shut down after 10 seconds. the machine is travelling the warning
Check engine oil level, repair the engine buzzer will sound, engine is shut down
if necessary. after 4 seconds.
f red = flashes if the engine overheats (oil tem- v red = Central warning light, lights if a fault code
perature), the warning buzzer sounds, is displayed
the engine is shut down after 2 minutes. x = Engine rpm-meter
Switch off vibration, run engine with idle
speed or shut down engine if necessary,
clean engine oil cooler and radiator, if
necessary repair engine.
g yellow = lights if combustion air filter cartridge is
soiled, clean or replace if necessary.
h red = flashes when the coolant (filling) level is
too low.
Engine is shut down after 10 seconds.
452 BOMAG 008 911 71

Fault code display TCD 2012 / 2013 11.12
11.12Fault code display TCD 2012 /
2013
Fig. 1 Display
For a detailed description of how to read out fault

codes and the display please refer to the page on
electrics in the Service Training Manual.
! Caution
All detected faults are displayed
Fault codes 5000 - 5499 are diesel engine related
A detailed reading out of fault code for the diesel
engine is only possible through Deutz-Serdia
008 911 71 BOMAG 453

11.13 EMR3 List of fault codes
11.13EMR3 List of fault codes
454 BOMAG 008 911 71

EMR3 List of fault codes 11.13
008 911 71 BOMAG 455

456 BOMAG 008 911 71

008 911 71 BOMAG 457

458 BOMAG 008 911 71

008 911 71 BOMAG 459

460 BOMAG 008 911 71

008 911 71 BOMAG 461

462 BOMAG 008 911 71

008 911 71 BOMAG 463

11.14 SerDia Service-Software TCD 2012 / 2013
11.14SerDia Service-Software TCD

2012 / 2013
EDC16
EMR3
Fig. 1 Service-Software TCD 2012 / 2013 which can even be used if no EMR-fault is present
SerDIA is a software program from Deutz which ena- (start behaviour, engine sawing, lack of power).
bles the use of a laptop computer to run a more de-
Connection
tailed fault analysis and to read out the error log in
particular. For this purpose the PC or laptop is connected to the
diagnostic interface by means of an interface cable.
This procedure displays information like:
Work with SERDIA is described in separate operating
Location of fault (e.g. ’coolant temperature sensor’)
instructions.
Type of fault (e.g. 'bottom limit value fallen short of',
'sporadic fault')
Environmental data/operating data (speed and oper-
ating hours at the time of the last occurrence of the
fault).
Number of fault locations.
Frequency of fault
Fault status (active - fault present / passive - fault no
longer present).
Fault messages for faults that are no longer active or
have been rectified can be deleted with SERDIA.
Other possible displays:
Function test: Control outputs and governor rod travel
can be activated with the engine stopped.
Assignment of inputs / outputs: Display of the current
assignment of inputs and outputs on the EMR-control
Representation of measuring values: There is a vast
variety of measuring values available for selection
464 BOMAG 008 911 71

SerDia Service-Software TCD 2012 / 2013 11.14
SerDia connection
Serdia
connection
socket
Fig. 2 Serdia connection socket electric cabinet Any other EMR components (sensors etc) must under
no circumstances be repaired, but must be replaced if
Replacing the EMR3 control unit
they are defective.
Each control unit is firmly assigned to the engine, ac-
cording to its application. In case of replacement the
control unit must therefore be completed with an en-
gine specific data set. When ordering a new control
unit the engine serial number (sticker on EMR control
unit) must be specified alongside the part number.
Note: The Deutz part number specified on the EMR
control unit is the part number without engine specific
software. The correct part number is to be taken from
the spare parts catalogue.
Replacing the EMR or DCR components

On TCD-engines with Common Rail technology the
system pressure is so high, that in case of leaks or re-
pair all parts need to be replaced. When replacing
sensors or other electric components, the new parts
must be calibrated with the EMR control unit. The cal-
ibration must be made with the help of SERDIA (Level
IIIa). (see also SERDIA manual).
008 911 71 BOMAG 465

11.14 SerDia Service-Software TCD 2012 / 2013
SerDia screen shot
Fig. 3 Error log
466 BOMAG 008 911 71

General trouble shooting chart TCD 2012 / 2013 11.15
11.15General trouble shooting
chart TCD 2012 / 2013
Faults Causes Action

Temperature below starting limit Check
Oil level too low Fill up lubrication oil
Lubrication oil level too high Check the lubrication oil level, drain off if nec-
essary
Lubrication oil cooler defective Check
Exhaust gas counter pressure too high Check
Engine does not
V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
start or starts
Engine oil with wrong SAE viscosity class Change the lubrication oil
poorly
Fuel quality not as specified in the operating Change the fuel
instructions
Air in the fuel system Bleed the fuel system
Battery defective or not charged Check the battery
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not engage Check starter
Engine does not Engine electronics prevent starting Check fault by fault code, repair as necessary
start and diag-
nostic lamp flash-
ing
Engine starts, but V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
runs irregularly or Incorrect valve clearance Adjust
misfires Injector defective replaced
Glow plugs defective replace
Air in the fuel system bleed
Fuel pre-filter/fuel pre-cleaner soiled Clean
instructions
Injection line leaking Check the injection line
Injection valve defective Check / replace the injection valve
Speed changes Engine electronics detected a system fault Check fault by fault code, repair as necessary
are possible and and activates a substitute speed
diagnostic lamp
lights
Bleeding line clogged Clean
Engine shut-down lever still in stop position Check/replace
(shut-down solenoid defective)
Injector defective replace
Coolant heat exchanger soiled Clean
Coolant pump defective (V-belt torn or loose) check, whether torn or loose
Lack of coolant top up
Charge air pipe leaking Check the charge air pipe
V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
Engine overheat-
Lubrication oil filter on air or lubrication oil replace
ing. Temperature
side soiled
warning system
Lubrication oil level too low Fill up lubrication oil
responds
Lubrication oil level too high Check the lubrication oil level, drain off if nec-
essary
Air filter clogged / exhaust turbocharger de- Check/replace
fective
Air filter service switch / indicator defective Check/replace
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Short circuit of heat in cooling system Check the cooling system
Resistance in cooling system too high / flow check
quantity too low
008 911 71 BOMAG 467

11.15 General trouble shooting chart TCD 2012 / 2013
Faults Causes Action

Engine oil level too high Check the oil level
Engine shut-down lever still in stop position Shut-down solenoid defective
instructions
Air filter clogged / exhaust turbocharger de- Check/replace
Insufficient en- fective
gine power Air filter service switch / indicator defective Check/replace
Intercooler soiled Clean
Injection line leaking Check the injection line
Injection valve defective Check the injection valves
Insufficient en- Engine electronics reducing the output power Check fault by fault code, repair as necessary
gine power and
diagnostic lamp
lights
Engine does not Injection line leaking Check the injection valve / replace if neces-
work with all cyl- sary
inders Injection valve defective Check the injection valve / replace if neces-
sary
Oil level too low Fill up lubrication oil
Engine has to low Extremely slanted position of engine Check engine pillow blocks / reduce the en-
or no oil pressure gine inclination
Engine oil of wrong SAE class or quality Change the lubrication oil
Engine has ex- Engine oil level too high Check oil level, drain off if necessary
cessive oil con- Extremely slanted position of engine Check engine pillow blocks / reduce the en-
sumption gine inclination
Blue engine ex- Engine oil level too high Check oil level, drain off if necessary
haust smoke Extremely slanted position of engine Check engine pillow blocks / reduce the en-
gine inclination
Temperature below starting limit
White engine ex-
instructions
haust smoke
Injection valve defective Check the injection valve / replace if neces-
sary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
fective
Air filter service switch / indicator defective Check / replace if necessary
Black engine ex-
haust smoke
Injection valve defective Check the injection valve / replace if neces-
sary
468 BOMAG 008 911 71

Valve adjustment TCD 2012 / 2013 11.16
11.16Valve adjustment TCD 2012 /
2013
Fig. 1 TCD 2012 and 2013 Sense of rotation

General definition Viewed on drive side (flywheel side)
turning ccw: counter-clockwise (see example)
Cylinder arrangement, engine side and sense of rota- Engine sides: Viewed on power take-off side.
tion left = left = exhaust side
right = right = operation side
The cylinders must be successively numbered, start-
ing with 1 at the flywheel .
Fig. 1 TCD 2012 / 2013 Valves Turn the rotation angle disc (3) clockwise, until the
specified angle is reached:
Adjusting the valve clearance (without exhaust
gas recirculation) Engine TCD 2012
Loosen the counter nut (1). IN = intake valve 75°
Attach the rotation angle disc (3) and the spanner EX = exhaust valve 120°
socket (4) to the valve clearance adjustment screw Engine TCD 2013
(2).
IN = intake valve 90°
Fix the magnet (5) of the rotation angle disc (3).
EX = Exhaust valve 150°Hold the rotation angle disc
Turn the rotation angle disc (3) clockwise against the (3) against turning
stop (rocker arm no clearance) and set the scale to ze-
Tighten the counter nut (1).
ro.
008 911 71 BOMAG 469

11.16 Valve adjustment TCD 2012 / 2013
Then adjust the second valve on the rocker arm as de-

scribed above.
Repeat the adjustment procedure on each cylinder.
470 BOMAG 008 911 71

Valve adjustment TCD 2012 / 2013 11.16
Fig. 2 TCD 2012 / 2013 Valves
Adjusting the valve clearance (with exhaust gas

recirculation) TCD 2012 / 2013 - 4 cylinder
For the exhaust valves the same adjustment proce- Overlapping of valves adjustment
dure is to be used as for engines with exhaust gas re- 1 4
circulation. 3 2
4 1
Adjusting the intake valves 2 3
Loosen the counter nut (6).
TCD 2012 / 2013 - 6 cylinder
Attach the rotation angle disc (3) with the special
spanner (8) to the valve adjustment screw (7) on the Overlapping of valves adjustment
intake valve. 1 6
5 2
Fix the magnet (5) of the rotation angle disc (3).
3 4
Turn the rotation angle disc (3) clockwise against the 6 1
stop (rocker arm no clearance) and set the scale to ze- 2 5
ro. 4 3
Turn the rotation angle disc (3) clockwise, until the
specified angle is reached:
Engine TCD 2012
IN = intake valve 75° Engine
TCD 2013
IN = intake valve 90°
Hold the rotation angle disc (3) tight to prevent it from
turning.
Tighten the counter nut (6).
Then adjust the second valve on the rocker arm as de-
scribed above.
Repeat the adjustment procedure on each cylinder.
Valve clearance adjustment schematic

Overlapping of valves: Exhaust valve not yet closed,
intake valve starts to open.
! Caution
These engines are equipped with an exhaust gas
recirculation system.
During the exhaust cycle the intake valve opens
for a short moment.
This must not be mistaken as overlapping of
valves!
008 911 71 BOMAG 471

11.17 Ribbed V-belt - fan drive TCD 2012 / 2013
11.17Ribbed V-belt - fan drive TCD

2012 / 2013
Fig. 1 Ribbed V-belt
i Note
Check the distance between the tongue of the move-
able tensioner arm and the stop on the fixed tensioner
housing.
If the distance "a" is smaller than 3 mm, replace the

belt.
472 BOMAG 008 911 71

Special tools, Deutz engine (TCD 2012 2V) 11.18
11.18Special tools, Deutz engine
(TCD 2012 2V)

TCD 2012 2V Standard tools
8002
Pressure pump
Checking fuel system for leak-tightness
057 250 66
© 35409-2
8005
Compression pressure tester
for diesel engines
10 - 40 bar
057 250 67
© 35410-3
8024
Assembly pliers
Removing valve stem gaskets
057 250 68
© 37509-2
008 911 71 BOMAG 473

11.18 Special tools, Deutz engine (TCD 2012 2V)
Standard tools TCD 2012 2V
8113
Socket wrench insert
Torx - E 14
057 250 69
© 43022-0
8114
Torx - E 20
057 250 70
© 35415-1
8115
V-belt tension meter
150 to 600 N
for checking the V-belt tension
079 947 09
© 35416-3
474 BOMAG 008 911 71


8189
Torx tool set
Case containing:
- Double-ended ring spanner E6/E8
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
079 947 01
© 39432-1
8190
Rotation angle disc
with magnet
Setting valve clearance
057 250 72
© 43528-0
8191
Screwdriver insert
for slotted screw
Valve clearance setting
057 250 74
© 43060-0
008 911 71 BOMAG 475

8192
Bowl wrench
Fuel pre-filter (type: Racor)
057 250 73
© 43193-1
8194
Screwdriver insert
with hexagonal socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)
057 250 75
© 43183-0
8196
Open end wrench adapter
Size 13,
for torque wrench
Tightening of lock nut of the valve clearance setting
screw
057 250 71
© 43019-0
476 BOMAG 008 911 71


8198
Pricker
Removing rotary shaft lip seal
057 250 76
© 43206-0
8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)
057 250 77
© 44309-0
9017
Assembly lever
Example: Removing and installing the valves
057 250 78
© 37511-2
008 911 71 BOMAG 477


TCD 2012 2V Special tools
100 190
Connection piece
(in conjunction with compression pressure tester 8005)
057 250 79
© 42524-1
100 320
Turning gear
flywheel side
057 250 80
© 35422-1
100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper
079 947 19
© 35423-1
3/12
478 BOMAG 008 911 71

Special tools TCD 2012 2V
100 400
Dial gauge with fixing wheel
Measuring range 0 -10mm / 0.01mm
057 250 81
© 35424-1
100 410
Digital gauge
Measuring range 0 -30 mm / 0.01 mm
057 250 82
© 43205-0
100 750
Measuring apparatus
Measuring bar with two spacing washers
(in conjunction with 100 400 or 100 410)
Checking valve lag dimension
Checking piston projection
057 250 83
© 39402-1
008 911 71 BOMAG 479


103 050
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)
057 250 84
© 43023-0
103 220
Special pliers
for removing the roller tappet
057 250 85
© 43010-0
110 500
Special wrench
Size 17
Removing and installing high-pressure lines
057 250 86
© 35436-1
480 BOMAG 008 911 71

110 700
long
Assembling/disassembling pressure sensors
(rail pressure, oil pressure, fuel pressure)
057 250 87
© 43198-2
110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three assembly sleeves
with guide:
- High pressure pump (Ø 36), 110 902
- Injector, 2V motor (Ø 16), 110 903
Disassembling/assembling O-rings
057 250 88
© 43208-0
120 430
Assembly tool
Removing and installing the heating plugs
057 250 89
© 43020-0
008 911 71 BOMAG 481


120 900
Support bracket
pivoting
Clamping cylinder head
057 250 90
© 35438-3
120 910
Base plate for support bracket
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)
057 250 91
© 35439-3
121 410
Assembly tool
Assembling valve stem gaskets
057 250 92
© 37614-2
482 BOMAG 008 911 71

121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket
057 250 93
© 43210-0
130 300
Universal piston ring pliers
Removing and installing the piston rings
057 250 94
© 43021-0
130 440
Trapezoidal groove wear gauge
for piston diameter 101 mm
Check piston ring groove
057 250 95
© 36461-2
008 911 71 BOMAG 483


130 450
for piston diameter 98 mm
Check piston ring groove
057 250 96
© 36461-2
130 660
Piston ring tensioning band
Piston diameter 98 mm
057 250 97
© 39408-1
130 670
Piston ring tensioning band
057 250 98
© 39408-1
484 BOMAG 008 911 71

142 670
Assembly tool
Assembling crankshaft sealing ring
(opposite side to flywheel)
079 947 26
© 35445-1
142 830
Assembly tool
for crankshaft (flywheel side)
079 947 27
© 35446-1
144 800
Counter support
Torsional vibration damper
057 250 99
© 35453-1
008 911 71 BOMAG 485


170 050
Special wrench
Unscrew the filter cartridges
079 947 28
© 37629-2
170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
079 947 29
© 43663-0
6066
Assembly block
Engine clamping, double-sided
079 947 30
© 35451-2
486 BOMAG 008 911 71

6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided
079 947 31
© 35452-1
008 911 71 BOMAG 487

11.19Special tools, Deutz engine

(TCD 2013 2V)

8002
Pressure pump
Checking cooling system for leak-tightness
057 250 66
© 35409-2
8005
Compression pressure tester
for diesel engines
10 - 40 bar
057 250 67
© 35410-3
8011
Hose clip pliers
e. g. fuel return pipe
© 39426-1
488 BOMAG 008 911 71

8024
Assembly pliers
Removing valve stem gaskets
057 250 68
© 37509-2
8035
reinforced, size 22
removing and installing main bearing
© 37504-2
8113
Torx - E 14
057 250 69
© 43022-0
008 911 71 BOMAG 489


8114
Torx - E 20
© 35415-1
8115
V-belt tension measuring device
150 to 600 N 079 947 09
for checking the V-belt tension
079 947 09
© 35416-3
8189
Torx tool set
Contents of case:
079 947 01
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
079 947 01
© 39432-1
490 BOMAG 008 911 71

8190
Rotation angle disc
with magnet
Setting valve clearance
057 250 80
© 43528-0
8191
Screwdriver insert
for slotted screw
Valve clearance setting
057 250 74
© 43060-0
8192
Bowl wrench
Fuel pre-filter (type: Racor)
057 250 73
© 43193-1
008 911 71 BOMAG 491


8193
Screwdriver insert
with pressed in hexagonal pin (5 mm),
© 43183-0
8194
Screwdriver insert
with hexagon socket (size 4 mm),
057 250 75
© 43183-0
8195
Multi-toothed screwdriver set
260 mm long
remove and install air compressor
© 43195-0
492 BOMAG 008 911 71

8196
Open end wrench adapter
Size 13,
for torque wrench
Tightening of lock nut of the valve clearance setting
screw
057 250 71
© 43019-0
8198
Pricker
Removing rotary shaft lip seal
057 250 76
© 43206-0
8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)
057 250 77
© 44309-0
008 911 71 BOMAG 493


9017
Assembly lever
Example: Removing and installing the valves
057 250 78
© 37511-2
9090
Spring band pliers
320 mm
tighten spring band clamp
© 35420-3
494 BOMAG 008 911 71


100 190
Connector
(in conjunction with compression pressure tester 8005)
057 250 79
© 42524-1
100 320
Turning gear
flywheel side
057 250 80
© 35422-1
100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper
079 947 19
© 35423-1
008 911 71 BOMAG 495

100 400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
057 250 81
© 35424-1
100 410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
057 250 82
© 43205-0
100 750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection
057 250 83
© 39402-1
496 BOMAG 008 911 71


103 050
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)
057 250 84
© 43023-0
103 220
Special pliers
for removing the roller tappet
057 250 85
© 43010-0
110 500
Special wrench
Size 17
Removing and installing high-pressure lines
057 250 86
© 35436-1
008 911 71 BOMAG 497

110 640
Lever tool
Remove injector
© 43941-0
110 700
long
Installing and removing pressure sensors
(rail pressure, oil pressure, fuel pressure)
057 250 87
© 43198-2
110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three
assembly sleeves with guide:
- High pressure pump (Ø 36), 110 902
Removing and installing O-rings
057 250 88
© 43208-0
498 BOMAG 008 911 71


120 430
Assembly tool
Removing and installing the glow plugs
057 250 89
© 43020-0
120 680
Puller
(in conjunction with slide hammer 150 800)
Removing fixed injector sealing ring
© 35437-1
120 900
Support bracket
pivoting
Clamping cylinder head
057 250 90
© 35438-3
008 911 71 BOMAG 499

120 910
Base plate
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)
057 250 91
© 35439-3
121 330
Assembly lever
Removing and installing the valves
© 43185-0
121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket
057 250 93
© 43210-0
500 BOMAG 008 911 71


130 300
Universal piston ring pliers
Removing and installing the piston rings
057 250 94
© 43021-0
130 420
© 36461-2
130 640
Piston ring compressor
© 39408-1
008 911 71 BOMAG 501

142 810
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
© 35446-1
142 820
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
© 35445-1
150 170
Puller, universal
Comprising traverse, support and threaded rod
(in conjunction with disc 150 171)
Removing cylinder liner
© 43207-0
502 BOMAG 008 911 71


150 171
Plate
(in conjunction with puller 150 170)
for liner diameter: 108 mm
Removing cylinder liner
© 43204-0
150 180
Liner holder
(Set comprises 7 holders)
Turning crankshaft with cylinder head removed
© 43181-0
150 190
Assembly lever
Lever with bolts
(in conjunction with disc 150 191)
Installing cylinder liner
© 43209-2
008 911 71 BOMAG 503

150 191
Washer
(in conjunction with assembly tool 150 190)
for liner diameter: 108 mm
Installing cylinder liner
© 43203-2
150 800
Slide hammer 079 947 18
(in conjunction with puller 120 680)
Removing injector sealing ring
079 947 18
© 35449-2
170 050
Special wrench
Unscrewing the filter cartridges
079 947 28
© 37629-2
504 BOMAG 008 911 71


170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
079 947 29
© 43663-0
6066
Assembly block
Engine clamping, double-sided
079 947 30
© 35451-2
6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided
079 947 31
© 35452-1
008 911 71 BOMAG 505

6068
Engine lifting device
Version for commercial vehicles with worm gear, ulti-
mate load (2t), 3-point suspension, spindle clamp,
traverse, chains and hooks
© 43184-0
6692
Slotted nut wrench
Cable plug
© 43199-0
506 BOMAG 008 911 71

12 Air conditioning system
008 911 71 BOMAG 507

12.1 Physical basics
12.1 Physical basics A - heat absorption
In order to understand the working principle of an air B- Heat dissipation

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.
Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.
508 BOMAG 008 911 71

Physical basics 12.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
● Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
● Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
● Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.
Fig. 4 Pressure - Temperature Diagram

In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
Fig. 3 Steam pressure curve A - compression
Steam pressure curve for refrigerant R134a B- condensation
The steam pressure curve is a means for explaining C- relaxation
the operation principle of an air conditioning system. D- evaporation.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0°C and a pressure of 5 bar, but becomes gaseous
at 40°C and 5 bar.
For better understanding one must also be aware of
the following:
1. A gas heats up when being compressed (e.g. air
pump, turbo charger, ...).
2. When relieving gas it will cool down (e.g. white frost
forms on the valve when relieving air pressure from a
car tire).
3. Condensing gas dissipates a lot of heat energy.
008 911 71 BOMAG 509

12.1 Physical basics
Excerpt from the wet steam table 1 R134a

1 This table is used for the determination of evaporation and con-
densation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar
reading Pe in bar) P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72
510 BOMAG 008 911 71

Refrigerant R134a 12.2
12.2 Refrigerant R134a Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
General lowing trade marks.
The evaporation and condensation process is the H-FKW 134a
method commonly used in mobile air conditioning sys- SUVA 134a
tems. The system in this case works with a substance KLEA 134a
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and Colour:
under a steam pressure of 1 bar. Refrigerant in form of vapour or liquid is colourless as
Although the refrigerant circuit is a hermetically closed water. The gas is invisible. Only the bordering layer
loop, the system loses approx. 100g of refrigerant between gas and liquid is visible. (Fluid level in rising
over the course of 1 year by diffusion through hoses, pipe of filling cylinder or bubbles in inspection glass).
pipes and seals, even though the system is free of In the inspection glass the liquid refrigerant R134a
leaks. If too much refrigerant is lost the cooling power may appear coloured (milky). This turbidity results
of the system will drop. from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Physical data of the refrigerant R134a
Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.
Boiling point at 1 bar:

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
-101.6 °C
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
008 911 71 BOMAG 511

12.3 Compressor oil / refrigeration oil
liquid container has absorbed approx. 8 gr. of water, 12.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
512 BOMAG 008 911 71

Working principle of the air conditioning system 12.4
12.4 Working principle of the air 12.5 Monitoring devices
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating
The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because
for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu-
tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig-
pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.
008 911 71 BOMAG 513

12.6 Description of components
Monitoring chain 12.6 Description of components
Compressor
Fig. 2 Monitoring chain consisting of:

● 1 Switch
● 2 Fuse
● 3 Thermostat
● 4 Low pressure switch contact Fig. 1
● 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
●
6 Relay
the function of the system. Coupling and decoupling is
●
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
●
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.
Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.
514 BOMAG 008 911 71

Description of components 12.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve
! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.
i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.
008 911 71 BOMAG 515

Dryer / filter / fluid container / inspection Safety valve

glass
Fig. 2
Fig. 1 The fluid container is equipped with a safety valve.

Response pressure 32 +/- 4 bar
Dryer / filter
Tightening torque 10 - 15 Nm
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve. Inspection glass
Moisture that has entered during assembly of the re-
frigerant circuit is absorbed by a dryer in the fluid con-
tainer.
At evaporation temperatures below zero the refriger-
ant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expan-
sion valve. Moreover, moisture in the refrigerant cir-
cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
Fig. 3
i Note During operation the refrigerant must flow through the
Since the absorbing capacity of this filter/dryer is lim- inspection glass without air bubbles. In most cases
ited, it must be changed within certain service inter- the presence of air bubbles is a sign for a too low re-
vals. We recommend to replace it 1 x per years, frigerant level in the system. Apart from this, the refrig-
before the start of the season. erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
! Caution down to a level, at which gaseous refrigerant could
The filter/dryer must generally be replaced when- flow through the rising tube to the inspection glass.
ever opening the refrigerant circuit, because This results in abnormally high temperatures in and on
moisture will enter in such a case. the fluid lines (between refrigerant container and ex-
This requires emptying the air conditioning sys- pansion valve), as well as very high pressures in the
tem! pressure side.
Installation position: However, incorrect evacuation or filling may also be

the reason for air entering into the system and since
The arrow marks on the filter/dryer must point in air cannot be condensed, one will not be able to get
flow direction, i.e. towards the expansion valve. rid of these bubbles by topping up refrigerant. In this
Filter/dryer cannot be treated for further use! case the air conditioning system needs to be evacuat-
ed and refilled.
516 BOMAG 008 911 71

i Note Expansion valve
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.
! Danger
In case of mechanical damage or corrosion on

this pressure container this collector unit must be
replaced, to avoid bursting and further damage. Fig. 1
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
008 911 71 BOMAG 517

Evaporator Defroster thermostat
Fig. 1 Fig. 1
The evaporator is mounted inside the HKL-module in The feeler of a defroster thermostat to switch off the
the cabin. It consists of a heat exchanger (inside air - magnetic clutch in case of icing up or to switch the
refrigerant), with refrigerant flowing to a pipe system clutch back on after defrosting, is mounted on the
with cooling flanges. evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
As with the condenser, correct operation of all fans
should be checked during maintenance.
and cleanliness of the fins must be assured.
Switching point on: + 1°C (± 1°C)
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator, Switching point off: + 5,5°C (± 1°C)
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. i Note
A condensation water filter is mounted in the air flow It is very important that the feeler is mounted down-
after the evaporator. This filter has the function to col- stream of the evaporator, but before the pressure sen-
lect the water that has condensed from the air in the sor, in countercurrent direction, with full length and
evaporator block and to discharge this water into the insulated against the outside temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
518 BOMAG 008 911 71

Pressure switch Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
Fig. 1
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure Recommended tightening torques for O-ring
side, the pressure switch will switch of the magnetic sealed fittings
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw- Thread Spanner width Torque
ing in external gases and foreign matter as a result of 5/8“ 17 or 19 13,6 - 20,3 Nm
too low pressure. 3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
Working pressure:
1 1/16“ 32 40,7 - 47,5 Nm
Low pressure off: 1,5 ±0,5 bar M30X2 36 105,0 - 115,0
Low pressure on: 3.5 bar Nm
M36X2 41 165,0 - 175,0
Overpressure off: 25,0 ±1,5 bar
Nm
Overpressure on: 18,0 ±1,5 bar
Bending radii for air conditioning hoses
Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm
008 911 71 BOMAG 519

12.7 Checking the compressor oil level
12.7 Checking the compressor oil

level
Checking the compressor oil level / refrig-

eration oil level
!Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
● Run the compressor for 10 minutes at engine idle
speed.
● In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi- Fig. 2
tioning system. ● Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.
i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
● Insert the oil dipstick.
● Pull out the dipstick and count the notches covered
by oil.
● Drain off oil or fill up as specified in the table.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
Fastening angle (de- Oil dipstick in incre-
● Measure the fastening angle (Fig. 1) of the com- gree) ments
pressor (oil plug at top) 0 5-7
●
Remove the oil filler plug. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
●
Screw the oil filler plug back in.
! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
● Refill the air conditioning system.
520 BOMAG 008 911 71

Checking the magnetic clutch 12.8
12.8 Checking the magnetic clutch i Note
● Measure the voltage. The gap should be 0.4 to 0.8 mm.
●
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
i Note
Nominal value = vehicle voltage
●
Check the magnetic coil locking ring for secure fit.
i Note
In case of excessive flatness faults or deviations the
●
Check the current consumption. magnetic clutch needs to be replaced.
Cross-section of magnetic clutch

Fig. 3 shows a cross-section of the magnetic clutch. If
the coil (7) is not supplied with operating voltage,
there is no contact between the front plate of the
clutch (1) and the V-belt pulley (2). A spring presses
the front plate away from the belt pulley. The V-belt
pulley rotates with the bearing (3) in idle speed, the
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is
generated and pulls the front plate of the clutch. Both
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works.
Fig. 1
i Note
Nominal value approx. 3.5 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.
Fig. 3 Cross-section of magnetic clutch
Fig. 2 Measuring the air gap

●
Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).
008 911 71 BOMAG 521

12.9 Inspection and maintenance work
12.9 Inspection and maintenance 12.10Checking, replacing the refrig-

work erant compressor V-belt1
● Visual inspection of the complete system for dam-
age. Danger
!
● Check the compressor mounting bracket on the ve- Danger of injury!
hicle engine for tight fit and damage.
Work on the V-belt must only be performed with
● Check the condition, alignment and tightness of the the engine shut down.
V-belt.
Wear safety goggles.
●
Check the routing of refrigerant hoses and cables in
the area of the vehicle engine and transmission, as
Check the V-belt
well as on the chassis for chafing and rectify any de-
tected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
● Check the routing of hoses and hoses on the at-
tachment box or in the cabin.
● Check all hose and screw fittings for leaks.
● Check the fastening of the condenser unit.
●
Clean the condenser fins, replace the condenser
block if damaged fins are found.
●
Check the fastening of the evaporator unit.
●
Check the function of evaporator and condenser
fans. Fig. 4
●
Check the electric control panel. If discolorations on ●
Inspect the entire circumference of the V-belt (Fig.
conductors are found, these should be replaced 4) visually for damage and cracks. Replace dam-
and possibly also the corresponding relays. aged or cracked V-belts.
●
Switch on the cooling system and check the refrig- ● Check with thumb pressure whether the V-belt can
erant level. be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
●
Filter/dryer and filter/dryer/fluid container combina-
essary.
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by Tighten the V-belt.
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
● Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
●
Measuring the pressure in the refrigerant circuit
Fig. 5
●
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).
1 Optional equipment
522 BOMAG 008 911 71

Service the air conditioning 12.11
Press the compressor in direction of arrow, until the
12.11Service the air conditioning1
●
correct V-belt tension is reached.

● Retighten all fastening screws.
Cleaning the condenser
Changing the V-belt
! Caution
● Slightly slacken the fastening screws 1, 2 and 3.
A soiled condenser results in a considerable re-
● Press the compressor against the direction of arrow duction of air conditioning power.
completely against the engine.
Under extremely dusty conditions it may be nec-
● Take the old V-belt off. essary to clean the condenser several times per
● Fit the new V-belt to the V-belt pulleys. day.
● Tension the V-belt as previously described. If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
Caution
!
In case of formation of foam have the air condi-
Check the V-belt tension after a running time of 30 tioning system inspected by the service depart-
minutes. ment.
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 6
● Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
●
Clean the condenser fins on front and back with
compressed air or cold water .
Checking the refrigerant level

●
Start the engine.
1 Optional equipment
008 911 71 BOMAG 523

12.11 Service the air conditioning
Fig. 7 Fig. 9
● Switch the air conditioning (Fig. 7) on. ● Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top.
i Note
The refrigerant level is correct.
Fig. 8
● Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
●
Open the air outlet nozzles.
●
Check, whether the outflowing air is noticeably cool-
er. Fig. 10
●
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
i Note
the service department.
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on. i Note
● Open the hood. The refrigerant level is not correct.
● Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.
524 BOMAG 008 911 71

Service the air conditioning 12.11
Checking the moisture level of the drying
agent
Fig. 12
● Check the drier/collector unit (Fig. 12) for mechani-
cal damage or rust.
Fig. 11
● Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too high.
● Inform the service department. Replace drier/col-
lector unit, check air conditioning system.
Caution
!
Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.
Checking the condition of the drier/col-

lector unit
!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.
! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.
008 911 71 BOMAG 525

12.12 Drying and evacuation
12.12Drying and evacuation 12.13Emptying in case of repair

Evacuation of air conditioning systems using R-type For repair work the air conditioning systems must very
refrigerants not only has the purpose of emptying the often be emptied of all refrigerant.
system of all air before filling in refrigerant, but also to Especially with expensive refrigerants and larger
verify the leak tightness over a longer lifetime in the amounts of oil it may be necessary to keep the refrig-
achieved vacuum. However, the most important factor erant for later use.
in this work step is the drying of the system.
For later use these refrigerants must be drawn out
Any water residues in the refrigerant circuit will com- with suitable equipment and intermediately stored in
bine with the refrigerant, which will lead to the previ- collecting containers.
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
Environment
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration Contaminated refrigerant must be disposed of en-
system. vironmentally
The refrigerant compressor is not suitable for the pur- Releasing refrigerant into the atmosphere is pro-
pose of evacuation, because it is not able to achieve hibited (see restrictive injunction concerning
a sufficient final vacuum and, apart from this, may be CFC, day of enforcement 01. 08. 1991, § 8)
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
! Danger
It is common practice to evacuate the refrigeration For draining refrigeration systems you should not
system to a final vacuum of 1 Torr, i.e. 1.33 mbar. simply use any delivery containers, but only ap-
An exact time for evacuation and drying cannot be propriate pressure bottles, which must be special-
predicted. It can only be determined by means of a ly marked and should comply with the pressure
vacuum meter. However, if there is no vacuum meter gas directive.
at hand it is generally better to evacuate 1 hour longer
When transferring refrigerant you must make sure
than 1 hour too less.
that the bottle does not contain more than the per-
Function drying: mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced, In order to reduce the evacuation period in case of
water will already evaporate, e.g. under a pressure of short repairs, you may fill the refrigerant circuit with
10 mbar, at an ambient temperature of almost 7°C, approx. 0.5 bar nitrogen when opening. This ensures
but the water will not evaporate all at once. Since it is that nitrogen will flow out of the refrigerant circuit while
very difficult to separate the steam from the vacuum in it is open and no air or moisture can enter. However,
the system, the evacuation process is supported by the necessity for vacuum generation and a dryer
the co-called vacuum breaking (filling the circuit with change remains.
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.
526 BOMAG 008 911 71

Leak test 12.14
12.14Leak test
! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
Leak test with electronic leak tester
Fig. 1 Electronic leak tester

Small leaks with only very low amounts of refrigerant
escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
than 5 gr. per year.
The leak tester used must be specially designed for
the refrigerant composition in the air conditioning sys-
tem. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.
Leak test with soap bubbles
Fig. 2 Soap bubble test

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.
008 911 71 BOMAG 527

12.15 Filling instructions
12.15Filling instructions
Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).
! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.
i Note
White frost on the suction line is no measure for as-
sessing the filling.
528 BOMAG 008 911 71

Filling instructions 12.15
Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge
008 911 71 BOMAG 529

12.15 Filling instructions
19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
530 BOMAG 008 911 71

Trouble shooting in refrigerant circuit, basic principles 12.16
12.16Trouble shooting in refriger-
ant circuit, basic principles
Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
● Expert knowledge
● technical equipment
Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
●
Service station
Filling the system with refrigerant causes an excess
●
Pressure gauge pressure of Pe = 3 bar.
●
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
●
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
●
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
●
Container for old oil
●
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
●
Hoses
● Scales
● Suction station
● Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.
Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
008 911 71 BOMAG 531

12.16 Trouble shooting in refrigerant circuit, basic principles
Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.
Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
Δ to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature. Δ to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.
Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause
532 BOMAG 008 911 71

Trouble shooting in refrigerant circuit, basic principles 12.16
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.
Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.
Supercooling is calculated as follows:
Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"
008 911 71 BOMAG 533

12.16 Trouble shooting in refrigerant circuit, basic principles
Fig. 1 Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion
534 BOMAG 008 911 71

Trouble shooting, refrigerant circuit diagram 12.17
12.17Trouble shooting, refrigerant
circuit diagram
Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air
008 911 71 BOMAG 535

12.18 Trouble shooting procedure
12.18Trouble shooting procedure ● Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
● The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
● Ambient temperature above 15 °C.
about the system design, the installed components ● The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:
Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.
i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites
● Cooler and condenser are clean, clean if neces-
sary.
● The ribbed belt for compressor and generator is
correctly tightened.
● All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
● The engine has operating temperature.
536 BOMAG 008 911 71

Trouble shooting procedure 12.18
Measuring points and measurements
Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
● C, condenser measuring points tainer the inspection glass is most suitable to check
● E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
● O, evaporator measuring points
The hot gas temperature can be used to check wheth-
● V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
● a) Which measuring equipment is required ?
can be used to derive the overheating of the evapora- ● b) Where to measure with which size ?
tor. Overheating is a clear indicator for the evaporator ● c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is ●
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- ● e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „Δto2h“ ?
Pressure and temperature at the condenser outlet can ●
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used
008 911 71 BOMAG 537

Solution: be a defect in the expansion valve or problems in the

● a) Pressure gauge, thermometer, steam table oil recirculation.
● b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
● c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
●
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
● e) Δto2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
● f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
● a) Which measuring equipment is required ?
●
b) Where to measure with which size ?
●
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
●
d) How high is the condensing temperature "tc" ?
●
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
●
f) Evaluation of the measured supercooling.
Solution:
●
a) Pressure gauge, thermometer, steam table
●
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
● c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
● d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
● e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
● f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.
Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also
538 BOMAG 008 911 71

Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X
008 911 71 BOMAG 539

Suction pressure too low (1), high pressure too

low to normal (2)
Fig. 3
Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently
540 BOMAG 008 911 71

Suction pressure normal (1), high pressure too
high (2)
Fig. 4

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power
008 911 71 BOMAG 541

Suction pressure too high (1), high pressure too

low to normal (2)
Fig. 5

Compressor defective Cooling power too low Replace the compressor
542 BOMAG 008 911 71

Suction pressure too high (1), high pressure too
high (2)
Fig. 6

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor
008 911 71 BOMAG 543

Other faults
Symptom Cause Possible effect Remedy

Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil
high, the hot gas line be- wear
comes so hot that it cannot
be touched long with a
hand
Compressor does not start Pressure switch or any oth- System stopped Check the control units,
er safety feature has trig- check cause for switching
gered, electrical fault, and rectify
cylinder filled with liquid re-
frigerant
Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units,
tinuously small, triggering of a creased wear, too low cool- check cause for switching
switching element (over- ing power and rectify
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating Expansion valve deadjust- low cooling power, hot gas Replace the expansion
ed or screen blocked, lack temperatures too high valve, clean the screen, fill
of refrigerant in refrigerant, leak test
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator sion valve, lack of refriger- into the evaporator valve, check the refrigerant
ant filling
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost flow volume tem check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure
shows condensation filter dryer clogged drop, replace the filter dryer
Exceptionally cold pres- "Wet intake" of the com- low cooling power, exces- Clean the compressor, re-
sure lines pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator the expansion valve if nec-
essary
Noise in system
Faults Possible cause Remedy

V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Refrigerant compressor is loud Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Fan is loud, fan motor excessively Replace the fan motor
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn Replace the bearing, check V-belt
tion, noticeable unevenness when pulley for wear
turning by hand
Rattling noise or vibration of high System overfilled Draw out refrigerant
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, refrigerant level in system too low Perform a leak test, fill up the system
on expansion valve, turbidity in in-
spection glass or ball does not float
544 BOMAG 008 911 71

Inspection glass

Steam bubbles in inspection glass No supercooling before expansion Fill up the system, replace the filter
valve, lack of refrigerant in system, dryer, perform a leak test
pressure loss in system, supercool-
ing caused by excessively soiled fil-
ter dryer
Discolouration of inspection glass Lubricant destroyed by excessive Replace the refrigeration oil, exam-
(black from inside) operating temperatures ine the temperature increase
Moisture indicator changes to pink Moisture level of drying agent too Replace the filter dryer
high
Ball floats at bottom lack of refrigerant Fill the system
Monitoring devices

The high pressure contact has System pressure exceeded, con- Clean the condenser, replace the
switched off the magnetic clutch denser excessively soiled, condens- expansion valve, check the con-
er fan defective, expansion valve denser fan
defective
The low pressure contact has System pressure fallen short of, re- Clean the evaporator, replace the
switched off the magnetic clutch frigerant level too low, expansion expansion valve, check the evapora-
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 °C
The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching
magnetic clutch expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
low evaporator fan
008 911 71 BOMAG 545

12.19 Steam table for R134a
Tempera- Pres- Density spec. volume spec. enthalpy Evapora-

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam
546 BOMAG 008 911 71

Steam table for R134a 12.19
008 911 71 BOMAG 547

548 BOMAG 008 911 71

Steam table for R134a 12.19
008 911 71 BOMAG 549

550 BOMAG 008 911 71

12.20Heating control / air conditioning control
008 911 71 BOMAG 551

12.20 Heating control / air conditioning control
552 BOMAG 008 911 71

Heating control / air conditioning control 12.20
008 911 71 BOMAG 553

554 BOMAG 008 911 71

Heating control / air conditioning control 12.20
008 911 71 BOMAG 555

556 BOMAG 008 911 71

13 Replacing the cab window panes
008 911 71 BOMAG 557

13.1 Assembly of window panes
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
558 BOMAG 008 911 71

Special tools 13.2
13.2 Special tools
1. Locking handle for fastening element
Fig. 1
2. Suction lifter
commercial
Fig. 2
008 911 71 BOMAG 559

13.3 Auxiliary materials
13.3 Auxiliary materials

Safety gloves
3. Cutter
Commercial
Fig. 1
4. Window glass bonding agent
Fig. 2
5. Activator
Fig. 3
560 BOMAG 008 911 71

Auxiliary materials 13.3
6. Silicone sealant
Fig. 4
008 911 71 BOMAG 561

13.4 Removing and installing the window pane
13.4 Removing and installing the window

pane
Environment
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.
! Danger
Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).
Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.
Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).
Fig. 3
562 BOMAG 008 911 71

Removing and installing the window pane 13.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).
i Note
Do not overtighten the thread.
Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).
i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.
Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.
Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 7
008 911 71 BOMAG 563

14. Remove the suction lifter (Fig. 8).
Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).
i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.
Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).
Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).
Fig. 11
564 BOMAG 008 911 71

Removing and installing the window pane 13.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).
Fig. 12
20. Treat the inside joint (Fig. 13)
Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.
i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 14
008 911 71 BOMAG 565

566 BOMAG 008 911 71

14 Drum
008 911 71 BOMAG 567

14.1 Special tools, drum, single drum rollers
14.1 Special tools, drum, single drum roll-

ers
1. Disassembly device for side plate
Fig. 1
2. Assembly device for side plate
Fig. 2
3. Assembly device for coupling hub and flanged
hub
Fig. 3
568 BOMAG 008 911 71

Special tools, drum, single drum rollers 14.1
4. Pressing plate for cylinder roller bearing
Fig. 4
5. Pressing plate for travel bearing
Fig. 5
6. Pressing bushing for radial seal
Fig. 6
7. Lifting device for exciter unit
Fig. 7
008 911 71 BOMAG 569

14.2 Repair overview for drum
Fig. 1
570 BOMAG 008 911 71

Repair overview for drum 14.2
1 Drum 13 Flanged hub
2 Cylinder roller bearing 14 Vibrator shaft
3 Coupling 15 Coupling
4 Vibration motor 16 Vibrator shaft
5 Rear shell 17 Change-over weight
6 Grooved ball bearing 18 Cylinder roller bearing
7 Spacer block 19 Basic weight
8 Rectangular rubber buffer 20 Flanged housing
9 Side plate 21 Flange
10 Spacer ring 22 Cylinder roller bearing
11 Grooved ball bearing 23 Cover
12 Mechanical seal
008 911 71 BOMAG 571

572 BOMAG 008 911 71

008 911 71 BOMAG 573

574 BOMAG 008 911 71

Fig. 2
008 911 71 BOMAG 575

576 BOMAG 008 911 71

008 911 71 BOMAG 577

578 BOMAG 008 911 71

Removing and installing the drum 14.3
14.3 Removing and installing the drum
i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).
Fig. 1
i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).
Fig. 2
Removing the drum
i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.
Environment
Catch running out hydraulic oil and dispose
of environmentally.
1. Mark the hydraulic hoses (Fig. 3) on the travel
motor and disconnect them from the ports.
2. Close all hydraulic hoses and motor ports with
suitable plugs.
3. Remove the guard plate (1).
Fig. 3
008 911 71 BOMAG 579

4. Unplug the plugs from solenoid valve and speed

sensor (Fig. 4) on travel motor side.
5. Close the connections with plugs.
Fig. 4
6. Mark the hydraulic hoses on the vibration motor
(Fig. 5) and disconnect them from the ports.
7. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 5
! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
Always secure the machine against unintend-
ed rolling!
8. Unscrew bolts 1 (Fig. 6) and nuts and remove the
front scraper (2).
9. Unscrew bolts 3 and nuts and remove the front
scraper (4).
Fig. 6
10. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).
Fig. 7
580 BOMAG 008 911 71

11. Support the rear cross-member safely with suita-
ble trestles or wooden blocks (Fig. 8).
Fig. 8
12. Disassemble bracket 1 (Fig. 9) for the hydraulic
hoses.
13. Pull the wiring loom off the speed sensor plug (ex-
citer shaft speed).
Fig. 9
14. Fasten the lifting gear to the side plate on the vi-
bration motor side.
15. Unscrew bolts 1 (Fig. 10) from the spacer blocks
on vibration and travel motors.
Fig. 10
16. Force out plug 1 (Fig. 11) and unscrew the bolts
(2) from the front and rear cross-members.
!Danger
17. Take off the side plate.
Fig. 11
008 911 71 BOMAG 581

18. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 12).
!Danger
Fig. 12
19. Check all rubber buffers (Fig. 13), replace if nec-
essary (see corresponding chapter).
Fig. 13
20. Check rectangular rubber buffers (Fig. 14), re-
place if necessary.
Fig. 14
582 BOMAG 008 911 71

Installing the drum
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 15).
Fig. 15
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
2. Attach the side plate, insert the bolts 2 (Fig. 16)
into rear and front cross-members and tighten
with 463 Nm.
3. Close the screw holes with plugs (1).
Fig. 16
4. Fasten the spacer blocks on travel and vibration
motor sides with bolts 1 (Fig. 17) and nuts to the
side plates.
Fig. 17
5. Connect hydraulic hoses (Fig. 18) to the connec-
tions on travel motor and vibration motor accord-
ing to the marking.
Fig. 18
008 911 71 BOMAG 583

6. Connect the wiring loom with the speed sensor

plug (vibration sensor).
7. Fasten bracket 1 (Fig. 19) for the hydraulic hoses.
Fig. 19
8. Plug the plugs from solenoid valve (Fig. 20) and
speed sensor on travel motor side.
Fig. 20
9. Connect hydraulic hoses (Fig. 21) to the connec-
tions on travel motor according to the marking.
10. Install the guard plate (1).
Fig. 21
11. Assemble the front scraper 2 (Fig. 22), fasten
with bolts (1), washers and nuts.
12. Assemble the rear scraper (4), fasten with bolts
(3), washers and nuts.
i Note
13. Observe the adjustment measurement 30-35 mm
Fig. 22
584 BOMAG 008 911 71

! Caution
Before resuming operation of the machine:
Bleed the hydraulic system and check for
function and leaks.
Adjust the pretension of the rubber buffers.
14. Measure distance „X“ between spacer piece 1
(Fig. 23) and side plate.
15. Calculate the thickness of the compensation
plates.
Nominal value:
Fig. 23
Distance "X" + 2 mm
16. Turn one screw (3) into the welded nut (2) at top
and bottom and open a sufficient gap to insert the
compensation plates.
17. Insert the compensation plates 4 (Fig. 24). Insert
screws (1), slide on washers (3), turn on and
tighten nuts (2).
18. Unscrew the screws from the welded nuts.
Fig. 24
008 911 71 BOMAG 585

14.4 Repairing the drum
Removing the travel motor

!Danger
Do not stand or step under suspended loads.
1. Attach the lifting tackle to travel drive 3 (Fig. 3).
2. Unscrew all nuts (1) from the rubber buffers.
3. Take drive disc (2) with travel drive off the rubber
buffers and lay it down.
Fig. 1
4. Unscrew fastening screws 3 (Fig. 5) and take off
support legs (4).
5. Unscrew fastening screws 1 and take off drive
disc (2).
Fig. 2
Disassembling the exciter unit (travel

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 3).
Fig. 3
586 BOMAG 008 911 71

Repairing the drum 14.4
2. Mount bracket 1 (Fig. 11) for the lifting device to
the flange.
3. Unscrew screws (2) from the flange.
i Note
Do not unscrew the thin drawn screws.
Fig. 4
4. Slide the lifting device over the bracket.
5. Force the exciter unit off with two forcing screws
(Fig. 5).
Fig. 5
! Danger
6. Pull the exciter unit out of the drum (Fig. 6).
7. Take the coupling element off the coupling half.
Fig. 6
008 911 71 BOMAG 587

Disassembling the exciter unit (travel

motor side)
1. Unscrew fastening screws 1 (Fig. 7) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.
Fig. 7
4. Unscrew all other fastening screws 1 (Fig. 8) from
the flange.
5. Press the flange off the flanged housing with forc-
ing screws (2).
Fig. 8
Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 9).
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 9
588 BOMAG 008 911 71

8. Unclip the circlip from the groove in the flange
(Fig. 10).
Fig. 10
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 11).
Fig. 11
10. Take the exciter unit (Fig. 12) out of the flanged
housing.
Fig. 12
11. Knock the radial seal (Fig. 13) out of the flanged
housing.
Fig. 13
008 911 71 BOMAG 589

12. Unclip the circlip from the groove in the flanged

housing (Fig. 14).
Fig. 14
screws out of the flanged housing (Fig. 15).
Fig. 15
14. Extract inner ring 1 (Fig. 16) for the radial seal
and inner bearing races (2).
! Danger
Danger of burning!
Wear safety gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 16
15. Unclip the circlip from the basic weight (Fig. 17).
Fig. 17
590 BOMAG 008 911 71

16. To change shaft 1 (Fig. 18) knock out dowel pins
(2 and 3) and press the shaft out of the basic
weight.
i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 18
Disassembling the exciter unit (vibra-

tion motor side)
1. Unscrew fastening screw 1 (Fig. 19).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.
iNote
Remove both rectangular rubber buffers.
Fig. 19
3. Unscrew fastening screws 1 (Fig. 20).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.
Fig. 20
008 911 71 BOMAG 591

5. To change the vibration motor loosen clamping

screw 1 (Fig. 21) and pull off coupling half (2).
Fig. 21
7. Take the vibration motor off the cover.
Fig. 22
8. Remove the coupling element (Fig. 23).
Fig. 23
9. Fasten the lifting device.
! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).
Fig. 24
592 BOMAG 008 911 71

11. Press the exciter unit out of the drum with forcing
screws (Fig. 25).
i Note
The second forcing screw is covered by the side
plate.
Fig. 25
!Caution
12. Pull the exciter unit out of the drum (Fig. 26).
Fig. 26
Removing, dismantling the side plate

1. Take off V-ring 1 (Fig. 27).
2. Unclip circlip (2).
Fig. 27
3. Attach the disassembly device to the side plate
(Fig. 28) and force off the side plate.
Fig. 28
008 911 71 BOMAG 593

4. Lift the side plate of the flanged hub (Fig. 29).
Fig. 29
5. Knock the grooved roller bearing out of the side
plate (Fig. 30) and take out the spacer ring.
Fig. 30
6. Unclip the circlip from the side plate (Fig. 31).
Fig. 31
7. Take the mechanical seal off the flanged hub
(Fig. 32).
Fig. 32
594 BOMAG 008 911 71

Dismantling the exciter unit (vibration
motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 33).
Fig. 33
3. Loosen hose clamp 1 (Fig. 34).
4. Pull coupling hub (2) off the shaft.
Fig. 34
5. Unscrew all other fastening screws 1 (Fig. 35)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 35
008 911 71 BOMAG 595


hub (Fig. 36).
Fig. 36
9. Knock the cylinder roller bearing out of the flang-
ed hub (Fig. 37).
Fig. 37
Environment
mentally.
10. Lift the exciter unit out of the flanged housing (Fig.
38).
Fig. 38
11. Knock the radial seal (Fig. 39) out of the flanged
housing.
Fig. 39
596 BOMAG 008 911 71

housing (Fig. 40).
Fig. 40
screws out of the flanged housing (Fig. 41).
Fig. 41
14. Extract inner rings 1 (Fig. 42) for the radial seals
and inner bearing races (2) from the shaft.
!Danger
Danger of burning!
Wear protective gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 42
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 43).
i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 43
008 911 71 BOMAG 597

Assembling the exciter unit (vibration

motor side)
! Caution
Ensure strict cleanliness.
i Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.
! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 44 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Close the bores on the short shaft with a
screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
44).
3. Secure shaft 1 (Fig. 45) with dowel pins (2 and 3).
! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
i Note
Unscrew the screw from the shaft.
Fig. 45
! Caution
Close the bores on the short shaft with a
screw.
46).
Fig. 46
598 BOMAG 008 911 71

! Caution
i Note
Unscrew the screw from the shaft.
Fig. 47
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 48).
Fig. 48
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 49).
Fig. 49 ! Danger
Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 50).
Fig. 50
008 911 71 BOMAG 599

! Danger
Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 51).
Fig. 51
!Danger
Danger of burning!
Wear safety gloves.
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 52).
Fig. 52
!Danger
Danger of burning!
Wear safety gloves.
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).
Fig. 53
13. Press cylinder roller bearing 1 (Fig. 54) with
pressing plate (2) into the flanged housing until it
bottoms.
Fig. 54
600 BOMAG 008 911 71

14. Insert the circlip into the groove in the flanged
housing (Fig. 55).
Fig. 55
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 56).
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 56
!Caution
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 57).
Fig. 57
pressing plate (2) into the flanged hub until it bot-
toms.
Fig. 58
008 911 71 BOMAG 601

19. Insert the circlip into the groove in the flanged hub
(Fig. 59).
Fig. 59
20. Attach the flanged hub to the flanged housing
(Fig. 60).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.
Fig. 60
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 61).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).
Fig. 61 !Danger
Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 62).
Fig. 62
602 BOMAG 008 911 71

1 (Fig. 63).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 63
28. Cover the thread of screw 1 (Fig. 64) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 64 ! Danger
Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 65) with marking letter
“L“ up t approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).
Fig. 65
008 911 71 BOMAG 603

Assembling and installing the side

plate
1. Fill grooved ball bearing 1 (Fig. 66) on both sides
with grease.
2. Press the grooved ball bearing completely in us-
ing pressing plate (2).
Fig. 66
3. Insert the circlip into the groove in the side plate
(Fig. 67).
Fig. 67
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
68).
Fig. 68
604 BOMAG 008 911 71

5. Fill grooved ball bearing 1 (Fig. 69) on one sides
with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).
i Note
Grease the other side after installing the exciter
unit.
Fig. 69
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 70).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.
Fig. 70
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 71).
Fig. 71
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 72).
Fig. 72
008 911 71 BOMAG 605

11. Bolt the threaded section of the assembly device

to the flanged hub (Fig. 73).
Fig. 73 ! Caution
under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 74).
Fig. 74
13. Attach bushing 2 (Fig. 75) of the assembly device
and turn on nut (1).
Fig. 75
14. Pull the side plate with the assembly device onto
the flanged hub.
! Caution
During assembly make sure that the mechan-
ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 76).
Fig. 76
606 BOMAG 008 911 71

15. Remove the assembly device.
16. Insert the circlip into the groove in the flanged hub
(Fig. 77).
Fig. 77
Assembling the exciter unit (travel

motor side)
!Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Fig. 78
78).
! Caution
Fig. 79
008 911 71 BOMAG 607

4. Insert the circlip into the groove in the basic

weight and on the cover (Fig. 80).
Fig. 80
! Danger
Danger of burning!
Wear safety gloves.
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 81).
Fig. 81
! Danger
Danger of burning!
Wear safety gloves.
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 82).
Fig. 82
! Danger
Danger of burning!
Wear safety gloves.
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 83).
Fig. 83
608 BOMAG 008 911 71

pressing plate (2) into the flanged housing until it
bottoms.
Fig. 84
9. Insert the circlip into the groove in the flanged
housing (Fig. 85).
Fig. 85
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 86).
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 86 ! Caution
12. Insert the exciter unit into the flanged housing
(Fig. 87).
Fig. 87
008 911 71 BOMAG 609


pressing plate (2) into the flange until it bottoms.
Fig. 88
14. Insert the circlip into the groove in the flange (Fig.
89).
Fig. 89
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 90).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Fig. 90
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 91).
Fig. 91
610 BOMAG 008 911 71

1 (Fig. 92).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 92
19. Cover the thread of screw 1 (Fig. 93) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 93
21. Insert the fitting key into the keyway of the shaft
(Fig. 94).
Fig. 94 !Danger
Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 95) with marking letter
“R“ up to approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.
Fig. 95
008 911 71 BOMAG 611

Assembling the exciter unit (travel

motor side)
1. Check coupling elements , replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 96).
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.
Fig. 96 ! Caution
4. Insert the vibrator unit into the drum (Fig. 97).
Fig. 97 i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
98) is in line with bore (2) in the drum.
Fig. 98
612 BOMAG 008 911 71

5. Turn in and tighten screws 2 (Fig. 99).
6. Remove bracket (1) for the lifting device.
Fig. 99
7. Cover the thread of screws (Fig. 100) with a
screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.
Fig. 100
Installing the travel motor

1. Assemble drive disc 2 (Fig. 101) and support (4)
with screws (3).
Fig. 101
! Danger
2. Attach the drive disc 2 (Fig. 102) with the assem-
bled travel drive (3) to the rubber buffers. Turn on
and tighten the nuts (1).
Fig. 102
008 911 71 BOMAG 613

Installing the exciter unit (vibration

motor side)
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
! Danger
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 103).
Fig. 103
! Caution
Ensure correct engagement of coupling and
alignment of shaft (Fig. 104).
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.
Fig. 104
2. Turn in and tighten screws 1 (Fig. 105).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.
Fig. 105
614 BOMAG 008 911 71

5. Check the end float of the exciter shafts (Fig.
106).
Nominal value: 0.6...1.8 mm
Fig. 106
6. Attach disc 1 (Fig. 107), turn in and tighten the
fastening screws (2).
Fig. 107
7. Lay a new V-ring over the journal of the flanged
hub (Fig. 108).
8. Fill the grooved ball bearing with grease.
Fig. 108
9. Check coupling element, replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 109).
Fig. 109
008 911 71 BOMAG 615

11. Fasten the vibration motor 1 (Fig. 110) to the cov-

er (5) so that the hydraulic connections and the
ventilation bore are opposite each other.
12. Turn in fastening screw (2) with ball disc (3) and
ball socket (4) and tighten.
Fig. 110
13. Slide on coupling half 2 (Fig. 111) and secure with
clamping screw (1).
Fig. 111
14. Attach the cover 2 (Fig. 112) with the installed vi-
bration motor, turn in and tighten the screws (1).
Fig. 112
15. Install rectangular rubber buffers 2 (Fig. 113) with
attached spacer block (3) and screws (1) to the
side plate.
i Note
Assemble both rectangular rubber buffers.
Fig. 113
616 BOMAG 008 911 71

008 911 71 BOMAG 617

14.5 Dismantling, assembling the change-over weights
14.5 Dismantling, assembling the change-

over weights
Dismantling the change-over weight

1. Unscrew all screws (Fig. 3).
Fig. 1
2. Force the cover off the basic weight with forcing
screws (Fig. 5).
Environment
mentally.
Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 6).
Fig. 3
618 BOMAG 008 911 71

Dismantling, assembling the change-over weights 14.5
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.
Fig. 4
Assembling the change-over weights

!Caution
1. Install new O-rings 1 and 2 (Fig. 5) with grease.
Fig. 5
2. Insert the change-over weight into the basic
weight (Fig. 6).
Fig. 6
3. Fill silicon oil 47 V 1000 cst up to the upper edge
of the change-over weight (approx. 2,5 litres) into
the basic weight (Fig. 13).
Fig. 7
008 911 71 BOMAG 619

14.5 Dismantling, assembling the change-over weights
4. Attach the cover (Fig. 14), so that the raised are-

as are in line.
5. Turn in screws with screw retention agent (e.g.
Loctite blue 243) and tighten with 120 Nm.
6. Check the end float of the shaft.
iNote
There must be play.
Fig. 8
620 BOMAG 008 911 71

Changing the rubber buffers and adjusting the pretension 14.6
14.6 Changing the rubber buffers and ad-
justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.
Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.
Fig. 2
4. Remove the compensation shims 1 (Fig. 3).
Fig. 3
008 911 71 BOMAG 621

14.6 Changing the rubber buffers and adjusting the pretension
5. Unscrew the screws (Fig. 4) from the welded

nuts.
Fig. 4
Changing the rubber buffers
6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.
Fig. 5
Adjusting the pre-load
12. Measure distance „X“ between spacer piece and
side plate (Fig. 6).
13. Calculate the thickness of the compensation
plates.
Nominal value:
Distance „X“ + 2 mm
Fig. 6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 7).
Fig. 7
622 BOMAG 008 911 71

Changing the rubber buffers and adjusting the pretension 14.6
15. Insert the compensation shims 1 (Fig. 8).
Fig. 8
16. Unscrew the screws (Fig. 9) from the welded
nuts.
Fig. 9
17. Tighten the fastening screws (Fig. 10).
18. Lower the frame again.
Fig. 10
008 911 71 BOMAG 623

14.6 Changing the rubber buffers and adjusting the pretension
624 BOMAG 008 911 71

15 Oscillating articulated joint
008 911 71 BOMAG 625

15.1 Special tools
15.1 Special tools

1. Pressing mandrel for rocker bearings
Fig. 1
2. Pressing sleeve for outer race of rocker bearing
Fig. 2
3. Pressing sleeve for inner race of rocker bearing
Fig. 3
4. Guide journal
Fig. 4
626 BOMAG 008 911 71

Special tools 15.1
5. Clamping device
Fig. 5
6. Disassembly device
Fig. 6
008 911 71 BOMAG 627

15.2 Repair overview oscillating articulated joint
Fig. 1
1 Housing 12 Cover
2 Seal ring 13 Cover
3 Cover 14 Intermediate ring
4 Self-aligning bearing 15 Self-aligning bearing
5 Bolt 16 Intermediate ring
6 Shim/supporting disc 17 Self-aligning bearing
7 Belleville springs 18 Beam
8 Self-aligning bearing 19 Friction bearing
9 Console 20 V-ring
10 Belleville springs 21 Seal ring
11 Shim/supporting disc
628 BOMAG 008 911 71

Repair overview oscillating articulated joint 15.2
Fig. 2
008 911 71 BOMAG 629

15.2 Repair overview oscillating articulated joint
Fig. 3
630 BOMAG 008 911 71

Removing and installing the oscillating articulated joint 15.3
15.3 Removing and installing the oscillat-
ing articulated joint
1. Jack up the frame (Fig. 1) at the back and secure
it with trestles or wooden blocks.
Fig. 1
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.
Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).
Fig. 3
008 911 71 BOMAG 631

15.3 Removing and installing the oscillating articulated joint

axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).
Fig. 4
!Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
with disc (2).
Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.
Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).
Fig. 7
632 BOMAG 008 911 71

Dismantling the oscillating articulated joint 15.4
15.4 Dismantling the oscillating articulated
joint
1. Unscrew the nuts from hexagon screw 1 (Fig. 1)
and pull out the hexagon screw.
2. Unscrew the screws (2) for the cover.
Fig. 1
3. Take off the cover with Belleville springs, shim
and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.
i Note
No Belleville springs, shim and backing disc are
under this cover.
Fig. 2
5. Drive the console with a plastic hammer to one
side against the end stop (Fig. 3).
i Note
The outer race of the rocker bearing is thereby
stripped off.
Fig. 3
008 911 71 BOMAG 633

15.4 Dismantling the oscillating articulated joint
6. Force inner race 1 (Fig. 4) of the rocker bearing

off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.
Fig. 4
10. Press bolt (3) out of the console with forcing
screws (2).
i Note
Remove the bolt on the opposite side in the same
way.
Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).
Fig. 6
12. Take the seal rings out of the console (Fig. 7).
Fig. 7
634 BOMAG 008 911 71

13. Remove the cover from the housing.
14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).
Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).
Fig. 9
16. Take the intermediate ring out of the housing
(Fig. 10).
Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.
Fig. 11
008 911 71 BOMAG 635

15.4 Dismantling the oscillating articulated joint
19. Pull the housing off the beam (Fig. 12).
Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).
Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).
Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.
Fig. 15
636 BOMAG 008 911 71

23. Check rocker bearings, if necessary press out of
the housing (Fig. 16).
Fig. 16
008 911 71 BOMAG 637

15.5 Assembling the oscillating articulated joint
15.5 Assembling the oscillating articulated

joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease.
Fig. 1
2. Slide the new V-ring on the beam against the stop
with the lip facing up (Fig. 2).
Fig. 2
3. Lay the seal ring into the beam (Fig. 3).
4. Fill the space between V-ring and seal ring with
multi-purpose grease.
Fig. 3
638 BOMAG 008 911 71

Assembling the oscillating articulated joint 15.5
5. Press the friction bearing fully into the housing
with the chamfered side pointing towards the out-
side (Fig. 4).
Fig. 4
6. Slide the housing over the beam (Fig. 5).
i Note
The journal on the housing must be centrally in
the recess of the beam.
Fig. 5
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).
Fig. 6
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
9. Press the outer rocker bearing race 1 (Fig. 7) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).
Fig. 7
008 911 71 BOMAG 639

10. Press inner rocker bearing race 1 (Fig. 8) in until

it bottoms, using pressing sleeve (2).
Fig. 8
11. Insert the intermediate ring (Fig. 9).
Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).
Fig. 10
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
13. Press the outer rocker bearing race 1 (Fig. 11) in
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).
Fig. 11
640 BOMAG 008 911 71

14. Press in intermediate ring 1 (Fig. 12) until it bot-
toms.
15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.
Fig. 12
Determining the shim thickness
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an ∅ 18 mm bore.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.
i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.
Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.
008 911 71 BOMAG 641

21. Insert shim 2 (Fig. 14) of appropriate thickness

and backing disc (1) into the cover.
Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).
Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).
Fig. 17
642 BOMAG 008 911 71

26. Lift console 1 (Fig. 18) over the housing (2).
Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).
Fig. 19
i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.
Fig. 20
! Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).
Fig. 21
008 911 71 BOMAG 643

29. Unscrew the guide pins .

30. Turn in the screws and tighten with 75 Nm (Fig.
22).
Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).
Fig. 23
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).
Fig. 24
33. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.
Fig. 25
644 BOMAG 008 911 71

35. Attach cover 1 (Fig. 26) to the bottom side of the
console.
36. Turn in and tighten screws (2).
Fig. 26
Determining the shim thickness
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
Fig. 27
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.
i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.
Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.
008 911 71 BOMAG 645

40. Insert shims 2 (Fig. 29) of appropriate thickness

and backing disc (1) into the cover.
Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).
Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.
Fig. 32
646 BOMAG 008 911 71

45. Assemble the washer, turn on and tighten the nut
with 120 Nm (Fig. 33).
Fig. 33
008 911 71 BOMAG 647

648 BOMAG 008 911 71

16 Suppliers documentation
008 911 71 BOMAG 649

650 BOMAG 008 911 71
16.1 Travel pump / vibration pump series 90R
008 911 71 BOMAG 651

652 BOMAG 008 911 71

Travel pump / vibration pump series 90R 16.1
Series 90
Axial Piston
Pumps and Motors
Service Manual
008 911 71 BOMAG 653

Series 90 Introduction
Introduction
Use of this Manual
This manual includes information for the normal opera- Since dirt and contamination are the greatest enemies of
tion, maintenance, and servicing of the Series 90 family any type of hydraulic equipment, cleanliness require-
of hydrostatic pumps and motors. ments must be strictly adhered to. This is especially
important when changing the system filter and during
The manual also includes the description of the units and adjustment and repair activities.
their individual components, troubleshooting informa-
tion, adjustment instructions, and minor repair proce- For further information refer to Series 90 Technical
dures. Unit warranty obligations should not be affected if Information. For information about fluid requirements
maintenance, adjustment, and minor repairs are per- refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id No.
formed according to the procedures described in this 697581).
manual.
A worldwide network of SAUER-SUNDSTRAND Autho-
Many service and adjustment activities can be performed rized Service Centers is available should repairs be
without removing the unit from the vehicle or machine. needed. Contact any SAUER-SUNDSTRAND Autho-
However, adequate access to the unit must be available, rized Service Center for details. A list of all Service
and the unit must be thoroughly cleaned before beginning Centers can be found in bulletin BLN-2-400527, or in
maintenance, adjustment, or repair activities. brochure SAW (Ident. No. 698266).
Safety Precautions
Observe the following safety precautions when using and servicing hydrostatic products.
Loss of Hydrostatic Braking Ability Fluid under High Pressure
WARNING WARNING
The loss of hydrostatic drive line power in any Use caution when dealing with hydraulic fluid
mode of operation (e.g., forward, reverse, or "neu- under pressure. Escaping hydraulic fluid under
tral" mode) may cause the loss of hydrostatic pressure can have sufficient force to penetrate
braking capacity. A braking system, redundant to your skin causing serious injury. This fluid may
the hydrostatic transmission must, therefore, be also be hot enough to burn. Serious infection or
provided which is adequate to stop and hold the reactions can develop if proper medical treat-
system should the condition develop. ment is not administered immediately.
S000 001E S000 003E
Disable Work Function Flammable Cleaning Solvents
WARNING WARNING
Certain service procedures may require the ve- Some cleaning solvents are flammable. To avoid
hicle/machine to be disabled (wheels raised off possible fire, do not use cleaning solvents in an
the ground, work function disconnected, etc.) area where a source of ignition may be present.
while performing them in order to prevent injury S000 004E
to the technician and bystanders.

S000 005E
Copyright 1987-1998, SAUER-SUNDSTRAND GmbH & Co. S90MVCTCD

S90PVMFCD
All rights reserved. Contents subject to change.
654 BOMAG 008 911 71

Series 90 Contents
Contents
Introduction ......................................................................................................................................................................... 2
Use of this Manual ........................................................................................................................................................................................ 2
Safety Precautions ........................................................................................................................................................................................ 2
Functional Description ....................................................................................................................................................... 5
General Description and Cross Sectional Views ......................................................................................................................................... 5
Variable Displacement Pumps ................................................................................................................................................................ 5
Fixed Displacement Motor ..................................................................................................................................................................... 5
Variable Displacement Motor .................................................................................................................................................................. 6
The System Circuit ....................................................................................................................................................................................... 7
The Basic Closed Circuit ........................................................................................................................................................................ 7
Case Drain and Heat Exchanger ........................................................................................................................................................... 7
Common Features of Pumps and Motors .................................................................................................................................................... 8
End Caps and Shafts ............................................................................................................................................................................. 8
Speed Sensors ....................................................................................................................................................................................... 8
Pump Features ............................................................................................................................................................................................. 9
Charge Pump .......................................................................................................................................................................................... 9
Charge Relief Valve ................................................................................................................................................................................. 9
Multi-Function Valves .............................................................................................................................................................................. 9
Pressure Limiter and High Pressure Relief Valves ....................................................................................................................... 10
System Check Valves .................................................................................................................................................................... 10
Bypass Valves ................................................................................................................................................................................ 10
Displacement Limiters .......................................................................................................................................................................... 11
Auxiliary Mounting Pads ....................................................................................................................................................................... 11
Filtration Options ................................................................................................................................................................................... 11
Pressure Override (POR) - 180 Frame Size Only ............................................................................................................................. 12
Pump Control Options .......................................................................................................................................................................... 13
Manual Displacement Control (MDC) ........................................................................................................................................... 13
Hydraulic Displacement Control (HDC) ........................................................................................................................................ 13
Electric Displacement Control (EDC) ............................................................................................................................................ 14
Automotive Control (FBA II B) ....................................................................................................................................................... 14
3-Position (FNR) Electric Control .................................................................................................................................................. 14
Motor Features ........................................................................................................................................................................................... 15
Motor Loop Flushing Valve and Charge Relief Valve ........................................................................................................................... 15
Variable Motor Displacement Limiters .................................................................................................................................................. 15
Variable Motor Controls ........................................................................................................................................................................ 16
Hydraulic 2-Position Control .......................................................................................................................................................... 16
Electric 2-Position Control .............................................................................................................................................................. 16
Technical Specifications .................................................................................................................................................. 17
General Specifications ................................................................................................................................................................................ 17
Circuit Diagrams ......................................................................................................................................................................................... 17
Hydraulic Parameters ................................................................................................................................................................................. 18
Size Specific Data ....................................................................................................................................................................................... 19
Pressure Measurement ................................................................................................................................................... 20
Required Tools ............................................................................................................................................................................................ 20
Port Locations and Pressure Gauge Installation ....................................................................................................................................... 20
Variable Pump ....................................................................................................................................................................................... 20
Fixed Motor ........................................................................................................................................................................................... 23
Variable Motor ....................................................................................................................................................................................... 24
Initial Start-Up Procedure ................................................................................................................................................ 25
Fluid and Filter Maintenance ........................................................................................................................................... 26
Troubleshooting ................................................................................................................................................................ 27
"NEUTRAL" Difficult or Impossible to Find ................................................................................................................................................. 27
System Operating Hot ................................................................................................................................................................................ 27
Transmission Operates Normally in One Direction Only .......................................................................................................................... 28
System Will Not Operate in Either Direction .............................................................................................................................................. 28
Low Motor Output Torque ........................................................................................................................................................................... 29
Improper Motor Output Speed .................................................................................................................................................................... 29
Excessive Noise and/or Vibration .............................................................................................................................................................. 30
System Response is Sluggish .................................................................................................................................................................... 30
008 911 71 BOMAG 655

Series 90 Contents
Inspections and Adjustments ......................................................................................................................................... 31
Pump Adjustments ...................................................................................................................................................................................... 31
Charge Pressure Relief Valve Adjustment ........................................................................................................................................... 31
Multi-Function Valve Pressure Adjustment .......................................................................................................................................... 33
Engaging the Bypass Function ............................................................................................................................................................ 35
Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ....................................................................... 36
Displacement Limiter Adjustment ......................................................................................................................................................... 37
Pump Control Adjustments ......................................................................................................................................................................... 38
Standard Manual Displacement Control (MDC) Adjustment .............................................................................................................. 38
Non-Linear Manual Displacement Control (MDC) .............................................................................................................................. 39
MDC Neutral Start Switch (NSS) Adjustments .................................................................................................................................... 40
Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment ....................................................... 46
Motor Adjustments ...................................................................................................................................................................................... 48
Charge Relief Valve Adjustment ........................................................................................................................................................... 48
Displacement Limiter Adjustment (MV) ................................................................................................................................................ 49
Displacement Control Adjustments ...................................................................................................................................................... 49
Speed Sensor Adjustment .......................................................................................................................................................................... 50
Minor Repair Instructions ................................................................................................................................................ 51
Pump and Motor Minor Repair .................................................................................................................................................................... 53
Pump / Fitting Torques .......................................................................................................................................................................... 53
Shaft Seal and Shaft Replacement ...................................................................................................................................................... 54
Pump Minor Repairs ................................................................................................................................................................................... 56
Multi-Function Valve Cartridges ........................................................................................................................................................... 56
Pressure Override Valve (Option for 180 Frame Size) ....................................................................................................................... 57
Charge Relief Valve ............................................................................................................................................................................... 57
Charge Pump - Remove ...................................................................................................................................................................... 58
Installing the Charge Pump .................................................................................................................................................................. 60
Auxiliary Pad Installation ....................................................................................................................................................................... 62
Auxiliary Pad Conversion ..................................................................................................................................................................... 63
Filtration Options ................................................................................................................................................................................... 64
Pump controls ....................................................................................................................................................................................... 65
Cover Plate ..................................................................................................................................................................................... 65
Manual Displacement Control (MDC) ........................................................................................................................................... 66
Solenoid Override Valve for MDC .................................................................................................................................................. 67
Solenoid Override Valve for MDC with Pressure Released Brake .............................................................................................. 67
Hydraulic and Electric Displacement Controls ............................................................................................................................. 68
Pressure Control Pilot (PCP) for Electric Displacement Control .................................................................................................. 68
3-Position (FNR) Electric Control .................................................................................................................................................. 69
Displacement Control Components ............................................................................................................................................... 69
Minor Repair - Motor ................................................................................................................................................................................... 71
Loop Flushing and Charge Relief Valves ............................................................................................................................................. 71
Variable Motor Displacement Limiters .................................................................................................................................................. 73
Variable Motor Controls ............................................................................................................................................................................... 74
Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) ..................................................................................................... 74
Hydraulic 2-Position Control (Type PT) ............................................................................................................................................... 74
Control Plugs ........................................................................................................................................................................................ 74
Variable Motor Control Orifices ............................................................................................................................................................ 75
Speed Sensor .............................................................................................................................................................................................. 77
Exploded View Parts Drawings / Parts Lists .................................................................................................................. 78
Variable Pumps ........................................................................................................................................................................................... 78
Minor Repair Parts ................................................................................................................................................................................ 78
Parts List ............................................................................................................................................................................................... 79
Variable Pump Controls ........................................................................................................................................................................ 80
Control Parts List .................................................................................................................................................................................. 81
Filter and Options ................................................................................................................................................................................. 82
Parts List Filter and Options ................................................................................................................................................................. 83
Name Plates ......................................................................................................................................................................................... 83
Fixed Motor ................................................................................................................................................................................................. 84
Parts List ............................................................................................................................................................................................... 85
Name Plates ......................................................................................................................................................................................... 85
Variable Motor .............................................................................................................................................................................................. 86
Parts List ............................................................................................................................................................................................... 87
Name Plate ............................................................................................................................................................................................ 87
656 BOMAG 008 911 71

Series 90 Functional Description

Functional Description
This section describes the operation of pumps, motors, and their various serviceable features. It is a useful reference for
readers unfamiliar with the functioning of a specific system.
General Description and Cross Sectional Views
Variable Displacement Pumps
The Variable Displacement Pump (PV) is designed to

convert an input torque into hydraulic power. The input
shaft turns the pump cylinder which contains a ring of
pistons. The pistons run against a tilted plate, called the
swashplate. This causes the pistons to compress the
hydraulic fluid which imparts the input energy into the
hydraulic fluid. The high pressure fluid is then ported out
to provide power to a remote function.
The swashplate angle can be varied by the control piston.

Altering the swashplate angle varies the displacement of
fluid in a given revolution of the input shaft.
F000 539
Series 90 Variable Displacement Pump (PV)
Slider Block
Servo Arm
Servo Valve
Cradle Hold Down
Servo Piston
Feed Back
Cradle Bearing
Cradle
Cradle Leveler
Cradle Guide
Charge Pump
P001 413E
Series 90 PV Cross Section
Fixed Displacement Motor
The Fixed Displacement Motor (MF) is designed to

convert an input of hydraulic power into an output torque.
It operates in the reverse manner of the pump. The high
pressure hydraulic fluid enters through the input port. The
fluid pressure builds behind the pistons causing them to
move down the swashplate (the path of least resistance).
As the piston returns up the swashplate again, the fluid is
allowed to exit through the exit port. The spinning pistons
are housed in a cylinder which is connected to the output
shaft. The output torque can be applied to a mechanical
function.
90000347
Series 90 Fixed Displacement Motor (MF)
008 911 71 BOMAG 657

In the Fixed Displacement Motor the "swashplate" is

Loop Flushing Valve fixed, so any variation in motor speed and torque must be
Valve Plate Piston made by the input mechanism, i.e. the pump.
Roller Bearing
Output Shaft
Fixed Swashplate
End Cap Cylinder Block
90000190E
Series 90 MF Cross Section
Variable Displacement Motor
The Variable Displacement Motor (MV) operates in the

same manner as the fixed motor. However, its swashplate
is not fixed; it can be switched between minimum and
maximum angle to amplify torque or speed like the
Variable Displacement Pump.
90000348
Series 90 Variable Displacement Motor (MV)
Minimum Angle
Valve Plate Piston Control Piston
End Cap
Roller Bearing
Cradle Swashplate
Output Shaft
"A" "A" Partial Section "A-A"

Cradle Swashplate in Full
Displacement Position
Cradle Swashplate
Cylinder Block
Electric 2-Position Control (optional) Maximum Angle
Control Piston
90000234E
Series 90 MV Cross Section
658 BOMAG 008 911 71


The System Circuit
System loop (low pressure)

Control Handle Displacement Control Valve
Case drain fluid
Heat Exchanger System loop (high pressure)
Bypass Valve
Orificed Reservoir
Control fluid
Check Valve
Vacuum Gauge
Suction line
Heat Exchanger
Charge Pressure Purge Relief Valve

Multi-Function Relief Valve
Servo Control Valve
Variable Cylinder Fixed Displacement
Displacement Motor
Pump
to Pump
Case
Servo Pres.
Relief Valve
Charge Pump
Input
Output Shaft
Shaft
Multi-Function Valve Motor Swashplate
Pump Swashplate Servo Control
Cylinder Loop Flushing Valve
Pump Fixed Motor

90000800E
Circuit Diagram for Series 90 PV and 90 MF
The Basic Closed Circuit
The main ports of the pump are connected by hydraulic

lines to the main ports of the motor. Fluid flows, in either
direction, from the pump to the motor then back to the
pump in this closed circuit. Either of the hydraulic lines
can be under high pressure. In pumping mode the
position of the pump swashplate determines which line is
high pressure as well as the direction of fluid flow.
Case Drain and Heat Exchanger
The pump and motor require case drain lines to remove Reservoir
hot fluid from the system. The motor should be drained
from its topmost drain port to ensure the case remains full Input Output
PV MF
of fluid. The motor case drain can then be connected to
the lower drain port on the pump housing and out the top
most port. A heat exchanger, with a bypass valve, is
required to cool the case drain fluid before it returns to the
reservoir.
Flow (Bi-directional)
Case Drain Line

90000803E
Basic Closed Circuit
008 911 71 BOMAG 659


Common Features of Pumps and Motors
End Caps and Shafts
Series 90 pumps and motors can be supplied with a

variety of end caps and shafts to allow for almost any
configuration. For pumps, end caps are available with
system ports on either side ("side ports") or both ports on
one side ("twin ports"). Motors have end caps with ports
on the face of the end cap ("axial ports") or both ports on
one side ("twin ports"). See the Series 90 Technical
Information manuals (BLN-10029 and BLN-10030) or the
Series 90 Price Book (BLN-2-40588) for information on
available options.
Removing the end cap will void the warranty on a

Series 90 pump or motor.
Speed Sensors
An optional speed sensor can be installed on Series 90

pumps and motors to provide unit speed information. The
sensor reads a magnetic ring wrapped about the unit's
cylinder. See the corresponding Section to locate, install
and adjust the sensor.
90000810
Speed Sensor
660 BOMAG 008 911 71


Pump Features
Charge Pump
The charge pump is necessary to supply cool fluid to the

system, to maintain positive pressure in the main system
loop, to provide pressure to operate the control system,
and to make up for internal leakage. Charge pressure
must be at its specified pressure under all conditions of
driving and braking to prevent damage to the transmis-
sion.
The charge pump is a fixed-displacement, gerotor type

pump installed in the variable displacement pump and
driven off the main pump shaft. Charge pressure is limited
by a relief valve.
90000243
The standard charge pump will be satisfactory for most
PV with Charge Pump
applications. However, if the charge pump sizes available
for the given main pump size are not adequate, a gear
pump may be mounted to the auxiliary mounting pad and Case
supply the required additional charge flow. Drain
Charge Relief Valve
Line
System
Charge Relief Valve Check
Valves
The charge relief valve on the pump serves to maintain Input PV PF
charge pressure at a designated level. A direct-acting
poppet valve relieves charge pressure whenever it sur- Charge
Pump
passes a certain level. This level is nominally set refer-
encing case pressure at 1500 rpm. This nominal setting
assumes the pump is in neutral (zero flow); in forward or
reverse charge pressure will be lower. The charge relief
valve setting is specified on the model code of the pump.
Inlet Filter
Tank
90000804E
Pump Charge System
Multi-Function Valves
The multi-function valve incorporates

the system check valve,
the pressure limiter valve,
the high pressure relief valve and
the bypass valve
in a replaceable cartridge.
These functions are described separately. There are two

multi-function valve cartridges in each Series 90 pump to
handle functions in either direction. See corresponding
Sections for adjustments and repairs.
NOTE: Some multi-function valves do not include a 90000243

pressure limiter valve. Multi-Function Valve
008 911 71 BOMAG 661


Pressure Limiter and High Pressure Relief Valves
Series 90 pumps are designed with a sequenced pres-

Pressure Limiter Housing High Pressure sure limiting system and high pressure relief valves.
Relief / check Check Valve When the preset pressure is reached, the pressure limiter
Pressure Limiter Valve Poppet Poppet
Lock Nut
system acts to rapidly destroke the pump so as to limit the
system pressure. For unusually rapid load application,
the high pressure relief valve acts to immediately limit
Pressure Limiter system pressure by cross-porting system flow to the low
Adjustment Screw
pressure side of the loop. The pressure limiter valve acts
as the pilot for the high pressure relief valve spool. The
high pressure relief valve is sequenced to operate at
Bypass approximately 35 bar (500 psi) above the level that ini-
Actuator Pressure Limiter Bypass tiates the pressure limiter valve.
Valve Poppet
Both the pressure limiter sensing valves and relief valves
are built into the multi-function valves (see above).
90000806E
NOTE: For some applications, such as dual path ve-
Cross Section of Multi-Function Valve
hicles, the pressure limiter function may be de-
feated so that only the high pressure relief valve
function remains.
System Check Valves
The system check valves allow pressurized flow from the

charge pump to enter the low pressure side of the loop
whenever system pressure dips below a certain level.
To Control This is needed as the pump will generally lose system
pressure due to leakage and other factors. Since the
Multi-Function Valve pump can operate in either direction, two system check
valves are used to direct the charge supply into the low
pressure lines. The system check valves are poppet
Servo Piston Bypass
Adjustment
valves located in the multi-function valve assembly.
Port "A"
Bypass Valves
Servo Pres.
Relief Valve
The bypass valves ("tow") can be operated when it is
Port "B"
desired to move the vehicle or mechanical function when
Servo Piston the pump is not running. The valve is opened by manually
Charge Pressure
Relief Valve
resetting the valve position.
Multi-Function Valve The bypass valves are built into the multi-function valves.
90000801E
Circuit Diagram showing Pressure
Control Mechanism
10
662 BOMAG 008 911 71


Displacement Limiters
All Series 90 pumps are designed for optional mechanical

displacement (stroke) limiters. The maximum displace-
ment of the pump can be limited in either direction.
The setting can be set as low as 0° in either direction.
For instructions on adjustment see corresponding Sec-

tion.
90000244
Auxiliary Mounting Pads PV with Displacement Limiters
Auxiliary mounting pads are available on all Series 90

pumps. SAE A through E mounts are available (availabil-
ity varies by pump size). This pad is used for mounting
auxiliary hydraulic pumps and for mounting additional
Series 90 pumps to make tandem pumps. The pads allow
for full through-torque capability.
90000242
Filtration Options PV with Auxillary Mounting Pad
All Series 90 pumps are available with provisions for

either suction or charge pressure filtration (integral or
remote mounted) to filter the fluid entering the charge
circuit.
Suction Filtration
The suction filter is placed in the circuit between the

reservoir and the inlet to the charge pump. When suction
filtration is used, a reducer fitting is placed in the charge
pressure gauge port (M3). Filtration devices of this type
are provided by the user.
90000243
PV with Suction Filtration
(No filtration device attached)
Charge Pressure Filtration
The pressure filter may be integrally mounted directly on

the pump or a filter may be remotely mounted for ease of
servicing.
A 125 m screen, located in the reservoir or the charge

inlet line, is recommended when using this filtration
option.
90000246 90000247
PV with Integral Charge PV with Remote Charge
Pump Pump
11
008 911 71 BOMAG 663


Pressure Override (POR) - 180 Frame Size Only
To Control
The pressure override valve (POR) modulates the control

pressure to the displacement control to maintain a pump
Multi-Function Valve
displacement which will produce a system pressure level
less than or equal to the POR setting. For unusually rapid
load application, the high pressure relief valve function of
Pressure
Override Control Valve Bypass the multifunction valves is available to also limit the
Adjustment
pressure level.
Port "A"
Shuttle
The pressure override consists of a three-way normally
Valve open valve which operates in series with the pump
Port "B" displacement control. Control supply pressure is nor-
mally ported through the pressure override valve to the
displacement control valve for controlling the pump's
displacement. If the system demands a pressure above
the override setting, the POR valve will override the
Multi-Function Valve Charge Pressure
Relief Valve control by reducing the control pressure supplied to the
displacement control. As the control pressure reduces,
the internal forces tending to rotate the swashplate
90000802E overcome the force of the servo pistons and allow the
POR-Valve (180 Frame Size only) pump's displacement to decrease.
12
664 BOMAG 008 911 71


Pump Control Options
Manual Displacement Control (MDC)
The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring- centered four-
way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates
the cradle swashplate through an angular rotation of ±17°, thus varying the pump’s displacement from full displacement
in one direction to full displacement in the opposite direction.
The MDC is designed so the angular position of the pump swashplate is proportional to the rotation of the control input
shaft.
Non-Linear MDC
The non-linear manual displacement control operates in

the same manner as the regular MDC except that it is
designed so the change in the angular position of the
pump swashplate progressively increases as the control
input shaft is rotated toward its maximum displacement
position.
Solenoid Override Valve for MDC
A solenoid override valve option (not shown here) is

available for MDC. This safety feature will return the 90000237
swashplate to zero displacement position when acti- PV with Manual Displacement Control
vated. The valve may be set in either a normally open or
normally closed mode.
Neutral Start Switch (NSS)
The neutral start switch is an optional feature available

with MDC. When connected properly with the vehicle’s
electrical system, the neutral start switch ensures that the
prime mover can be started only when the control is in a
neutral position.
90000239
PV with Manual Displacement Control and
Hydraulic Displacement Control (HDC) Neutral Start Switch
The hydraulic displacement control uses a hydraulic input

signal to operate a spring-centered four-way servo valve.
This valve ports hydraulic pressure to either side of a
dual-acting servo piston. The servo piston rotates the
cradle swashplate through an angular rotation of ±17°,
thus varying the pump’s displacement from full displace-
ment in one direction to full displacement in the opposite
direction. The HDC is designed so the angular position of
the pump swashplate is proportional to input pressure.
90000240
PV with Hydraulic Displacement Control
13
008 911 71 BOMAG 665


Electric Displacement Control (EDC)
The electric displacement control is similar to the hydrau-

lic displacement control with the input signal pressure
controlled by a pressure control pilot (PCP) valve. The
PCP valve converts a DC electrical input signal to a
hydraulic signal which operates a spring- centered four-
way servo valve. This valve ports hydraulic pressure to
either side of a dual-acting servo piston. The servo piston
rotates the cradle swashplate through an angular rotation
of ±17°, thus varying the pump’s displacement from full
displacement in one direction to full displacement in the
90000241 opposite direction. The control is designed so the angular
PV with Electric Displacement Control position of the swashplate is proportional to the EDC
input.
Automotive Control (FBA II B)
Automotive Control allows a vehicle to be driven in a

manner similar to an automobile with an automatic trans-
mission.
The Automotive Control includes a three-position electric

control to provide direction control.
3-Position (FNR) Electric Control
This control utilizes a 12 or 24 VDC electrically operated

spool valve to port pressure to either side of the pump
displacement control piston. Energizing one of the sole-
noids will cause the pump to go to its maximum displace-
ment in the corresponding direction.
All functions of the three-position (FNR) electric control

are preset at the factory.
90000354
PV with 3-Position (FNR) Electric Control
14
666 BOMAG 008 911 71


Motor Features
Motor Loop Flushing Valve and Charge Relief

Valve
All Series 90 motors are designed to accommodate a loop

flushing valve. The loop flushing valve is used in instal-
lations which require additional fluid to be removed from
the main hydraulic circuit because of transmission cool-
ing requirements, or unusual circuits requiring additional
loop flushing to remove excessive contamination in the
high pressure circuit. 90000248
Loop Flushing Valve (MF)
A shuttle valve and charge relief valve are installed in the
motor end cap to provide the loop flushing function. The
shuttle valve provides a circuit between the low pressure
side of the closed loop and the charge relief valve in the
motor end cap.
The motor charge relief valve regulates the charge pres- Top of Motor Charge Relief Valve
sure level only when there is a pressure differential in the
main loop. The shuttle valve is spring centered to the
closed position so that no high pressure fluid is lost from
the circuit when reversing pressures.
For charge relief valve adjustment see corresponding

Section.
Loop Flushing Shuttle Valve End Cap
90000238E
Motor Charge Relief Valve and Loop Flushing

Shuttle Valve
Variable Motor Displacement Limiters
All Series 90 variable motors include mechanical dis-

placement (stroke) limiters. Both the maximum and mini-
mum displacement of the motor can be limited.
The range of the settings is as follows:
055 MV 075 MV
Minimum 19 - 40 cm3 26 - 54 cm3

Displacement 1.2 - 2.4 in3 1.6 - 3.3 in3 90000352
Maximum MV Maximum Displacement Limiter
65 - 100 % 65 - 100 % (Minimum Displacement Limiters on opposite side)
Displacement
T002 251E
15
008 911 71 BOMAG 667


Variable Motor Controls
Hydraulic 2-Position Control
This control utilizes a hydraulically operated three-way

hydraulic valve to port system pressure to either of the
motor displacement control pistons. The motor is nor-
mally held at its maximum displacement. Supplying pilot
hydraulic pressure to the valve will cause the motor to go
to its minimum displacement.
90000350
MV with Hydraulic 2-Position Control
Electric 2-Position Control
This control utilizes an electric solenoid operated three-

way hydraulic valve to port system pressure to either of
the motor displacement control pistons. The motor is
normally held at its maximum displacement. Energizing
the solenoid will cause the motor to go to its minimum
displacement.
90000351
MV with Electric 2-Position Control
16
668 BOMAG 008 911 71

Series 90 Technical Specifications

Technical Specifications
General Specifications
Design Port Connections

(for details see chapter "Pressure Measurement")
Variable Pumps and Motors: Axial piston pump of vari-
able displacement, cradle swashplate design. Main pressure ports: SAE flange, Code 62,
Remaining ports: SAE straight thread O-ring boss.
Fixed Motors: Axial piston motor with fixed displacement,
fixed swashplate design. Direction of Rotation
Type of Mounting (per SAE J744) Clockwise or counterclockwise (motors are bi-directional)
SAE flange, Size "B", 2 bolts, Recommended Installation Position

SAE flange, Size "C and E", 4 bolts.
Pump installation recommended with control position on
Cartridge flange, 2 bolts (for motor only). the top or side. Consult SAUER-SUNDSTRAND for non-
conformance guidelines. The housing must always be
filled with hydraulic fluid.
Circuit Diagrams
L2 M3
A M1
M3
Vg max
X5
A
M1
M5
M4
B M2
L1
M2
B
MV with Electrohydraulic 2-Position
Control
L1 S L2
PV with Charge Pump and Manual

Displacement Control L2 M3
A M1
B M2
L1
90000811
MF 90000812
90000813
17
008 911 71 BOMAG 669

Hydraulic Parameters
Temperature Range1)
System Pressure Range bar psi
°C [°F]
Minimum -40 [-40] intermittent, cold start
Rated Pressure 420 6000
Rated 104 [220]
Maximum 115 [240] intermittent
Maximum Pressure 480 6960
T002 006E
1)
T002 252E At the hottest point, normally the case
drain port.
Charge Pump Inlet Vacuum Viscosity

bar abs in Hg
(on pumps only) mm2/s [SUS]
Minimum Vacuum Minimum 7 [49] intermittent
0.7 10 Recommended
(continuous) 12-60 [70-278]
operating range
Minimum Vacuum during intermittent,
Cold Start 0.2 25 Maximum 1600 [7500]
cold start
(Intermittent) T002 010E
T002 253E
Cleanliness Level and β x-Ratio

Case Pressure bar psi Required fluid cleanliness
ISO 4406 Class 18/13
level
Maximum (Continuous) 3 44 Recommended βx-ratio
for suction filtration β35-45=75 (β10≥2)
Recommended βx-ratio
Maximum during Cold Start β15-20=75 (β10≥10)
5 73 for charge pressure
(Intermittent) filtration
Recommended inlet
T002 254E
screen size for charge 100 m-125 m
pressure filtration
T002 007E
Hydraulic Fluid Cleanliness

Refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id Refer to SAUER-SUNDSTRAND Publications BLN 9887
No. 697581). Also refer to publication ATI-E 9101 for or SDF (NO. 697581) and ATI-E 9201.
information relating to biogradable fluids.
Refer to Series 90 technical information for definitions.
18
670 BOMAG 008 911 71


Size Specific Data
Variable Displacement Pumps
Dimension 030 PV 042 PV 055 PV 075 PV 100 PV 130 PV 180 PV 250 PV

3
Displacement cm 30 42 55 75 100 130 180 250
(maximum) in3 1.83 2.56 3.35 4.57 6.10 7.93 10.98 15.25
Minimum Speed min-1 (rpm) 500 500 500 500 500 500 500 500
Rated Speed min-1 (rpm) 4200 4200 3900 3600 3300 3100 2600 2300
Maximum Speed min-1 (rpm) 4600 4600 4250 3950 3650 3400 2850 2500
Maximum attainable Speed

min-1 (rpm) 5000 5000 4700 4300 4000 3700 3150 2750
at max. Displacement
Theoretical Torque at Nm/bar 0.48 0.67 0.88 1.19 1.59 2.07 2.87 3.97
max. Displacement lbf in/1000 psi 290 380 530 730 870 1260 1750 2433
Weight kg 28 34 40 49 68 88 136 154
(only base unit) lb 62 75 88 108 150 195 300 340
T002 257E
Fixed and Variable Displacement Motors
Einheit 030 MF 042 MF 055 MF 075 MF 100 MF 130 MF 055 MV 075 MV

3
cm 30 42 55 75 100 130 55 75
Displacement (maximum)
in3 1.83 2.56 3.35 4.57 6.10 7.93 3.35 4.57
cm3
Displacement (minimum) -- -- -- -- -- -- 19 26
in3
at maximum
min-1 (rpm) 4200 4200 3900 3600 3300 3100 3900 3600
Rated displacement
speed at minimum
min-1 (rpm) -- -- -- -- -- -- 4600 4250
displacement
at maximum
min-1 (rpm) 4600 4600 4250 3950 3650 3400 4250 3950
Maximum displacement
speed at minimum
min-1 (rpm) -- -- -- -- -- -- 5100 4700
displacement
Max. attainable speed at
min-1 (rpm) 5000 5000 4700 4300 4000 3700 4700 4300
max. displacement
Theoretical torque at max. Nm/bar 0.48 0.67 0.88 1.19 1.59 2.07 0.88 1.19
displacement lbf in/1000 psi 290 380 530 730 970 1260 530 730
Maximum flow ar max. l/min 138 193 234 296 365 442 234 296
displacement gal/min 36.5 51 62 78 96 117 62 78
kW 111 155 187 237 292 354 224 282
Max. corner power
hp 149 208 251 318 392 475 300 378
Weight kg 11 15 22 26 34 45 39 44
SAE-Flange lb 24 34 49 57 74 99 86 98
Weight kg 21 26 33 40 46
-- -- --
Cartridge Motor lb 46 57 72 88 101
T002 258E
Refer to Series 90 technical information for definitions.
19
008 911 71 BOMAG 671

Series 90 Pressure Measurement

Pressure Measurement
Required Tools
The service procedures described in this manual for Pressure gauges should be calibrated frequently to en-
Series 90 pumps and motors can be performed using sure accuracy. Snubbers are recommended to protect
common mechanic's tools. Special tools, if required are pressure gauges.
shown.
Port Locations and Pressure Gauge Installation
The following sections list the ports for each type of Outline drawings showing port locations follow the tables
hydraulic unit. The recommended pressure gauge and below.
fitting are also specified.
Variable Pump
Gauge Size Gauge Size

Port Function and Port Function and
Fitting
Fitting
System Pressure 1000 bar or 10 000 psi
M1 L1 Case Pressure
Port "A" 9/16-18 O-ring 10 bar or 100 psi
L2
System Pressure 1000 bar or 10 000 psi
M2 030
Port "B" 9/16-18 O-ring fitting 7/8-14 O-ring
M3 50 bar or 1000 psi 042
Charge Pressure
(M6) 9/16-18 O-ring 055
M4 50 bar or 1000 psi 075 1-1/16-12 O-ring
Servo Pressure 100
M5 9/16-18 O-ring
T002 259E 130 1-5/16-12 O-ring
180
1-5/8-12 O-ring
250
50 bar or 1000 psi
X1 HDC / EDC 7/16-20 O-ring
X2 Control Pressure or
9/16-18 O-ring
External Control 50 bar or 1000 psi
X3
Pressure 9/16-18 O-ring
S Charge Pump Inlet Vacuum Gauge, Tee into
Inlet Line
030
1-1/16-12 O-ring
042
055
1-5/16-12 O-ring
075
100
130 1-5/8-12 O-ring
180
1-1/2 SAE-Split
250 Flange
T002 260E
20
672 BOMAG 008 911 71

Servo / Displacement
Cylinder Pressure
Gauge Port M4
Case Drain
Port L1
System Pressure
Port B
Cylinder Pressure
Gauge Port M5
Top View
90000814E
System Pressure
Port B External Control Pressure
System Pressure Supply Port X3
Gauge Port M2 Speed Sensor
Charge Inlet Pressure
System Pressure
Gauge Port M1
Carge Pump
Inlet Port S System Pressure Case Drain Port L2 Charge Pressure
Port A Gauge Port M3
Left Side View Right Side View
90000815E
90000816E
PV with Side Port End Cap and Manual Displacement Control
21
008 911 71 BOMAG 673

Cylinder Pressure
System Pressure Gauge Port M4
Case Drain
Gauge Port M2 Port L1
System Pressure
Port B
Charge Pump Inlet

Port S
System Pressure
Port A
System Pressure Servo / Displacement
Gauge Port M1 Cylinder Pressure
Case Drain Port L2 Gauge Port M5
Top View
Left Side View
90000819E
90000820E
PV with Twin Port End Cap and Manual Displacement Control
Charge Pressure
Gauge Port M6
(before the filter)
Port E
(from filter)
Port D
(to filter)
Charge Pressure
Gauge Port M3
Charge Pressure
(after the filter)
Gauge Port M3
(after the filter)
Rear View Rear View
90000817E
90000818E
PV with Side Port End Cap and Remote Pressure Filtration PV with Side Port End Cap and Integral Pressure Filtration
22
674 BOMAG 008 911 71


Fixed Motor

Fitting Fitting
System Pressure 1000 bar or 10 000 psi L1 Case Pressure)
M1 10 bar or 500 psi
Port "A" 9/16-18 O-ring L2
System Pressure 1000 bar or 10 000 psi 030
M2
Port "B" 9/16-18 O-ring 042 7/8-14 O-ring
M3 50 bar or 1000 psi 055
Charge Pressure
9/16-18 O-ring 075
T002 261E 100 1-1/16-12 O-ring
130
T002 262E
System Pressure
Gauge Port M1
Charge Pressure System Pressure
Gauge Port M3 Gauge Port M2 Case Drain Port L1
System Pressure Port B

Speed Sensor
System Pressure Port A Case Drain Port L2
Rear View Left Side View
MF with SAE Flange
System Pressure
Gauge Port M1
Charge Pressure System Pressure Case Drain Port L1
Gauge Port M3 Gauge Port M2
Speed Sensor
System Pressure Port B
System Pressure Port A Case Drain Port L2
Rear View Left Side View
90000821E
MF with Cartridge Flange
23
008 911 71 BOMAG 675


Variable Motor

Fitting Fitting
Systempressure 1000 bar or 10 000 psi Control Cylinbder
M1 1000 bar or 10 000 psi
Port "A" 9/16-18 O-ring M4 Pressure "Minimum
7/16-20 O-ring
Systempressure 1000 bar or 10 000 psi Displacement"
M2
Port "B" 9/16-18 O-ring Control Cylinbder
1000 bar or 10 000 psi
M3 50 bar or 1000 psi M5 Pressure"Maximum
Charge Pressure 7/16-20 O-ring
9/16-18 O-ring Displacement"
T002 263E L1 10 bar or 500 psi
Case Pressure
L2 1-1/16-12 O-ring
T002 264E
Displacement Control
Cylinder Pressure
Gauge Port M4
System Pressure Min. Displacement
Gauge Port M2
Control Pressure Displacement Control
Port X1 Cylinder Pressure
(Hydraulic 2-Position Control) Gauge Port M5
Max. Displacement
(Earlier Production -
Not available as gauge
port with servo orifices)
System Pressure Port B Displacement Control

Cylinder Pressure
Gauge Port M5
Max. Displacement
(Newer Production)
Left Side View
MV with Cartridge Flange and Hydraulic 2-Position Control (SAE Flange Version Similar)
Case Drain Port L1

System Pressure
Gauge Port M1
charge Pressure
Gauge Port M3
(Same position as in MF)
Speed Sensor
System Pressure Port A
Case Drain Port L2

Right Side View
90000823E
MV with SAE Flange (Cartridge Flange Version Similar)
24
676 BOMAG 008 911 71

Series 90 Initial Start-Up Procedure

Initial Start-Up Procedure
The following start-up procedure should always be fol- connections for EDC) be disconnected at the pump
lowed when starting-up a new Series 90 installation or control until after initial start-up. This will ensure that the
when restarting an installation in which either the pump or pump remains in its neutral position.
motor had been removed.
WARNING WARNING
The following procedure may require the vehicle/ Do not start prime mover unless pump is in neutral
machine to be disabled (wheels raised off the ground, position (0° swashplate angle). Take precautions to
work function disconnected, etc.) while performing prevent machine movement in case pump is actuated
the procedure in order to prevent injury to the during initial start up.
technician and bystanders. Take necessary safety S000 008E
precautions before moving the vehicle/machine.

S000 007E
“Jog” or slowly rotate prime mover until charge pressure

starts to rise. Start the prime mover and run at the lowest
Prior to installing the pump and/or motor, inspect the units possible RPM until charge pressure has been estab-
for damage incurred during shipping and handling. Make lished. Excess air may be bled from the high pressure
certain all system components (reservoir, hoses, valves, lines through the high pressure system gauge port.
fittings, heat exchanger, etc.) are clean prior to filling with
fluid. Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure should
Fill the reservoir with recommended hydraulic fluid. This be as indicated in the pump model code. If charge
fluid should be passed through a 10 micron (nominal, no pressure is inadequate, shut down and determine cause
bypass) filter prior to entering the reservoir. The use of for improper pressure. Refer to Troubleshooting.
contaminated fluid will cause damage to the components,
which may result in unexpected vehicle/machine move-
ment. See the publications BLN-9887 and SDF 697581 WARNING
for further related information. Take necessary precautions that the motor shaft
remains stationary during the adjustment
The inlet line leading from the reservoir to the pump must procedure.
be filled prior to start-up. Check inlet line for properly S000 010E
tightened fittings and make sure it is free of restrictions Shut down the prime mover and connect the external
and air leaks. control input signal. Also reconnect the machine function
if disconnected earlier. Start the prime mover, checking
Be certain to fill the pump and/or motor housing with to be certain the pump remains in neutral. With the prime
clean hydraulic fluid prior to start up. mover at normal operating speed, slowly check for for-
ward and reverse machine operation.
Fill the housing by pouring filtered oil into the upper case
drain port. Charge pressure may slightly decrease during forward or
reverse operation. Continue to cycle slowly between
Install a 50 bar (or 1000 psi) pressure gauge in the charge forward and reverse for at least five minutes.
pressure gauge port to monitor the charge pressure
during start-up. Shut down prime mover, remove gauges, and plug ports.
Check reservoir level and add filtered fluid if needed.
It is recommended that the external control input signal
(linkage for MDC, hydraulic lines for HDC, or electrical The transmission is now ready for operation.
25
008 911 71 BOMAG 677

Series 90 Fluid and Filter Maintenance

Fluid and Filter Maintenance
To ensure optimum service life of Series 90 products,

regular maintenance of the fluid and filter must be per-
formed. Contaminated fluid is the main cause of unit
Mano- failure. Care should be taken to maintain fluid cleanliness
Vacuummeter while performing any service procedure.
Hydraulic fluid reservoir Check the reservoir daily for proper fluid level, the pres-
ence of water (noted by a cloudy to milky appearance, or
Filter free water in bottom of reservoir), and rancid fluid odor
(indicating excessive heat). If either of these conditions
Charge pump
occur, change the fluid and filter immediately.
It is recommended that the fluid and filter be changed

per the vehicle/machine manufacturer’s recommenda-
Adjustable
Charge pressure relief valve
tions or at the following intervals:
to low
pressure
side and First change
control To pump case
500 operating hours after start up
second and subsequent changes

P000 797E
Suction Filtration Schematic every 2000 operating hours or once a year.
This recommendation applies for the most applications.

High temperatures and pressures will result in acceler-
ated fluid aging and an earlier fluid change may be
required. At lower fluid loads longer change intervalls are
Screen possible. Therefore we suggest to check the fluid with the
manufacturer for suitability. This should be done at latest
half way between fluid changes.
Hydraulic fluid reservoir
Adjustable
Charge pressure It may be necessary to change the fluid more frequently
relief valve than the above intervals if the fluid becomes contami-
nated with foreign matter (dirt, water, grease, etc.) or if
Charge pump
the fluid has been subjected to temperature levels greater
than the recommended maximum. Never reuse fluid.
to low
pressure To pump case The filter should be changed whenever the fluid is changed
side and
control or whenever the filter indicator shows that it is necessary
to change the filter.
Filter
Cleanliness Level and β x-Ratio

Required fluid cleanliness
ISO 4406 Class 18/13
level
P000 798E Recommended βx-ratio
for suction filtration β35-45=75 (β10≥2)
Charge Pressure Filtration Schematic Recommended βx-ratio
(Partial flow) for charge pressure β15-20=75 (β10≥10)
filtration
Recommended inlet
screen size for charge 100 m-125 m
pressure filtration
T002 007E
26
678 BOMAG 008 911 71

Series 90 Toubleshooting
Troubleshooting
This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in
a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section
is referenced. Always observe the safety precautions listed in the section "Introduction" and related to your
specific equipment.
"NEUTRAL" Difficult or Impossible to Find
Check Description Action
1. Input to pump control. Input to control module is operating Check control input and repair or re-
improperly. place as necessary.
2. Pump displacement control. Control linkages are not secure, control Adjust, repair, or replace control mod-
orifices are blocked, etc. ule as necessary.
If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND Authorized Service Center.
System Operating Hot

1. Oil level in reservoir. Insufficient hydraulic fluid will not meet Fill reservoir to proper level.
cooling demands of system.
2. Heat exchanger. Heat exchanger not sufficiently cooling Check air flow and input air tempera-
the system. ture for heat exchanger. Clean, repair
or replace heat exchanger.
3. Charge pressure. Low charge pressure will overwork sys- Measure charge pressure. Inspect and
tem. adjust or replace charge relief valve. Or
repair leaky charge pump.
4. Charge pump inlet vacuum. High inlet vacuum will overwork sys- Check charge inlet vacuum. If high,
tem. A dirty filter will increase the inlet inspect inlet filter and replace as neces-
vacuum. Inadequate line size will re- sary. Check for adequate line size,
strict flow. length or other restrictions.
5. System relief pressure settings. If the system relief settings are too low, Verify settings of pressure limiters and
the relief valves will be overworked. high pressure relief valves and adjust
or replace multi-function valves as nec-
essary.
6. For internal leakage in motor.
Leakage will reduce low side system Monitor motor case flow without loop
pressure and overwork the system. flushing in the circuit (use defeat spool).
If flow is excessive, replace motor.
7. System pressure. High system pressure will overheat Measure system pressure. If pressure
system. is high reduce loads.

27
008 911 71 BOMAG 679

Transmission Operates Normally in One Direction Only

2. Pump displacement control. Control linkages are not secure, control Repair or replace control module as
orifices are blocked, etc. necessary.
3. Interchange system pressure limit- Interchanging the multi-function valves Interchange multi-function valves. If the
ers, high pressure relief valves, and will show if the problem is related to the problem changes direction, repair or
system check valves. valve functions contained in the multi- replace the valve on the side that does
function valves. not operate.
4. Charge pressure. If charge pressure decays in one direc- Measure charge pressure in forward
tion the loop flushing valve may be and reverse. If pressure decays in one
“sticking” in one direction. direction, inspect and repair the motor
loop flushing valve.
System Will Not Operate in Either Direction

1. Oil level in reservoir. Insufficient hydraulic fluid to supply Fill reservoir to proper level.
system loop.
4. Ensure bypass valve(s) are closed. If bypass valve(s) is open, the system Close bypass valves. Replace multi-
loop will be depressurized. function valve if defective.
5. Charge pressure with pump in neu- Low charge pressure insufficient to re- Measure charge pressure with the pump
tral. charge system loop. in neutral. If pressure is low, go to step
6; otherwise continue with step 5.
6. Charge pressure with pump in Low charge pressure with the pump in Measure charge pressure with pump in
stroke. stroke indicates a motor charge relief stroke. If pressure is low, adjust or
valve or system pressure relief valve replace motor charge relief valve, oth-
may be improperly set. erwise go to step 9.
7. Pump charge relief valve. A pump charge relief valve that is leaky Adjust or replace pump charge relief
or set too low will depressurize the valve as necessary.
system.
8. Charge pump inlet filter. A clogged filter will undersupply system Inspect filter and replace if necessary.
loop.
9. Charge pump. A malfunctioning charge pump will pro- Repair or replace the charge pump. If
vide insufficient charge flow. OK go to last step.
28
680 BOMAG 008 911 71

11. System pressure. Low system pressure will not provide Measure system pressure. Continue
power necessary to move load. with next step.
12. System multi-function valves. Defective multi-function valves will Repair or replace multi-function valve(s).
cause system pressure to be low.

Low Motor Output Torque
1. System pressure at motor. Low system pressure at the motor will Measure system pressure at motor. If
reduce torque. pressure limiter setting is low, increase
setting.
2. Variable motor stuck at minimum Minimum motor displacement yields low Check control supply pressure or re-
displacement. output torque. pair displacement control. Check mo-
tor control orifices.
3. For internal leakage. Internal leakage will reduce system Check for leakage in O-rings, gaskets,
pressure. and other fittings. Repair unit as re-
quired, or replace leaky unit.

Improper Motor Output Speed
1. Oil level in reservoir. Insufficient hydraulic fluid will reduce Fill oil to proper level.
motor speed.
2. Pump output flow. Incorrect outflow will affect output Measure pump output and check for
speed. Incorrect output flow indicates proper pump speed and see that the
the swashplate is out of position. pump is in full stroke.
3. Variable motor displacement con- If variable motor displacement control See if variable motor displacement con-
trol. is not functioning correctly, variable trol is responding. If not, repair or re-
motor swashplate may be in wrong place control.
position.
4. For internal leakage. Internal leakage will reduce system Check for leakage in O-rings, gaskets,
pressure. and other fittings. Repair unit as re-
quired, or replace leaky unit.

29
008 911 71 BOMAG 681

Excessive Noise and/or Vibration

1. Oil in reservoir. Insufficient hydraulic fluid will lead to Fill reservoir to proper level.
cavitation.
2. Air in system. Air bubbles will lead to cavitation. Look for foam in reservoir. Check for
leaks on inlet side of system loop. After-
wards, let reservoir settle until bubbles
are gone. Run system at low speed to
move system fluid to reservoir. Repeat.
3. Pump inlet vacuum. High inlet vacuum will create noise. A Inspect and replace filter as necessary.
dirty filter will increase the inlet vacuum. Check for proper suction line size.
4. Shaft couplings. A loose shaft coupling will cause exces- Replace loose shaft coupling in charge
sive noise. pump or replace pump or motor.
5. Shaft alignment. Unaligned shafts will create excessive Align shafts.

frictional noise.

System Response is Sluggish

1. Oil level in reservoir. Insufficient hydraulic fluid will reduce Fill reservoir to proper level.
output pressure.
2. Multi-function valves’ pressure set- Incorrect pressure settings will affect Adjust or replace multi-function valves.
tings. system reaction time.
3. Pump inlet vacuum. High pump inlet vacuum will reduce Measure charge inlet vacuum. If high
system pressure. replace inlet filter.
4. Prime mover speed. Low engine speed will reduce system Adjust engine speed.
performance.
5. Charge and control pressures. Incorrect charge or control pressures Measure charge and control pressures
will affect system performance. and correct if necessary.
6. System internal leakage. Internal leakage will reduce system Check for leakage in O-rings, gaskets,
pressure. and other fittings.

30
682 BOMAG 008 911 71

Series 90 Inspections and Adjustments

Inspections and Adjustments
This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read
through the entire related section before beginning a service activity. Refer to the corresponding section for location of
gauge ports and suggested gauge size.
Pump Adjustments
Charge Pressure Relief Valve Adjustment
The following procedure explains how to check and adjust

the charge pressure relief valve.
WARNING
The following procedure may require the vehicle/
machine to be disabled (wheels raised off the ground,
work function disconnected, etc.) while performing
the procedure in order to prevent injury to the
technician and bystanders. Take necessary safety
S000 007E
90000243
Charge Pressure Gauge Port (Reducer fitting shown - if
filtration device attached)
1. To measure pump charge pressure, install a pres-
sure gauge in the pump charge pressure gauge port
(M3). Also install a gauge to measure case pressure
(tee into L1 or L2 or use servo gauge port). Operate
the system with the pump in “neutral” (zero displace-
ment) when measuring pump charge pressure. Nominal
90L055 EA 1 N Charge Pressure
2. The table shows the acceptable pump charge pres- 6 S 3 C6 C 03
sure range for some nominal charge relief valve HNN 35 35 24
settings (see sample model code at right). These
pressures assume 1500 pump rpm and a reservoir Model Code on Unit Name Plate (“24 bar”)
temperature of 50°C (120°F ), and are referenced to
case pressure (see footnote on next page). Smaller
displacement charge pumps will produce charge
pressure readings in the lower portion of the range, Model Code Measured Charge Pressure *
while larger displacement charge pumps will produce 18.1 bis 21.7 bar
readings in the higher portion of the range. 20
(262 to 315 psi)
22.0 bis 26.9 bar
24
(319 to 390 psi)
25.8 bis 30.7 bar
28
(374 to 445 psi)
T002 266E
* This is the actual charge pressure port gauge reading minus the
case pressure port gauge reading.
Note: These pressures assume a pump speed of

1450 - 1500 rpm. At higher pump input speeds
(with higher charge flows) the charge pressure
will rise over the rated setting.
* This is the actual charge pressure port gauge reading minus

the case pressure port gauge reading.
31
008 911 71 BOMAG 683

3. Earlier production Series 90 pumps are equipped

with a shim adjustable charge pressure relief valve.
Shim kits are available from SAUER-SUNDSTRAND.
Adjustment of charge pressure is accomplished by
removing the plug [1 inch Hex] and changing the shim
thickness behind the spring. The plug for this type of
charge relief valve should be torqued to 68 Nm
(50 lbf ft).
Later production Series 90 pumps are equipped with

90000262 90000264 an external screw adjustable charge pressure relief
Shim Adjustable Charge Screw Adjustable Charge valve. Adjustment of the charge pressure is accom-
Pressure Relief Valve Pressure Relief Valve plished by loosening the lock nut -
(Pump) (Pump)
Frame Size Wrench Size
030 - 100 1-1/16 inch
130 - 250 1-5/8 inch
T002 267E
and turning the adjustment plug with a large screw-

driver or a 1/2 inch hex wrench.
Clockwise rotation of the plug increases the setting,

and counterclockwise rotation decreases the setting
(at a rate of approximately 3.9 bar (50 psi) per turn).
The lock nut for this type of charge relief valve should
be torqued to 52 Nm (39 lbf ft).
4. Once the desired charge pressure setting is achieved,

remove the gauges.
32
684 BOMAG 008 911 71


Multi-Function Valve Pressure Adjustment
Adjustment of the pressure limiter setting and the high

pressure relief valve setting is accomplished simulta-
neously. The latter is automatically set approximately
35 bar (500 psi) above the former.
In order to adjust the pressure limiter setting, the motor

output shaft must be locked so it does not rotate. This
may be accomplished by locking the vehicle’s brakes or
rigidly fixing the work function so it cannot rotate.
WARNING
Take necessary precautions that the motor shaft
remains stationary during the adjustment procedure.
S000 010E
90000258
Multi-Function Valves on PV
1. Install two 1000 bar (or 10 000 psi) pressure gauges

in the high pressure gauge ports (M1 and M2). Install
a 50 bar (or 1000 psi) pressure gauge in the pump
charge pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. Loosen locking nut.

early
10 mm
042 - 100
newer
19 mm
030 - 100
early 130 13 mm
130 - 250 24 mm
T002 268E
4. Insert a internal hex wrench into the pressure adjust-

ing screw.
Frame Size Internal Hex Wrench Size

early 90000259
3 mm
042 - 100 Loosen Pressure Adjusting Screw Lock Nut
newer
5 mm
030 - 100
early 130 4 mm
130 - 250 8 mm
T002 269E
Note: A plastic dust plug is installed in the adjusting

screw on 030 and late 042 through 250 units.
33
008 911 71 BOMAG 685


90L055 EA 1 N 5. The factory preset pressure limiter setting is shown
on the model code as at right. It is referenced to
6 S 3 C6 C 03 charge pressure, so the pressure limiter setting is the
HNN 35 35 24 difference between the high and low pressure sides
of the system loop. Activate or move the control input
so that pressure increases in the high pressure side
Pressure Limiter Setting
of the closed circuit to the pressure limiter pressure
Ports A and B (differential setting. The pressure limiter setting is reached when
pressure in 10s of bars, the pressure stops increasing and remains steady at
e.g. “35” = 350 bar) a given pressure level (as shown on the gauges).
6. Return the pump to its “neutral” (zero flow) position

and adjust the pressure limiter setting by rotating the
pressure adjusting screw with the internal hex wrench.
Clockwise rotation of the pressure adjustment screw

will increase the pressure setting, and counterclock-
wise rotation will decrease the pressure setting. Each
complete rotation of the pressure adjusting screw
changes the pressure as shown in the following table.
Approx Change per Rev of the

Frame Size
Adjusting Screw
early
80 bar (1157 psi) per Rev
042 - 100
newer
90 bar (1300 psi) per Rev
030 - 100
130 - 250 80 bar (1157 psi) per Rev
90000260
T002 270E
Rotate Pressure Adjusting Screw
7. To verify the actual pressure setting, actuate or move

the control input so that the pump again develops
pressure in the high pressure circuit to the newly
adjusted pressure limiter pressure setting, and read
the high pressure gauge. Then allow the pump to
return to its “neutral” position. The pressure in the
high pressure circuit should return to the charge
pressure setting.
8. While holding the pressure adjusting screw station-

ary, tighten the pressure adjusting screw lock.
Frame Size Torque

early
3 Nm (26 lbf in)
042 - 100
newer
20 Nm (15 lbf ft)
030 - 100
130 - 250 40 Nm (30 lbf ft)
T002 271E
Do not overtorque.
90000261 9. Shut down the prime mover, remove the gauges and
Tighten Lock Nut install the gauge port plugs. Replace the plastic dust
plugs (if used).
The same procedure is used for setting the pressure limit

of the other multi-function valve, but the control input
signal must be activated or moved in the opposite direc-
tion so that high pressure develops in the opposite side
of the closed circuit.
34
686 BOMAG 008 911 71


Engaging the Bypass Function
The bypass function is performed by the multi-function

valve cartridges. The prime mover should be shut down
when opening or closing the bypass valves.
The bypass valves on both of the multi-function valves

must be opened to engaged the bypass function.
1. Using a

newer
1-1/16 inch
030 - 100
130 - 250 1-3/8 inch
T002 272E
wrench on the middle sized hex of the multi-function

90000266
valve cartridge, and a
Loosening and Rotating Bypass Hex on Multi-Function
Frame Size Wrench Size Valve
newer
1-1/4 inch Opening Bypass Valve
030 - 100
allows flow to circuit
130 - 250 1-5/8 inch Bypass through Multi-Function Valves
T002 273E Actuator
wrench on the large hex to prevent rotation of the

cartridge assembly, rotate the middle hex three
revolutions counterclockwise to open the bypass
valve. Do not rotate more than 3-1/2 revolutions,
as additional rotation will permit external leak-
age.
2. For units with an MDC-type control, prior to moving 90000827E
the vehicle or otherwise causing the motor shaft to Multi-Function Valve with Bypass Function Engaged
turn, move the control handle of the manual displace-
ment control on the pump to the maximum full
forward position. Hold the handle in this position
during bypass valve operation.
Caution
"Tow" at extremely low speeds and for short
distances only.
S000 011E
3. To close the bypass valve, rotate the middle hex

clockwise until it is seated. Then torque the middle
hex.
Frame Size Torque

newer
41 Nm (30 lbf ft)
030 - 100
130 - 250 100 Nm (75 lbf ft)
T002 274E
35
008 911 71 BOMAG 687


Pressure Override (POR) Valve Pressure
Adjustment (Option for 180 Frame Size)
The Pressure Override Valve is explained in the corre-

sponding section.
1. Install two 1000 bar (or 10 000 psi) pressure gauges

Pressure Override Valve Adjusting Screw in the high pressure gauge ports (M1 and M2). Install
Lock Nut
a 50 bar (or 1000 psi) pressure gauge in the pump
charge pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. With the pump operating at approximately 20% dis-

placement, load the work function and note the
pressure as the POR valve operates (pump displace-
ment reduces to “zero”).
4. Adjustment of the pressure override setting is made

by loosening the lock nut with a 9/16 inch hex wrench
and turning the adjustment screw with a 3/16 inch
internal hex wrench. The POR setting should be at
Right Side View least 50 bar (750 psi) below the high pressure relief
90000828E valve setting of the multi-function valves for proper
Pressure Override Valve for 180 Frame Size operation.
5. Following the adjustment, torque the lock nut to

43 Nm (32 lbf ft).
6. Shut down the prime mover and remove the gauges

and install the gauge port plugs.
36
688 BOMAG 008 911 71


Displacement Limiter Adjustment
The maximum displacement can be limited in either

direction.
1. Loosen the seal lock nut retaining the displacement

limiter adjusting screw.

030 - 100 13 mm
130 17 mm
180 - 250 19 mm
T002 275E
2. Rotate the adjusting screw.
Frame Size Internal Hex Wrench Size

030 - 100 4 mm
90000267
130 5 mm
Loosen Displacement Limiter Lock Nut
180 - 250 6 mm
T002 276E
Rotating the adjusting screw clockwise will decrease

the maximum displacement of the pump while rotat-
ing the adjusting screw counterclockwise will in-
crease the maximum displacement.
Caution
Care should be taken in adjusting displacement
limiters to avoid undesirable flow or speed conditions.
The seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in
operating conditions and to prevent external leakage
during unit operation.
S000 012E
90000268
Rotate Adjusting Screw
3. After establishing the desired maximum displace-
ment setting, tighten the lock nut on the adjusting
screw as follows.
Frame Size Torque

030 - 100 24 Nm (18 lbf ft)
130 48 Nm (35 lbf ft)
180 - 250 125 Nm (92 lbf ft)
T002 278E
4. One turn of the adjusting screw will change the

maximum displacement approximately as follows.
Approx Change in Disp per Rev of

Frame Size
Adjusting Screw 90000269
030 2.8 cm3 / Rev (0.17 in3 / Rev) Tighten Lock Nut
042 3.5 cm3 / Rev (0.21 in3 / Rev)
055 4.2 cm3 / Rev (0.26 in3 / Rev)
075 5.1 cm3 / Rev (0.31 in3 / Rev)
100 6.2 cm3 / Rev (0.38 in3 / Rev)
130 8.8 cm3 / Rev (0.53 in3 / Rev)
180 12.5 cm3 / Rev (0.76 in3 / Rev)
250 17.3 cm3 / Rev (1.06 in3 / Rev)
T002 277E
37
008 911 71 BOMAG 689


Pump Control Adjustments
Standard Manual Displacement Control (MDC)

Adjustment
There are no adjustable elements in the manual dis-

placement control. The control spool is held in its “neutral”
position by centering springs and washers on each end of
the spool. Since there is no centering spring on the control
input shaft, the shaft will automatically assume the appro-
priate position when the control is installed on the pump.
90000237
Variable Displacement Pump with Standard Manual
38
690 BOMAG 008 911 71


Non-Linear Manual Displacement Control
(MDC)
A centering spring, located on the control input shaft,

locates the control shaft in its “neutral” position. A bias
spring on the control spool maintains a force on the spool
and the control linkage to eliminate looseness (“free-
play”) in the linkage.
The “neutral” adjustment is the only adjustment that can

be made on the nonlinear manual displacement control.
All other functions are preset at the factory.
This adjustment must be made on a test stand or on the

vehicle/machine with the prime mover operating. 90000829
Variable Displacement Pump with Non-Linear Manual
WARNING
S000 007E
1. Install two 50 bar (or 1000 psi) gauges in each of the

displacement control cylinder gauge ports (M4 and
M5). Disconnect the external control linkage from the
control handle and make certain the control shaft is
in its “neutral” position. Start the prime mover and
operate at normal speed.
2. Loosen the lock nut on the neutral adjusting screw 90000357 90000358
with a 13 mm hex wrench. Rotate Neutral Adjusting Tighten Neutral Adjusting
Screw Screw Lock Nut
3. Using a 4 mm internal hex wrench, rotate the neutral
adjusting screw clockwise until the pressure increases
on one of the pressure gauges. Note the angular
position of the wrench.
4. Rotate the adjusting screw counterclockwise until the

pressure increases by an equal amount on the other
gauge. Note the angular position of the wrench.
5. Rotate the adjusting screw clockwise half the dis-

tance between the locations noted above. The gauges
should read the same pressure (case pressure),
indicating that the control is in its “neutral” position.
6. Hold the adjusting screw stationary and tighten the

lock nut to 13.5 Nm (10 lbf ft). Do not overtorque
the nut.
7. Once the neutral position is set, stop the prime

mover, remove the gauges, and install the gauge
port plugs. Reconnect the external control linkage.
39
008 911 71 BOMAG 691


MDC Neutral Start Switch (NSS) Adjustments
The neutral start switch (NSS) provides a means to

A A prevent the system prime mover from starting while the
pump control handle and control input shaft are in a
Control Shaft Switch Cam position which would command the pump to go “in-
stroke” in either the “forward” or “reverse” direction.
Switch Lock Nut When the control input shaft is in its “neutral” position, the
inner end of the switch pin moves into a slot on the
Neutral Start Switch
eccentric cam attached to the control shaft. This allows
Eccentric Plug the spring loaded NSS to close, completing the electrical
Switch Pin starting circuit for the prime mover.
Special Lock Nut
for Eccentric Plug
When the control input shaft is NOT in its “neutral”
MDC with Neutral Start switch position, the eccentric cam moves the switch pin out of
the slot. This forces the NSS to open, breaking the
electrical starting circuit for the prime mover.
The neutral start switch is threaded into the special lock

nut for the eccentric plug.
Turning the NSS clockwise (CW) into the special nut will
move the NSS closer to the switch cam on the control
Orifice Check Valve Seat shaft, and will narrow the NSS deadband. Turning the
Control Spool Assembly
Control Link Assembly
NSS counterclockwise (CCW) out of the special nut will
move the NSS farther from the switch cam on the control
View at Section A-A shaft, and will widen the NSS deadband.
90000830E
The switch pin is located in an eccentric plug which is
Components of the Standard Manual Displacement Control turned to move the center of the NSS deadband.
with Neutral Start Switch
(continued)
40
692 BOMAG 008 911 71


The NSS must be adjusted to meet the following three
requirements:
NSS Deadband Control Shaft
(Switch closed, "ON") ("Free-Play")
i. The distance the control handle can be turned with-
out opening the NSS is called the “NSS Deadband.” Control Deadband
The distance the control handle can be moved with- ("Neutral")
out moving the control spool enough to port hydraulic
fluid to the pump displacement control cylinders is
Total Control
called the “Control Deadband.” These deadbands Shaft Rotation
must be centered in relation to each other.
Since the position of the control deadband cannot be Control Shaft

adjusted, the position of the NSS deadband must be
adjusted to match it.
ii. The NSS deadband must be wide enough so the NSS

will not open within the loose area of control handle
movement caused by normal operating clearances in
the control linkage (control shaft “free-play”).
By setting the NSS to open outside this area, the

control spool springs or control shaft centering spring
can always act to return the handle to “neutral” and
re-close the NSS.
iii. The NSS deadband must be narrow enough so the

NSS will open before the unit builds 7 bar (100 psi)
differential system pressure in either direction.
90000831E
(continued) Neutral Start Switch Adjustment Requirements
41
008 911 71 BOMAG 693


NSS Deadband Adjustment (Conditions ii & iii)
The NSS deadband must be wide enough so the NSS will

not open within the control shaft “free-play” area, and it
must be narrow enough so the NSS will open before the
unit builds 7 bar (100 psi) differential system pressure in
either direction.
1. Install two 1000 bar (10 000 psi) pressure gauges in

the system pressure gauge ports M1 and M2.
2. Using two 1-1/8 inch wrenches, hold the neutral start

switch from turning and loosen the locknut.
3. Disconnect the external control linkage and make

certain the control shaft is in its “neutral” position.
4. Attach a continuity checker to the terminals of the

switch. With the control shaft in its “neutral” position,
turn the switch clockwise (CW) until electrical conti-
90000253
nuity is broken, then turn the switch counterclockwise
Loosening the NSS Lock Nut
(CCW) until electrical continuity is obtained. Turn the
switch counterclockwise (CCW) an additional 1/4
turn (90°) after continuity has been obtained.
5. Hold the switch in place and tighten the locknut to

27 Nm (20 lbf ft) torque.
Control Shaft
6. With the continuity checker attached to the switch,
rotate the control handle (or the control shaft) in each
direction to assure continuity is broken when the
control is not in the “neutral” position.
Switch Lock Nut
Switch Cam 7. If continuity is obtained in “neutral” and satisfactorily

Neutral Start Switch
interrupted in each direction, proceed to check the
switch with the prime mover running. The switch
must open before the unit builds 7 bar (100 psi)
Switch Pin 1-1/8 in. hex wrench differential system pressure in either direction.
Torque: 27 Nm (20 lbf ft)
If the switch opens after the unit builds system
90000832E pressure in either direction, loosen the switch lock
NSS nut and turn the switch clockwise (CW) 1/12 turn
(30°). Tighten the switch lock nut and recheck the
switch operation. Repeat this procedure if neces-
sary.
8. If continuity is not interrupted with an equal move-

ment of the control handle in each direction, turn off
prime mover, remove the pressure gauges, and
continue with the next section.
9. If neutral start switch operation is satisfactory, turn

off the prime mover, remove the pressure gauges,
and reconnect the external control linkage.
90000870
Checking Continuity of NSS (System Pressure Gauges
installed on far side)
42
694 BOMAG 008 911 71


Neutral Start Switch Eccentric Plug Adjustment (Con- 12.7 9.14
dition i) (0.5) (0.36)
The NSS deadband and the control deadband must be

centered in relation to each other.
Since the position of the control deadband cannot be

3.175 1.52
adjusted, the position of the NSS deadband must be
(0.125) (0.06)
adjusted to match it. The switch pin is located in an 25.4+
eccentric plug which is turned to move the center of the (1.0)
NSS deadband.
90000834E
The MDC should be installed on the pump and be in its
Eccentric Plug Adjustment Tool
“neutral” position when adjusting the neutral start switch
eccentric plug.
The accompanying drawing provides dimensions for an

Eccentric Plug Adjustment Tool.
1. Hold the switch and eccentric plug from turning and

use two 1-1/8 inch wrenches to loosen the locknut.
Remove the neutral start switch.
WARNING Switch
Lock Nut
Do not start the prime mover while the neutral start Eccentric Plug
switch is removed from the control. Case pressure X
Switch Pin
will force the pin out of the eccentric plug, causing Special Lock Nut
oil loss. for Eccentric Plug Neutral Start Switch
S000 032E
MDC with Neutral Start Switch
Special Lock Nut

for Eccentric Plug
Control Eccentric Plug

Mounting
Surface
Switch Pin
View in Direction X
(Switch and lock nut removed)
90000833E
NSS with Eccentric Plug
2. Note the slots on the eccentric plug for the adjust-

ment tool. Hold the eccentric plug in place with the
adjustment tool, and loosen the lock nut with a
1-1/8 inch wrench.
(continued)
90000256 90000257
Loosen Eccentric Lock Nut NSS Removed
43
008 911 71 BOMAG 695

3. Position the eccentric plug so the switch pin is offset

Switch Pin
toward the control mounting surface. This will provide
Eccentric Plug
the best contact between the pin and the cam on the
control shaft.
4. Hold the control shaft in its “neutral” position (in the

center of the control shaft “free-play” area). Locate
the switch pin in the slot of the switch cam by turning
the eccentric plug while checking the pin position
90˚ 90˚
(depth) in the plug. When the pin engages the cam
slot, the pin will be at its maximum depth in the plug.
Eccentric Plug
Adjustment Range
Hand tighten the plug lock nut to hold the eccentric
Control Mounting plug in position.
Surface
90000835E 5. Turn the control shaft an equal amount in either
Eccentric Plug Adjustment direction from “neutral.” The switch pin should move
out of the eccentric plug an equal distance when the
control shaft is turned. Turn the eccentric plug to
center the switch pin with the cam slot. Only a small
amount of adjustment in either direction should be
needed to center the pin.
6. While holding the eccentric plug in place, tighten the

eccentric plug lock nut to 27 Nm (20 lbf ft). Reinstall
and adjust the switch as outlined in the previous
section.
Note: The eccentric plug normally requires between

5-1/2 and 6-1/2 turns to install into the control
housing .
90000256
Adjust the Eccentric Plug
Caution
Do not turn the eccentric plug into or out of the
housing beyond specifications.
S000 014E
7. Once the switch is correctly adjusted, hold the switch

in place and tighten the locknut to 27 Nm (20 lbf ft)
torque.
(continued)
44
696 BOMAG 008 911 71


Checking Switch Continuity
Recheck switch continuity to determine whether addi-

tional adjustment of the eccentric plug is necessary.
WARNING
S000 007E

displacement control cylinder gauge ports (M4 and
M5). Attach a continuity checker to the terminals of
the neutral start switch.
2. Energize the starter circuit, and start the prime

mover.
3. While operating at normal speed and with the pump

in its “neutral” (zero flow) position, note the pressure
reading on the gauges. This reading should be noted
as the base pressure.
4. Slowly move the control handle in one direction while

observing the pressure gauges and the continuity
checker. Continuity must be broken before the pres-
sure on either gauge increases more than 1 bar
(12 psi) from the base pressure obtained at “neutral.”
5. Slowly move the control handle in the opposite

direction. Again, continuity must be broken before
the gauge pressure increases more than 1 bar (12 psi)
from base pressure.
6. Continuity must again be verified when the control is 90000255

returned to neutral. Checking Continuity of NSS
(Gauges installed in Servo Gauge Ports)
7. If continuity is not broken at base pressure plus 0 to
1 bar (0 to 12 psi) in either direction, stop the prime
mover and readjust the eccentric plug as described
in the previous section. If the pressure difference is
equal in each direction but greater than 1 bar (12 psi),
loosen the switch locknut and turn the switch clock-
wise 1/12 turn (30°) to increase the sensitivity. Re-
tighten the locknut and recheck pressure differences
and continuity.
8. After verifying proper control and switch operation,

stop the prime mover. Remove the continuity checker
and pressure gauges. Reinstall the servo pressure
port plugs and reconnect the electrical leads from the
machine starter circuit to the neutral start switch.
Install and adjust, if necessary, the external control
linkage.
45
008 911 71 BOMAG 697


Hydraulic Displacement Control (HDC) and
Electric Displacement Control (EDC) Adjust-
ment
The “neutral” adjustment is the only adjustment that can

be made on hydraulic and electric displacement controls.
All other functions are preset at the factory.
This adjustment must be made on a test stand or on the

vehicle/machine with the prime mover operating.
The neutral adjustment is performed by adjusting a

neutral adjusting shaft (earlier production EDCs) or a
90000240 neutral adjusting screw (HDCs and current production
PV with Hydraulic Displacement Control EDCs).
WARNING
S000 007E
90000241
PV with Electric Displacement Control

two displacement control cylinder gauge ports (M4
and M5). Disconnect the external control input (hy-
draulic or electronic) from the control. Start the prime
mover and operate at normal speed.
2. Loosen the lock nut with a 17 mm hex wrench for the

neutral adjusting shaft or with a 10 mm or 13 mm hex
wrench for the neutral adjusting screw.
90000249
Install Gauges in Displacement Control Cylinder Gauge
Ports
46
698 BOMAG 008 911 71

3. Using a 5 mm internal hex wrench for the neutral

adjusting shaft or a 3 mm or 4 mm internal hex
wrench for the neutral adjusting screw, rotate clock-
wise until the pressure increases in one of the
pressure gauges. Note the angular position of the
wrench. Then rotate the neutral adjusting shaft or
screw counterclockwise until the pressure increases
by an equal amount on the other gauge. Again note
the angular position of the wrench.
4. Rotate the neutral shaft or adjusting screw clockwise 90000250 90000252

half the distance between the locations noted above. Rotate Neutral Adjusting Tighten Neutral Adjusting
Shaft Shaft Lock Nut
The gauges should read the same pressure (case
(Early production) (Early production)
pressure), indicating that the control is in its “neutral”
position.
5. Hold the neutral adjusting shaft or screw stationary.

Tighten the neutral shaft lock nut (early production
controls) to 22 Nm (195 lbf in.). Tighten the neutral
adjusting screw lock nut (later production controls) to
7 Nm (62 lbf in.) for the 6 mm screw or 13.5 Nm
(120 lbf in.) for the 8 mm screw. Do not overtorque
the nut.
6. Once the neutral position is set, stop the prime

mover, remove the gauges, and install the gauge 90000251 90000318
port plugs. Reconnect the external control input. Rotate Neutral Adjusting Tighten Neutral Adjusting
Screw Screw Lock Nut
(Later production) (Later production)
90000355 90000356
Rotate Neutral Adjusting Tighten Neutral Adjusting
Shaft Shaft Lock Nut
(Current production HDC) (Current production HDC)
47
008 911 71 BOMAG 699


Motor Adjustments
Charge Relief Valve Adjustment
1. To measure motor charge pressure, install a 50 bar

(or 1000 psi) pressure gauge in the motor charge
pressure gauge port (M3). Size 30 and 42 don’t have
the M3 gauge port. Install pressure gauge in the
motor system pressure gauge port. For this kind of
measurement add 1 bar (14.5 psi) to the nominal
values shown in the table. Also install a gauge to
measure case pressure. Operate the system with the
pump in stroke (forward or reverse) when measuring
motor charge pressure.
90000248 2. The following table shows acceptable motor charge

Charge Pressure Gauge Port (MF) pressures for some nominal charge relief valve set-
tings (see model code at right). These pressures
90M055 NC 0 N Nominal charge
assume a reservoir temperature of 50°C (120°F).
Pressure Setting
8 N 0 C6 W 00 They are referenced to case pressure and assume a
NNN 00 00 24 one pump/one motor system.
Motor Charge Pressure 3. Earlier production Series 90 motors are equipped

Model Code
(±1.4 bar [±20 psi]) with a shim adjustable charge relief valve. Shim kits
are available as service items. Adjustment of the
10 8.1 bar (117 psi)
charge pressure is accomplished by removing the
plug (7/8 inch hex) and changing the shim thickness
18 16.1 bar (233 psi)
behind the spring. The plug for this type charge relief
port should be torqued to 68 Nm (50 lbf ft).
20 18.1 bar (262 psi)
Later production Series 90 motors are equipped with
24 22.1 bar (320 psi)
an external screw adjustable charge relief valve.
Adjustment of charge pressure is accomplished by
28 26.1 bar (378 psi)
loosening the lock nut,
30 30.0 bar (435 psi) Frame Size Wrench Size
030 - 130 1-1/16 inch
T002 279E
T002 293E
Model Code at the Name Plate (24 bar)
and turning the adjustment plug with a large screw-
driver or a 1/2 inch hex wrench. Clockwise rotation of
the plug increases the setting, and counterclockwise
rotation decreases the setting (at a rate of approxi-
mately 5.4 bar [78 psi] per turn). The lock nut for this
type charge relief valve should be torqued to 52 Nm
(38 lbf ft).
4. Once the desired charge pressure setting is achieved,

remove the gauges.
90000263 90000343
Shim Adjustable Charge Screw Adjustable Charge
Pressure Relief Valve Pressure Relief Valve
(Motor) (Motor)
48
700 BOMAG 008 911 71


Displacement Limiter Adjustment (MV)
Tamper-Resistant Cap
Both the maximum and minimum displacement may be
limited. Seal Lock Nut
Maximum Displacement
1. Remove the tamper resistant cap from the displace- Limiter Screw
ment limiter screw. Loosen the seal lock nut retaining
the displacement limiter adjusting screw with a 19 mm
wrench.
Caution
The displacement limiters act as travel stops for the
swashplate. Do not turn the limiter screws
counterclockwise beyond the point of contact with
the swashplate for either the maximum or minimum
S000 015E
2. All adjustments can only be done when the motor is

running and the pump is in neutral position. Steer the Minimum Displacement
Limiter Screw
respective displacement limiter by the control.
Seal Lock Nut
Rotate the adjusting screw with a 6 mm internal hex Tamper-Resistant Cap

wrench. Rotating the maximum displacement adjust-
SAE Flange Version shown
ing screw clockwise will decrease the maximum
(Cartridge Version similar)
displacement of the motor. Rotating the minimum
displacement adjusting screw clockwise will increase 90000837E
the minimum displacement of the motor. MV Displacement Limiters
Caution
Care should be taken in adjusting displacement
limiters to avoid undesirable flow or speed
conditions. See corresponding section for speed
and pressure limits.
The seal lock nut must be retorqued after every

adjustment to prevent an unexpected change in
S000 016E 90000359 90000360
Rotate Adjusting Screw for Tighten Lock Nut for
Minimum Displacement Minimum Displacement
3. After establishing the desired displacement setting,
Limiter Limiter
tighten the lock nut on the adjusting screw to 54 Nm
(40 lbf ft). Install a new tamper resistant cap.
4. One turn of the adjusting screw will change the

maximum or minimum displacement according to the
following chart.

Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 280E
Displacement Control Adjustments
All variable motor displacement control settings do not 90000352

require adjusting. Maximum Displacement Limiter
49
008 911 71 BOMAG 701


Speed Sensor Adjustment
When installing or adjusting the speed sensor on a pump

or motor, it must be set at a specific distance from the
speed ring on the unit’s cylinder. To locate the position of
Gap the speed sensor on the unit or description see the
corresponding section.
Speed Sensor 1. Loosen the sensor lock nut with an 1-1/16 inch hex
Magnetic Speed Ring wrench.
90000838E
Cross Section View of Speed Sensor in Variable Pump 2. Turn the sensor clockwise (CW) by hand until it
contacts the speed ring.
Gap
3. Turn the sensor counterclockwise (CCW) 1/2 turn
(180°) to establish the nominal gap of 0.71 mm
(0.028 inch).
4. Then turn the sensor clockwise (CW) until the wrench

Magnetic Speed Ring
flats on sensor body are positioned at a 22° angle to
Speed Sensor the pump shaft center line.
90000839E Note: Many adjustable wrenches have a 22° handle

Cross Section View of Speed Sensor in fixed Motor offset.
5. The final sensor position should be between

1/2 (180°) and 1/4 turn (90°) counterclockwise (CCW)
from the point where the sensor contacts the speed
Gap ring.
6. Hold sensor in position with a 1/2 inch hex wrench

Speed Sensor while tightening the lock nut to 13 Nm (10 lbf ft).
Magnetic Speed Ring
90000840E
Cross Section View of Speed Sensor in Variable Motor
Shaft Centerline
1/2 in. Wrench Flats
22˚ 22˚
Speed Sensor with Speed Sensor with

Packard Connector Turck Connector
Shaft Centerline
1/2 in. Wrench Flats
22˚ 22˚
Speed Sensor with Speed Sensor with

Packard Connector Turck Connector
90000841E
Positioning Speed Sensor relative to Pump or Motor Shaft
50
702 BOMAG 008 911 71

Series 90 Minor Repair Instructions

Minor Repair Instructions
Minor repairs may be performed, following the proce- items must be kept free of foreign materials and chemi-
dures in this section, without voiding the unit warranty. cals.
Although specific models are shown, these procedures
apply to all series and types of units in the Series 90 Protect all exposed sealing surfaces and open cavities
Family. from damage and foreign material.
Cleanliness is a primary means of ensuring satisfactory It is recommended that all gaskets and O-rings be
transmission life, on either new or repaired units. Clean- replaced when servicing. All gasket sealing surfaces
ing parts by using a solvent wash and air drying is must be cleaned prior to installing new gaskets. Lightly
adequate, providing clean solvent is used. As with any lubricate all O-rings with clean petroleum jelly prior to
precision equipment, the internal mechanism and related assembly.
51
008 911 71 BOMAG 703

Hydrostatic Unit Outlines for Minor Repair Reference
Charge Pressure
Relief Valve
Control Filtration Options

Control Orifice
Charge Pump Shaft Seal
Main Shaft Speed Sensor

(Auxiliary Pad)
Left Side View Right Side View

90000843E
SAE-Flange PV
Charge Pressure Charge Pressure

Relief Valve Relief Valve
Loop Flushing
Valve
Loop Flushing
Valve
Shaft Shaft
Seal Seal
(Speed Sensor) (Speed Sensor)
Left Side View Left Side View
90000844E
SAE Flange MF Cartridge Flange MF
Control Orifices
Maximum Angle Control Orifices
Charge Pressure Displacement Limiter
Relief Valve Charge Pressure Maximum Angle
Relief Valve Displacement Limiter
Loop Flushing Loop Flushing
Valve Valve
Shaft Shaft
Seal Seal
Control Control
Minimum Angle
Minimum Angle Displacement Limiter
Displacement Limiter
Left Side View Left Side View

90000845E
Cartridge Flange MV SAE Flange MV
52
704 BOMAG 008 911 71


Pump and Motor Minor Repair
Pump / Fitting Torques

Description Torque
If any plugs or fittings are removed from the pump or 7/16-20 O-ring 20 Nm
motor during servicing, they should be torqued as indi- 9/16 inch Hex Wrench (15 lbf ft)
cated in the accompanying table. 7/16-20 O-ring 12 Nm
3/16 inch Internal Hex Wrench (9 lbf ft)
Always install new O-rings before reinstalling the plugs or 9/16-18 O-ring 37 Nm
fittings. 11/16 inch Hex Wrench (27 lbf ft)
9/16-18 O-ring 23 Nm
3/4-16 O-ring 68 Nm
7/8 inch Hex Wrench (50 lbf ft)
3/4-16 O-ring 68 Nm
7/8-14 O-ring 95 Nm
Caution 1 inch Hex Wrench (70 lbf ft)
Plugs or fittings installed into aluminum housings 7/8-14 O-ring 68 Nm
should always be torqued to the lower values 3/8 inch Internal Hex Wrench (50 lbf ft)
specified for internal hex plugs of the same size. 1-1/16-12 O-ring 163 Nm
S000 017E 1 1/4 inch Hex Wrench (120 lbf ft)
1-1/16-12 O-ring 115 Nm
1-5/16-12 O-ring 190 Nm
1-1/2 inch Hex Wrench (140 lbf ft)
1-5/16-12 O-ring 129 Nm
1-5/8-12 O-ring 224 Nm
1-7/8 inch Hex Wrench (165 lbf ft)
T002 281E
53
008 911 71 BOMAG 705


Shaft Seal and Shaft Replacement
Lip type shaft seals are used on Series 90 pumps and

motors. These seals and/or the shafts can be replaced
without major disassembly of the unit. However, replace-
ment usually requires removal of the pump or motor from
the machine.
1. Position the pump with the shaft facing up.
Note: If the unit is positioned horizontally when the

shaft is removed, the cylinder block could move
out of place, making shaft installation difficult.
2. Remove the three or four screws holding the retainer

plate and seal carrier to the housing, using a 10 mm
hex wrench (030 and 042 units), a 5 mm internal hex
wrench (055 through 100 units), or a 6 mm internal
90000270 90000271
Remove Screws Holding Remove Seal Carrier hex wrench (130 through 250 units). Remove the
Retainer Plate and Seal retainer plate.
Carrier
Note: Certain earlier production units use a one piece
retainer plate and seal carrier.
3. After removing the screws, the spring force on the

shaft may move the seal carrier out of its bore by
approximately 5 mm (1/4 inch). If the seal carrier
does not move from its bore after removing the
screws, pry it from its bore as shown and/or lightly tap
the end of the shaft with a soft mallet.
4. Remove the O-ring from the seal carrier.
5. Place seal carrier and seal in an arbor press and

90000272 90000273
press out old seal.
Press Out Old Seal New Seal Installed in Carrier
6. Inspect the seal carrier, the new seal and the O-ring
Screw for any damage or nicks.
Retaining Plate
Seal Carrier 7. Using the arbor press, press the new seal into seal
Seal carrier. Be careful not to damage the seal.
Screw
Seal Carrier
(One Piece) Note: The outside diameter of the seal may be lightly
coated with a sealant (such as Loctite High
Seal
Performance Sealant #59231) prior to installa-
O-ring tion. This aids in preventing leaks caused by
damage to the seal bore in the seal carrier.
90000846E
Series 90 Shaft Seal Components
54
706 BOMAG 008 911 71

Roller Bearing
8. Inspect the sealing area on the shaft for rust, wear, Assembly Retaining Ring
or contamination. Tapered
Shaft
If the shaft is not being replaced proceed to step Splined OR Roller Bearing
Shaft
12.
OR
9. Remove shaft and roller bearing assembly from
OR
pump or motor. The bearing assembly can be trans- Straight Key
ferred to the new shaft. Shaft
90000866E
10. Remove the retaining ring that secures roller bearing Fixed Motor Shaft Configuration
assembly with a snap ring pliers. Remove the roller
bearing assembly. Roller Bearing
Assembly Retaining Ring
11. Place roller bearing assembly on new shaft and Rollen Bearing
Splined OR
secure with the retaining ring. Shaft
Tapered
12. Wrap spline or key end of shaft with plastic film to Shaft
prevent damage to the sealing lip on the seal during OR
installation.
OR
13. Prior to assembly, lubricate the O-ring on the O.D. of
Straigt Key
the seal carrier and the I.D. of the seal with clean Shaft
petroleum jelly.
90000867E
14. Assemble the seal carrier and seal over the shaft and Variable Pump Shaft Configuration
into the housing bore. Install the retainer plate (if
used).
Roller Bearing
Assembly Retaining
15. Install the screws and torque like the tables. Ring
Splined
Pumps
Shaft
Frame Size Torque Pumps
OR
030 - 042 12 Nm (9 lbf ft) Tapered
055 - 100 16 Nm (12 lbf ft) Shaft
130 - 250 32 Nm (24 lbf ft)
T002 282E 90000868E
Variable Motor Shaft Configuration
Motors
Frame Size Torque Motors

030 - 100 9.5 Nm (7 lbf ft)
130 22.5 Nm (16.6 lbf ft)
T002 283E
Note: Torque the screws in a sequenced pattern then

recheck.
90000274 90000275
Install Seal Carrier Torque Retainer Screw
55
008 911 71 BOMAG 707


Pump Minor Repairs
Multi-Function Valve Cartridges
1. The multi-function valve cartridge is removed with a

hex wrench on the largest hex on the cartridge.

030 - 100 1-1/4 inch
130 - 250 1-5/8 inch
T002 284E
2. Inspect cartridge for damage to parts and O-rings.
90000276 90000277 The multi-function valve cartridge may be disas-

Remove Multi-Function Install and Torque Cartridge sembled for cleaning. However, if the pressure limiter
Valve Cartridge housing assembly is disassembled, the pressure
settings must be readjusted. Usually, if there is
contamination problem, it will be in the valve seat
assembly. If it is not necessary to clean the interior of
the cartridge, proceed to step 7.
Note: Multi-function valve components are not sold

separately as service parts (except O-rings).
90000278
Multi-Function Valve Cartridge Components 3. On early versions of the multi-function valves, the
(Earlier production)
valve seat assembly is held by a retaining ring.
Remove retaining ring with a snap ring pliers.
On late versions, the valve seat section is pressed over

a lip. Place the cartridge in a vise and pry the lower
section off with an appropriate tool. Maintain sufficient
control to prevent the contents from flying loose.
90000279
Multi-Function Valve Cartridge Components
(Later production) 4. Remove pressure limiter lock nut and bypass actuator.
5. Unscrew the pressure limiter adjustment screw from

the bypass actuator. Clean and inspect all disas-
sembled parts.
Pressure Limiter High Pressure
Pressure Limiter Relief/Check
Lock Nut
Valve Spring 6. Reassemble with new, lightly lubricated O-rings by
Valve Poppet
Pressure Limiter
reversing the above procedure. For early versions
Spring Seat assemble with the retaining ring. For late versions,
Housing Check Valve
Poppet
place the cartridge in a vise and press on lower
assembly.
Caution
The pressure settings must be readjusted after
disassembling the pressure limiter housing of the
multi-function valve cartridge.
Valve Seat S000 018E
Pressure Limiter Spring
Pressure Limiter Valve Poppet
Adjustment Screw Pressure Limiter 7. Install cartridge in multi-function valve cavity and torque.
Valve Poppet
Bypass
Frame Size Torque
Actuator
030 - 100 89 Nm (66 lbf ft)
90000869E
Multi-Function Valve Cartridge Sectional View 130 - 250 210 Nm (155 lbf ft)
T002 285E
Do not overtorque the multi-function valve cartridge.
56
708 BOMAG 008 911 71

Screws
Pressure Override Valve (Option for 180 Frame
Size) Pressure Override
Valve
1. Remove the four screws attaching the pressure
override valve to the pump end cap with a 5 mm O-rings
internal hex wrench. Remove the O-rings.
2. Inspect valve for damage to parts.
3. Install new O-rings. Install the valve onto the pump

end cap and torque the screws to 16 Nm (12 lbf ft).
Charge Relief Valve
The pump charge relief valve may be shim adjustable

(early models) or screw adjustable (late models).
90000870E
1. Remove the shim adjustable charge relief valve plug
Pressure Override Valve Components
with a 1 inch hex wrench.
Before removing the screw adjustable relief valve

plug, mark the plug, lock nut, and housing so as to
approximately maintain the original adjustment when
assembling. Remove the screw adjustable charge
relief valve plug by loosening the lock nut with a
wrench.

030 - 100 1-1/16 inch
130 - 250 1-5/8 inch
T002 286E
Unscrew the plug with a large screwdriver or 1/2 inch

hex wrench. 90000280 90000262
Remove Charge Relief Valve Shim Adjustable Charge
(Shim adjustable) Relief Valve
2. Remove the spring and relief valve poppet.
3. Inspect the poppet and mating seat in the end cap for
damage or foreign material.
When inspecting shim adjustable valves, do not alter

the shims or interchange parts with another valve.
4. Install the poppet and spring. For shim adjustable

valves, install the plug and torque to 68 Nm (50 lbf ft).
For screw adjustable valves, install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 lbf ft).
90000264 90000265
Remove Charge Relief Valve Screw Adjustable Charge
Check the charge pressure and adjust, if necessary. (Screw adjustable) Relief Valve
57
008 911 71 BOMAG 709


Charge Pump - Remove
The following procedure shows how to remove and install

a charge pump.
1. For pumps with an auxiliary mounting pad, remove

the four screws holding the pad to the end cap and
remove the pad. Refer to the Auxiliary Mounting Pad
Installation instructions (next section) for details.
Note: At earlier production frame size 75 pumps with

twin ports secure the end cap to the pump
housing with a clamp to avoid gasket damage.
90000281 90000303
Remove Auxiliary Pad Remove Auxiliary Pad
Adapter Screws Adapter
Caution
Do not allow the force of the cylinder block spring
and swashplate leveler springs to separate the end
cap from the pump housing. Gasket damage and
external leakage may result.
S000 019E
2. Remove the six screws holding the charge pump

cover retainer.

90000282 90000284 030 - 100 10 mm
Remove Retainer Screws Remove Charge Pump Cover
130 - 250 13 mm
T002 287E
3. Remove the retainer and the charge pump cover. For

pumps with an auxiliary mounting pad, remove the
auxiliary drive coupling. Note the orientation of the
gerotor.
4. Remove the charge pump shaft and charge pump

drive key.
5. Remove the spacer plate(s), if present (intermediate

production pumps only).
90000297
Remove Drive Coupling Remove the charge pump outer port plate, if present
(early and intermediate production pumps).
Discharge Gerotor Discharge Remove the charge pump gerotor assembly.

Assembly
Alignment Pin
6. Remove the outer eccentric ring and alignment pin.
Inlet Inlet
7. Remove the inner port plate.
Alignment Pin
Gerotor Assembly 8. Inspect all parts for abnormal wear or damage.
Left Hand Rotation Right Hand Rotation
(Outside looking into pump) (Outside looking into pump)
90000871E
Orienting Alignment Pin
58
710 BOMAG 008 911 71


Note: If a different displacement charge pump is be-
ing installed, the gerotor assembly, gerotor outer Standard End Cap Screws
eccentric ring, and inner port plate (early and Alignment Pin
late production pumps) or outer spacer plate(s) Charge Pump Assembly
(intermediate production pumps) must be re- Thin Port Plate
placed together. If different thickness port plates
Key
are used in an early production charge pump Thick Port Plate
Shaft
assembly, the thicker plate is the inner port Eccentric Ring
O-ring
plate (installed next to the pump end cap). Cover
Gerotor Assembly
Each charge pump assembly includes a different quan- Journal Bearing

tity / types of port plates and spacer plates. Cover Retainer
Retainer Screw
The charge pump kit "No Charge Pump" includes a
spacer.
90000872E
Charge Pump Components (Early Production)
Standard End Cap Screw
Alignment Pin
Thin Port Plate
Charge Pump Assembly
Key Eccentric Ring
Shaft Gerotor Assembly
O-ring Thin Port Plate
Cover Spacer Plate(s)
Journal Bearing
Cover Retainer
Retainer Screw
90000873E
Charge Pump Components (Intermediate Production)
Alignment Pin
Charge Pump Assembly
Key
Shaft Port Plate
O-ring Eccentric Ring
Cover Gerotor Assembly
Journal Bearing
Cover Retainer
Retainer Screw
90000874E
Charge Pump Components (Late Production)
Spacer
Shaft
O-ring
Cover
Plug
Journal Bearing
Cover Retainer
Retainer Screw
90000875E
"No Charge Pump" Components
59
008 911 71 BOMAG 711


Installing the Charge Pump
Discharge Gerotor Discharge
Assembly
Alignment Pin Be sure to install the charge pump in the proper orienta-
tion. If unsure of charge pump rotation, refer to the model
code.
Inlet Inlet
Alignment Pin Note: The charge pump rotation is determined by the

Gerotor Assembly
orientation of the gerotor assembly outer ec-
centric ring and the location of the alignment pin
Left Hand Rotation Right Hand Rotation in the end cap.
(Outside looking into pump) (Outside looking into pump)
90000871E
Do not mix charge pump piece parts from differ-
Orienting Alignment Pin ent production periods. Always install as a com-
plete assembly.
1. Install the inner port plate and the gerotor assembly

outer ring.
2. Install the alignment pin to properly orient the port

plates and outer eccentric ring for corresponding
pump rotation.
3. Prior to installation, apply a small quantity of petro-

leum jelly to the I.D., O.D., and side faces of the
gerotor assembly to provide initial lubrication.
4. Install the gerotor assembly.
90000285 90000286 5. Install the outer port plate (early production and
Install Inner Port Plate Install Gerotor Assembly intermediate production pumps only).
Outer Ring
6. Install the spacer plate, if present (intermediate
production pumps).
7. Install the charge pump drive key into the charge

pump shaft and retain with petroleum jelly.
90000287 90000288
Install Alignment Pin Install Gerotor Assembly
90000289 90000290
Install Outer Port Plate Install Spacer Plate
(Early and intermediate (Intermediate production
production only) only)
60
712 BOMAG 008 911 71


Note: Intermediate production 75 cc and 100 cc pumps
use the same charge pump drive shaft. Two
keyways are provided in the drive shaft for the
charge pumps used in these units. The rear
keyway (with identifier groove) is used in 75 cc 100 cc 75 cc
pumps. The front keyway (closest to the inter-
nally splined end of the shaft) is used in 100 cc
pumps.
8. Install the charge pump shaft. The internally splined

end of the shaft must engage the main pump shaft.
Note: The outside diameter of the internally splined

end of some early production charge pump
shafts was chamfered. Early production end
caps may not be machined to accept a non- 90000291 90000292
chamfered shaft. Always use a chamfered Keyways in Charge Pump Install Charge Pump Shaft
Shaft (Intermediate Produc-
charge pump shaft in pumps with the early end
tion 075 and 100)
cap.
9. For pumps with an auxiliary mounting pad, install the

auxiliary drive coupling.
10. Install a new O-ring onto the non-auxiliary pad charge

pump cover. (If an auxiliary pad is installed, an O-ring
is not used on the cover.)
11. Carefully remove the alignment pin from the charge

pump parts. Install the pin in its hole in the charge
pump cover (see previous page for correct orienta-
tion) and retain with petroleum jelly. Install the cover
(with alignment pin) into the end cap and aligned
charge pump parts. (Take care not to damage the
cover O-ring, if used.)
Caution
In order to avoid loss of charge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole located
on the same side of the end cap as the charge inlet
port. Refer to the section Auxiliary Pad Installation“ 90000293 90000294
for details. Alignment Pin Installed in Install Charge Pump Cover
S000 020E Cover
12. Install the charge pump cover retainer and the six hex
screws and torque the screws.
Frame Size Torque

030 - 100 13.5 Nm (10 lbf ft)
130 - 250 32 Nm (24 lbf ft)
T002 288E
13. For pumps with auxiliary mounting pads, install the

O-ring and auxiliary mounting pad adaptor onto the
end cap. Refer to the corresponding section for 90000283 90000295
Install Cover Retainer Torque Retainer Screws
instructions on auxiliary pad installation.
61
008 911 71 BOMAG 713


Auxiliary Pad Installation
1. Remove the six screws holding the charge pump

cover retainer. Remove the retainer.

030 - 100 10 mm
130 - 250 13 mm
T002 287E
2. Remove the charge pump cover and its O-ring.
Note: The original charge pump cover will not be used

when installing the auxiliary pad.
90000282 90000284
Remove Screws and Remove Charge Pump Cover 3. Remove the four large screws which fasten the end
Retainer
cap to the pump housing.
Frame Size Wrench Sizes

Internal Hex External Hex
030 -
8 mm
early 042
late 042 10 mm
055 19 mm
075 - 100 24 mm
100 - 130 14 mm
180 - 250 17 mm
T002 289E
Note: At earlier production frame size 75 pumps with

90000296
Remove Large End Cap Screws twin ports secure the end cap to the pump
housing with a clamp to avoid gasket damage.
Charge Pump Parts
Cover Caution
Assembly
Coupling Do not allow the force of the cylinder block spring
Special Washer (Typical) and swashplate leveler springs to separate the end
Journal Bearing
End Cap cap from the pump housing. Gasket damage and
Screw O-ring external leakage may result.
S000 019E
auxiliary Pad
(Typical)
O-ring Cover Retainer
Retainer Screw
Auxiliary Pad Kit
Pad Cover 4. Take care to assure the surfaces are clean and free
Screw
of any foreign material or paint prior to installing the
auxiliary pad.
90000876E
Auxiliary Pad Components (Typical) 5. Install the auxiliary drive coupling onto the pump
drive shaft spline (auxiliary drive spline must be
toward the rear of the pump).
62
714 BOMAG 008 911 71


6. Carefully remove the alignment pin from the charge
pump parts. Install the pin in its hole in the new
charge pump cover (with hole for the auxiliary cou-
pling) and retain with petroleum jelly. Install the new
charge pump cover with alignment pin into the end
cap and the aligned charge pump parts.
Caution
In order to avoid loss of charge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole lo-
cated on the same side of the end cap as the
charge inlet port. Refer to the section "Auxiliary
Pad Installation" for details.
S000 020E 90000297 90000298
Install Drive Coupling Install Alignment Pin in
Cover (CCW rotation shown)
7. Install the charge pump cover retainer and the six hex
screws and torque the screws.
Frame Size Torque

030 - 100 13.5 Nm (10 lbf ft)
130 - 250 32 Nm (24 lbf ft)
T002 288E
8. Install O-ring on end cap pilot.
9. Install the auxiliary mounting pad adapter on external

pilot on rear of end cap.
90000299 90000300
10. Install four new large screws and washers through Install New Charge Pump Install Screws and Cover
the mounting pad and end cap into the housing. Cover Retainer
Torque per the accompanying table.
Frame Size Torque

030 -
58 Nm (43 lbf ft)
early 042
late 042 122 Nm (90 lbf ft)
055 122 Nm (90 lbf ft)
075 - 100 256 Nm (189 lbf ft)
100 - 130 298 Nm (220 lbf ft)
180 - 250 580 Nm (429 lbf ft)
T002 290E
90000302 90000303
Install O-ring on End Cap Install Auxiliary Pad Adapter
11. Install the O-ring and flange cover or auxiliary pump.
Pilot
Auxiliary Pad Conversion
To convert an auxiliary mounting pad to a different size

mounting pad, use the above procedure with the following
additions:
After removing the charge pump cover (step 2), remove

the old auxiliary drive coupling.
After removing the four end cap retaining screws, remove

the old auxiliary mounting pad adapter.
90000281 90000305
Install Auxiliary Pad Adapter Torque Pad Adapter Screws
Screws
63
008 911 71 BOMAG 715

Series 90 Minor Repair

Filtration Options
Suction Filtration Installation
1. Install the hydraulic fitting to connect the external

suction filter to the charge pump inlet port.
2. The reducer fitting (placed on the charge pressure

gauge port) is installed as follows.
Frame Size Wrench Size Torque

030 - 042 1-1/4 inch 70 Nm (52 lbf ft)
055 - 130 1-1/2 inch 122 Nm (90 lbf ft)
180 - 250 1-1/2 inch 156 Nm (115 lbf ft)
T002 291E
90000310 90000243
Charge Pump Inlet Reducer Fitting and
The gauge port plug takes a 1/4 inch internal hex
Gauge Port Plug wrench and is torqued to 27 Nm (20 lbf ft).
Remote Charge Pressure Filtration or Integral Charge

Pressure Filtration
Install either of these two filtration devices as follows.
1. Remove the reducer fitting, located at charge pres-

sure gauge port, from pump end cap (this part will not
be used).
2. Install the filter manifold or filter head into the port.

The hydraulic tube should enter its mating bore in the
90000311 90000314
remote Pressure Filter Integral Pressure Filter Head pump end cap with a low force.
Manifold
3. After rotating the filter manifold or filter head clock-
wise so that the threads engage with the threads in
the end cap, continue to rotate it clockwise between
6 and 7 revolutions. Face manifold or head to the
desired position.
Caution
Failure to install the filter manifold or filter head to a
sufficient depth in the end cap will result in insufficient
engagement of the tube in the end cap bore. This may
allow unfiltered oil to bypass the filter and enter the
90000312 90000315 charge system.
Install Remote Pressure Install Integral Pressure S000 021E
Filter Manifold Filter Head
4. While holding the filter manifold or filter head in the

desired position, tighten the swivel lock nut.
Frame Size Wrench Size Torque

030 - 042 1-3/8 inch 70 Nm (52 lbf ft)
055 - 130 1-5/8 inch 122 Nm (90 lbf ft)
180 - 250 1-5/8 inch 156 Nm (115 lbf ft)
T002 292E
90000313 90000316
Tighten Remote Pressure Tighten Integral Pressure 5. After installing the integral pressure filter head as-
Filter Manifold Lock Nut Filter Head Lock Nut sembly, install the filter canister per the instructions
on the filter canister.
64
716 BOMAG 008 911 71


Pump controls
Cover Plate
1. Thoroughly clean external surfaces prior to removal

of cover plate.
2. Using a 5 mm internal hex wrench, remove the eight

cover plate mounting screws. Remove the cover
plate and gasket from housing.
Caution
Protect exposed surfaces and cavities from damage
and foreign material.
S000 022E 90000361
Pump with Cover Plate
3. In preparation for installing the cover plate, place a

new gasket on the housing. Place the cover plate into
position and install the screws. Torque the screws to
16 Nm (12 lbf ft).
NOTE
A sealing washer must be installed under the head of
any mounting screws that are installed into "thru"
holes in the housing.
S000 023E
65
008 911 71 BOMAG 717


Manual Displacement Control (MDC)

of control.

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.
Caution
S000 022E
90000319 90000320
Remove Mounting Screws Remove Control 3. In preparation for installing the control, place a new
gasket on the housing. Inspect to assure that the
control orifice check valve and spring are in their
proper position in the control.
4. While setting the control into position, engage the pin

on the control linkage into the mating hole in the link
attached to the swashplate.
5. With the control in position, move control lever both

directions to check proper engagement of control
linkage pin. Proper engagement will be indicated by
centering torque as the lever is moved from center.
90000321 90000322 Non-engagement of control linkage pin is indicated
Inner Face of Control Assemble Control to Linkage by lack of centering torque as the lever is moved. In
case of non-engagement remove the control and
repeat the above procedure.
6. Align the control gasket and install the screws. Torque

the screws to 16 Nm (12 lbf ft).
NOTE
any mounting screws that are installed into "thru"
S000 023E
90000323 90000324 7. If the control is equipped with a neutral start switch,

Assemble Control to Torque Mounting Screws refer to the "MDC Neutral Start Switch Adjustment"
Pump
instructions.
WARNING
The neutral start switch "neutral" must be read-
justed after reassembling the MDC module.
S000 024E
66
718 BOMAG 008 911 71


Solenoid Override Valve for MDC

of valve.
2. Using a 5 mm internal hex wrench, remove the two

screws and remove solenoid manifold from housing.
Remove the old gasket.
3. The solenoid may be removed from the valve by

removing the nut with a 3/4 inch hex wrench. The
solenoid valve may be removed from the manifold
with a 7/8 inch hex wrench.
4. When installing the solenoid valve into the manifold,

the valve should be torqued to 24 ± 2.4 Nm (17.7 ± 1.8 90000363
lbf ft). When installing the solenoid onto the valve, Components of Solenoid Override for MDC
torque the nut to 6 Nm (53 ± 12 lbf in).
5. In preparation for installing the solenoid manifold,

place a new gasket on the control housing. Install the
manifold onto the control housing, align the gasket,
and install the screws. Torque the screws to
13.5 Nm (10 lbf ft).
Solenoid Override Valve for MDC with Pressure

Released Brake

of valve.
2. Using a 4 mm internal hex wrench, remove the four

solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings) from the adapter plate.

adapter plate mounting screws. Remove the adapter
plate and O-rings from the control housing.
4. Remove the check valve seat and O-ring from the

control side of the adapter plate. Remove the check
ball and spring.
5. Install a new O-ring on the check valve seat and

reassemble the check valve spring, ball, and seat
into the adapter plate.
6. Install new O-rings on the adapter plate. Place the 90000364

adapter plate into position and install the screws. Components of Solenoid Override with Brake Pressure
Torque the screws to 5.4 Nm (48 lbf in). Defeat for MDC
7. Install new O-rings onto the solenoid valve assembly

and install the solenoid valve onto the adapter plate.
Install the screws and torque to 5.4 Nm (48 lbf in).
67
008 911 71 BOMAG 719


Hydraulic and Electric Displacement Controls

of control.

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.
Caution
S000 022E
3. In preparation for installing the control, place a new

90000325 90000326
Remove Mounting Screws Remove Control gasket on the housing. Inspect to ensure that the
control orifice check valve and spring are in their
proper position in the control.
4. While setting the control into position, engage the pin

on the control linkage into the mating hole in the link
attached to the swashplate.
5. With the control in position, move control assembly

left and right to check engagement of pin in the link.
Proper engagement will be indicated by an increas-
ing resistance as the control is moved away from
center position. Non-engagement of pin will be indi-
90000327 90000328
cated by lack of spring force. In case of non-engage-
Inner Face of Control Assemble Control to Linkage ment, remove control and repeat the above proce-
dure.
6. Align the control gasket and install the screws. Torque

the screws to 16 Nm (12 lbf ft).
Caution
A sealing washer must be installed under the
head of any mounting screws that are installed
into "thru" holes in the housing.
S000 023E
Pressure Control Pilot (PCP) for Electric Displace-

ment Control
90000329 90000330
Install Mounting Screws Torque Mounting Screws
1. Thoroughly clean external surfaces of control.

screws and remove the PCP.
3. Check surfaces for nicks or damage. Clean internal

screens.
4. Install new O-rings in PCP Housing. Place PCP

against EDC housing and install the screws. Torque
to 5.4 Nm (48 lbf in).
Note: Do not remove black plastic cover from the

90000332 90000334
PCP Components Torque PCP Valve Screws aluminum plate. This is not a serviceable item
and will void the product warranty.
68
720 BOMAG 008 911 71


3-Position (FNR) Electric Control

of control.

solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings and orifice) from the adapter
plate.

adapter plate mounting screws. Remove the adapter
plate and gasket from housing.
Caution 90000362
Protect exposed surfaces and cavities from damage 3-Position Electric Control Components
S000 022E
4. Inspect the orifice installed between the valve and

adapter plate. This orifice MUST be installed in the
case drain passage for proper pressure limiter op-
eration.
5. In preparation for installing the adapter plate, place a

new gasket on the housing. Place the adapter plate
into position and install the screws. Torque the
screws to 16 Nm (12 lbf ft).
NOTE
any mounting screws that are installed into thru“
S000 023E
6. Install new O-rings and the orifice onto the solenoid

valve assembly and install the solenoid valve onto
the adapter plate. Install the screws and torque to
5.4 Nm (48 lbf in).
Displacement Control Components
Displacement Control Orifices

A
1. Remove the control assembly as described in the
B
instructions for the specific displacement control.
TA P
TB
2. Orifice plugs may be located in the control assembly,
at the pump housing face surface. Remove the
orifice plugs with a 4 mm internal hex wrench. Note
the location of each plug, do not interchange plugs.
Torque the orifice plugs to 3 Nm (26 lbf in).
3. Assemble the control onto the pump. Refer to the Orifice Plugs
instructions for the specific control.
Orifice Check Valve
90000849E
Underside of an HDC/EDC Module Showing Orifice
Locations
69
008 911 71 BOMAG 721


Displacement Control Orifice Check Valve
1. Remove the control assembly as described in the

instructions for the specific displacement control.
2. The orifice check valve is located in the control

assembly, at the surface of the pump housing face.
TA A B TB Remove the spring retainer and spring from the
orifice check valve cavity and then remove the orifice
P
check valve.
3. Install the desired orifice check valve in the cavity and

then install the spring and spring retainer to hold the
orifice check valve in position.
Orifice Plugs
4. Assemble the control onto the pump. Refer to the
instructions for the specific control.
Orifice check Valve
90000848E
Underside of an MDC Module Showing Orifice Locations
Displacement Control Adapter Plate (Early produc-

tion 130 Pumps only)
The screws fastening the control adapter plate to the

housing have retaining compound on the threads. They
are removed with a 6 mm internal hex wrench.
When installing the adapter plate, ensure the O-rings are

in the proper position and torque the screws to 32 Nm
(24 lbf ft).
Displacement Control Filter Screens
If the pump is equipped with control filter screens in the

pump housing (late production), they should be pressed
into position (with the rounded edge of the filter screens
facing the control until they are flush to 2.0 mm (0.08 inch)
below the surface of the housing.
90000847
Displacement Control Adapter Plate (Early production
130cc Pumps only)
70
722 BOMAG 008 911 71


Minor Repair - Motor
Loop Flushing and Charge Relief Valves
Loop Flushing Valve
1. Using an 1-1/16 inch wrench, remove the hex plugs

and O-rings from both sides of the valve. Remove the
springs, shoulder washers, and flushing valve shuttle
spool. Note orientation of the washers. Remove the
flushing valve spool.
2. Inspect parts for damage or foreign material.
Note: Early production motors used a small diameter 90000338 90000339

shuttle valve spool. Late production motors use Remove Plugs Springs Remove Flushing Shuttle
a larger diameter spool. Spool
3. Install flushing valve spool in end cap, then install the

shoulder washers (with shoulders facing “out”) and
springs on each end of the spool. Install the hex plugs
with O-rings, and torque to 41 Nm (30 lbf ft) on 030
through 100 motors or 68 Nm (50 lbf ft) on 130
motors.
Motor Charge Relief Valve
1. Remove the shim adjustable charge relief valve plug

with a 7/8 inch hex wrench. 90000340 90000341
Install Flushing Shuttle Torque Plugs
Before removing the screw adjustable relief valve Spool
plug, mark the plug, lock nut, and housing so as to be
able to maintain the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut with a 1-1/16 inch
hex wrench for 030 through 100 units, or a 1-5/8 inch
hex wrench for 130 units, and unscrewing the plug
with a large screwdriver or 1/2 inch hex wrench.
2. Remove the spring and valve poppet.
3. Inspect the poppet and mating seat in the end cap for
damage or foreign material. When inspecting shim 90000342 90000343
adjustable valves, do not alter the shims or inter- Remove Shim Charge Relief Remove Screw Charge Relief
change parts with another valve. Valve Valve
71
008 911 71 BOMAG 723

4. Install the poppet and spring. For shim adjustable

valves, install the plug and torque to 68 Nm (50 lbf ft).
For screw adjustable valves, install the plug with its
and torque the lock nut to 52 Nm (38 lbf ft).
5. Check and adjust the charge pressure.
90000344 90000345
Shim Adjustable Charge Screw Adjustable Charge
Relief Valve Relief Valve
Defeating the Loop Flushing Valve

Lock Nut
Plug
Plug 1. Remove loop flushing valve components (these parts
O-ring
O-ring
will not be used).
Shims
Spring Spring
2. Install defeating spool into spool bore in end cap.
Poppet Poppet
Plug with O-ring
(defeat) 3. Install hex plugs provided and torque to 41 Nm
(30 lbf ft).
4. Remove charge relief valve components (these parts

Plug with O-ring are not necessary).
(defeat)
5. Replace with the hex plug provided and torque to

Plug
41 Nm (30 lbf ft).
O-ring Spool (defeat)
Spring
Plug with O-ring
(defeat)
Shoulder Washer
Note orientation of washers!

Shoulder OUT (toward spring). Spool
Shoulder Washer
Spring
O-ring
Plug
90000850E
Motor charge Relief Valve and Loop Flushing Valve Parts
72
724 BOMAG 008 911 71


Variable Motor Displacement Limiters
1. Remove the tamper-resistant cap from the displace-

ment limiter. Measure and note the length of the
adjustment screw up to the seal lock nut. Using a
19 mm hex wrench, loosen the seal lock nut and
remove the nut. Remove the limiter screw from the Tamper-Resistant Cap
motor housing with a 6 mm internal hex wrench. Seal Lock Nut
Maximum Displacement
Limiter Screw
2. Install the limiter screw with the noted length between
adjustment screw and the seal lock nut. Do not install
a new tamper-resistant cap until the limiter has been
adjusted.
3. Final adjustment of the displacement limiters should

be performed on a test stand.
Do not turn the limiter screws counterclockwise

beyond their initial adjustment positions.
Minimum Displacement
Caution Limiter Screw
Care should be taken in adjusting displacement Seal Lock Nut
limiters to avoid undesirable speed conditions. The
Tamper-Resistant Cap
seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in SAE Flange Version shown
(cartridge Version similar)
S000 026E
90000851E
One full turn of the displacement limiter adjustment MV Displacement Limiters
screw will change the displacement as follows:

Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 295E
4. Following the final adjustment, install new tamper

resistant caps.
73
008 911 71 BOMAG 725


Variable Motor Controls
Electrohydraulic 2-Position Control (Types

NA, NB, NC, and ND)

of the control.
2. Disconnect the external electrical signal connection.

Note: Remove BEFORE removing control.
Install AFTER installing control. 3. Remove the hex nut and solenoid from the control
Refer to "Control Orifices" Section
valve.
4. Remove the orifice check valve for the maximum

angle control cylinder, if equipped.
Hydraulic 2-Position
Control Valve
5. Remove the control valve from the motor housing.
6. Remove O-rings from the valve.
7. Install new O-rings on the control valve.

Electric 2-Position
Control Valve
8. Install the valve into the motor housing and torque to
47 Nm (35 lbf ft). Do not overtorque the control
valve. Over-torquing may result in the valve spool
sticking.
9. Install the solenoid onto the valve and torque the hex
90000852E nut to 5 Nm (44 lbf in). Do not overtorque the nut.
MV Control components
10. If previously removed, reinstall the orifice check
valve. Reconnect the external signal connection.
Hydraulic 2-Position Control (Type PT)
Follow the steps above, except that in step 2 a hydraulic

signal line will be disconnected, and steps 3 and 9 are not
applicable.
1/8 in. int. hex wrench
Torque: 5.4 Nm (48 lbf in)
Control Plugs
Remove the control plugs from the housings of earlier

9/16 in. hex wrench
Torque: 34 Nm (25 lbf ft) production motors, if necessary. Install new O-rings,
reinstall, and torque.
7/8 in. hex wrench
90000853E
MV Control Plugs
74
726 BOMAG 008 911 71


Variable Motor Control Orifices
Control Suply Orifice
Control Supply Orifice
Screen (pressed in)
1. Remove the control supply orifice from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer
2. Remove the O-rings and the backup washers. Check O-ring

that the filter screen is secure in the orifice body and Backup Washer
that the screen and the orifice are not plugged.
3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor housing O-ring
and torque to 37 Nm (27 lbf ft). Backup Washer Backup Washer
Caution
Screen
Do not interchange the control supply orifice with the (pressed in)
minimum displacement orifice (next section).
S000 027E Orifice Body
O-ring
Cross-section View of
Control Supply Orifice Assembly
90000854E
MV Control Supply Orifice
Minimum Displacement Cylinder Orifice or Orifice

Check Valve
Orifice Orifice / Check Valve
Assembly
1. Remove the minimum displacement cylinder drain
orifice or the orifice check valve from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer
2. Remove the O-rings and the backup washers. Check O-ring

that the orifice is not plugged. Check that the check Backup Washer
valve seat is secure in the body and that the check
ball is free.
3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor housing
and torque to 37 Nm (27 lbf ft).
O-ring O-ring
Orifice Body Orifice Body

Caution
Do not interchange the control supply orifice (previous Backup Washer
Spring Pin
Backup Washer
section) with the minimum displacement orifice. O-ring O-ring
S000 028E Kugel
Backup Washer Backup Washer
Orifice Seat
(Spot welded)
Cross-Section View of Cross-Section View of
Orifice Assembly Orifice / Check Valve
Assembly
90000855E
MV Minimum Displacement Orifice
75
008 911 71 BOMAG 727


Maximum Displacement Cylinder Orifice Check Valve
1. Remove the seal lock nut with a 3/4 inch hex wrench.
Housing Plug Remove the maximum displacement cylinder orifice
check valve from the motor housing with a 1/4 inch
Seal Lock Nut
(seal toward housing) end wrench. Remove the O-ring. The check ball in
the valve must be free.
O-ring
2. Reinstall the check valve and torque to 15 Nm
Orifice / Check Valve Assembly
(11 lbf ft). Install a new O-ring. Install the seal lock
nut with the seal toward the motor housing.
Seal Lock Nut
(seal toward housing)
Hold the check valve from turning while torquing
the seal lock nut to 34 Nm (25 lbf•ft).
O-ring
3. If no orifice check valve is installed, the housing plug
Orifice Body may be removed with a 9/16 inch hex wrench. Always
install a new O-ring. Reinstall the plug and torque to
Check Ball
20 Nm (15 lbf ft).
Spring Pin
Cross-Section View of
Orifice / Check Valve
Assembly
90000856E
MV Maximum Displacement Orifice
76
728 BOMAG 008 911 71


Speed Sensor
1. Remove the speed sensor by disconnecting the

electrical connector, loosening the lock nut, and Housing Plug
Speed Sensor 1/4 in. int. hex wrench
unscrewing the speed sensor from the pump or or Torque: 23 Nm (17 lbf ft)
motor housing.
2. Always install a new O-ring before installing the 1-1/16 in. hex wrench
sensor. After adjustment!
3. Reinstall the speed sensor (with lock nut and O-ring)

into the housing. Adjust the gap between the sensor
and the magnetic speed ring as instructed in Section
"Speed Sensor Adjustment" and torque the sensor
lock nut.
4. If a speed sensor is not installed, the housing plug

should be torqued as indicated in the accompanying 90000857E
figure. Typical Location of Speed Sensor - PV
1-1/16 in. hex wrench

After adjustment!
or
Housing Plug Speed Sensor

1/4 in. int. hex wrench
90000858E
Typical Location of Speed Sensor - MF

After adjustment!
or
Speed Sensor
Housing Plug
90000859E
Typical Location of Speed Sensor - MV
77
008 911 71 BOMAG 729

Series 90 Exploded View Parts Drawings / Parts Lists

Exploded View Parts Drawings / Parts Lists
Variable Pumps
Minor Repair Parts
K90 L35
B70 K10 K018 (Early Production
bis 075 Frame Size) (L70)
B83 G532 K50 K042
OR G536 K70
B83 (L40) L60 L70
G542 K80
G546 (B80)
L40
B82 (B90) L30
P2B_
(B70)
B90
P30 P06
P13
L50
P30
B71
P2A_ P06
P13 G512
G516
G502
G506
G172
G522 G176
G526
B80
(G502
G506) (G502
G506)
(G63)
G63
(CODE 61 OPTION)
(G64)
G64
(CODE 61 OPTION) (K018
BOTH SIDES THRU
K042)
G531
G501
G538
G508
G511
G518
OR
G541
G548
G63
(CODE 61 OPTION)
G521
G528
(G63)
(G501
G508) (G64)
G64
(G501
(CODE 61 OPTION)
G508)
90000860E
78
730 BOMAG 008 911 71


Parts List
Item Description Qty Item Description Qty
B70 ............... Plug ......................................................... 2 G532 ............ Plug ......................................................... 1

B71 ............... Plug ......................................................... 1 G536 ............ O-ring ...................................................... 1
B80 ............... Plug ......................................................... 1 G538 ............ O-ring ...................................................... 1
B82 ............... Plug ......................................................... 1 G541 ............ Plug ......................................................... 1
B90 ............... Filter screen ............................................ 3 G542 ............ Plug ......................................................... 1
G546 ............ O-ring ...................................................... 1
G63 .............. Split flange clamp .................................... 4 G548 ............ O-ring ...................................................... 1
G64 .............. Plug ......................................................... 4
G172 ............ Plug ......................................................... 1 K10 ............... Plug assembly ......................................... 1
G176 ............ O-ring ...................................................... 1 K50 ............... O-ring ...................................................... 1
G501 ............ Plug ......................................................... 3 K70 ............... Spring ...................................................... 1
G502 ............ Plug ......................................................... 3 K80 ............... Poppet ..................................................... 1
G506 ............ O-ring ...................................................... 3 K90 ............... Nut ........................................................... 1
G508 ............ O-ring ...................................................... 3
G511 ............ Plug ......................................................... 1 L30 ............... Seal carrier .............................................. 1
G512 ............ Plug ......................................................... 1 L35 ............... Seal carrier .............................................. 1
G516 ............ O-ring ...................................................... 1 L40 ............... Lip seal .................................................... 1
G518 ............ O-ring ...................................................... 1 L50 ............... O-ring ...................................................... 1
G521 ............ Plug ......................................................... 1 L60 ............... Retainer ................................................... 1
G522 ............ Plug ......................................................... 1 L70 ............... Screw ...................................................... 3
G526 ............ O-ring ...................................................... 1
G528 ............ O-ring ...................................................... 1 L8 ................. Key .......................................................... 1
G531 ............ Plug ......................................................... 1 L9 ................. Slotted nut ............................................... 1
79
008 911 71 BOMAG 731


Variable Pump Controls
M0DC
M90D M1DC M0DD
M1DD
OR
M11D
M0MA M0ME
M0MB M0MF
M0MC M0MG
M0MD M0M9 M0CA
M9ME M76M M74M M90C
M78M M1CA M87C
M92M M11C
M97M M77M
M95M M98M M75M
M96M S40
M72M
M90M
M71M
M1MA M880 OR
M1MB M7MA
T201
M1MC M7MB
THRU
T001 M1MD M7MC
T209, M0EA
THRU M1ME M7MD
T222 M0EF M91E
T009, M1MF M7ME
T250 M0EP
T022 M1MG M7MF
T050 T301 M7MG
THRU T401
M87M M11M M9EA M98E
T309, THRU
M9EP
T322 T409, M90E M95E
T422 M97E
T350
T450 M1EA M880
M1EF
M870
M1EP M96E
M860
M11E
M850
M840 M87E
M840 M810
REF
M830 M840
M820
REF
(Early Production
130 cc Frame Size)
OR
M1HA, M1HC
OR
M1HF, M1HG
M90H
M1HH, M1HJ
M880
M1HK, M1HL M87H
M1HM, M1HN
M11H M0HA, M0HC

M0HF, M0HG
M0HH, M0HJ
M0HK, M0HL
M0HM, M0HN
90000861E
80
732 BOMAG 008 911 71


Control Parts List
M0CA ........... Cover plate kit ......................................... 1 M71M ........... Washer .................................................... 1
M1CA ........... Cover plate .............................................. 1 M72M ........... Nut ........................................................... 1
M11C ........... Control gasket ......................................... 1 M80 .............. Control gasket ......................................... 1
M11D ........... Control gasket ......................................... 1 M87M ........... Washer, seal (042) ................................. 1
M87C ........... Washer, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6
M90C ........... Screw ...................................................... 6 S40 ............... Neutral start switch kit ............................. 1
M0DC ........... Control kit, 3-position FNR 12V .............. 1 M0MC .......... Control MDC w/ sol. valve ...................... 1
M0DD ........... Control kit, 3-position FNR 24V .............. 1 M7M ............. Control handle ......................................... 1
M1DC ........... Control, 3-position FNR 12V ................... 1 M71M ........... Washer .................................................... 1
M1DD ........... Control, 3-position FNR 24V ................... 1 M72M ........... Nut ........................................................... 1
M80 .............. Control gasket ......................................... 1 M74M ........... Solenoid valve ......................................... 1
M87D ........... Washer, seal (042) ................................. 1 M75M ........... Control manifold ...................................... 1
M90D ........... Screw ...................................................... 6 M77M ........... Manifold gasket ....................................... 1
M78M ........... Screw ...................................................... 2
M0EA ........... Control kit, EDC with M80 .............. Control gasket ......................................... 1
MS connector .......................................... 1 M87M ........... Washer, seal (042) ................................. 1
M0EP ........... Control kit, EDC with M90M ........... Screw ...................................................... 6
Packard connector .................................. 1
M1EA ........... Control, EDC with M0MD .......... Control MDC w/ sol. valve and
MS-connector .......................................... 1 neutral start switch .................................. 1
M1EP ........... Control, EDC with M7M ............. Control handle ......................................... 1
Packard-connector .................................. 1 M71M ........... Washer .................................................... 1
M9EA ........... PCP type 3 oil filled (MS) ........................ 1 M72M ........... Nut ........................................................... 1
M9EA ........... PCP type 3 oil filled (Packard) ................ 1 M75M ........... Control manifold ...................................... 1
M80 .............. Control gasket ......................................... 1 M76M ........... Solenoid valve ......................................... 1
M87E ............ Washer, seal (042) ................................. 1 M77M ........... Manifold gasket ....................................... 1
M90E ............ Screw ...................................................... 6 M78M ........... Screw ...................................................... 2
M91E ............ Plastic cap (MS) ...................................... 1 M80 .............. Control gasket ......................................... 1
M95E ............ O-ring ...................................................... 2 M87M ........... Washer, seal (042) ................................. 1
M96E ............ O-ring ...................................................... 1 M90M ........... Screw ...................................................... 6
M97E ............ O-ring ...................................................... 1 S40 ............... Neutral start switch ................................. 1
M98E ............ Screw ...................................................... 4
M1MA ........... Servovalve kit .......................................... 1 M810 ............ Adapter plate - Control (130 cc) ............. 1
M820 ............ O-ring (130 cc) ........................................ 1
M0HA ........... Control kit, hydraulic, HDC ..................... 1 M830 ............ O-ring (130 cc) ........................................ 1
M0HC ........... Control kit, hydraulic, HDC ..................... 1 M840 ............ O-ring (130 cc) ........................................ 2
M1HA ........... Control, hydraulic, HDC .......................... 1 M850 ............ Plug (130 cc) ........................................... 1
M1HC ........... Control, hydraulic, HDC .......................... 1 M860 ............ Screw (130 cc) ........................................ 6
M11H ........... Control gasket ......................................... 1 M870 ............ Plug (130 cc) ........................................... 1
M80 .............. Control gasket ......................................... 1
M87H ........... Washer, seal (042) ................................. 1 M9ME ........... 4/2 Way valve ......................................... 1
M90H ........... Screw ...................................................... 6 M92M ........... Screw ...................................................... 4
M95M ........... O-ring ...................................................... 1
M0MA ........... Control MDC M96M ........... O-ring ...................................................... 1
w/o neutral start switch ........................... 1 M97M ........... O-ring ...................................................... 1
M7M ............. Control handle ......................................... 1 M98M ........... Screw ...................................................... 4
M71M ........... Washer .................................................... 1
M72M ........... Nut ........................................................... 1 T001-9 .......... Control orifice kit ..................................... 1
M80 .............. Control gasket ......................................... 1 T201-9 .......... Orificed check valve ................................ 1
M87M ........... Washer, seal (042) ................................. 1 T301-9 .......... Spring ...................................................... 1
M90M ........... Screw ...................................................... 6 T401-9 .......... Spring retainer ......................................... 1
M0MB ........... Control MDC

w/ neutral start switch ............................. 1
M7M ............. Control handle ......................................... 1
81
008 911 71 BOMAG 733


Filter and Options
N40P
N40L
N00M
N00S
N35M
REF N35S
N10M
N10S
N30R N35M N25M Or
N00R
N20M
N10R N15M
N31R
N20R OR
N15R
N35R N25R
90000862E
H50L
H50
H40
OR H05
H30
H60
H50
H40
H30
OR H05
(H30)
J80N
H40
H60 H05
H50 OR
H60
H50
H90L
J40N
J15N
H70 J15_
J30 J10_
J30
H80 J70_
H70
OR
J80_ J50_
J60_
J90_ H80
J00_
J92_
J95_
90000863E
82
734 BOMAG 008 911 71


Parts List Filter and Options
H05B-H ........ Kit - Charge pump ................................... 1 J80A-V ......... Screw ...................................................... 4
H50L ............ Spacer (No charge pump) ...................... 1 J80N ............. Screw ...................................................... 4
H30 .............. Port plate ................................................. 2 J90A-V ......... O-ring ...................................................... 1
H40 .............. Pin ........................................................... 1 J92A-V ......... Cover plate .............................................. 1
H50 .............. Charge pump shaft ................................. 1 J95A-V ......... Screw ................................................... 2/4
H60 .............. Key .......................................................... 1
H70 .............. Retaining plate ........................................ 1 N00M ........... Filtration manifold kit (Int) ....................... 1
H80 .............. Screw ...................................................... 6 N10M ........... Manifold ................................................... 1
H90L ............ Plug ......................................................... 1 N15M ........... O-ring ...................................................... 2
N20M ........... Nut ........................................................... 1
J00A ............. Aux. mtg. SAE A flange .......................... 1 N25M ........... Tube ........................................................ 1
J00B ............. Aux. mtg. SAE B flange .......................... 1 N35M ........... Plug ......................................................... 2
J00C ............. Aux. mtg. SAE C flange .......................... 1 N40L ............ Filter ........................................................ 1
J00D ............. Aux. mtg. SAE D flange .......................... 1 N40P ............ Filter ........................................................ 1
J00T ............. Aux. mtg. SAE A flange (11 T) ............... 1
J00V ............. Aux. mtg. SAE B-B flange ....................... 1 N00R ............ Filtration manifold kit (Rmt) ..................... 1
J00N ............. Aux. mtg. flange - none .......................... 1 N10R ............ Manifold ................................................... 1
J10A-V ......... Coupling .................................................. 1 N15R ............ O-ring ...................................................... 1
J15 ............... Charge pump cover assembly ................ 1 N20R ............ Nut ........................................................... 1
J15N ............. Charge pump cover assembly ................ 1 N25R ............ Tube ........................................................ 1
J30 ............... Bushing ................................................... 1 N30R ............ Plastic plug .............................................. 2
J50A-V ......... O-ring ...................................................... 1 N35R ............ Plug ......................................................... 1
J60A/T .......... Flange adaptor SAE A ............................ 1
J60B/V ......... Flange adaptor SAE B ............................ 1 N00S ............ Filtration kit (Suction Flt) ......................... 1
J60C ............. Flange adaptor SAE C ............................ 1 N10S ............ Reducer fitting (Suction Flt) .................... 1
J60D ............. Flange adaptor SAE D ............................ 1 N35S ............ Plug ......................................................... 1
J70A-V ......... Washer .................................................... 4
Name Plates
Ames, Iowa, U.S.A. Neumünster, Germany Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ Model Code Typ
90L055 EA 1 N 90L055 EA 1 N
Model Model
6 S 3 C6 C 03 6 S 3 C6 C 03 Code
Code
Model No. Ident Nr Model No. Ident Nr
Model Number Model Number 687459
94 – 2029
Serial Number Serial Number
Serial No. Fabr Nr Serial No. Fabr Nr
MADE IN U.S.A. MADE IN GERMANY
Place of Manufacture Place of Manufacture
Name Plate (U.S.A. Production) Name Plate (German Production)
83
008 911 71 BOMAG 735


Fixed Motor
Minor Repair Parts
H68W
H60W L35
(Early Production
H62W 075 Frame Size) (L70)
H64W
(L40) L60 L70
H66W
H60N L30
L40
(H50N) (B80)
(G50)
(H50W) (H30W)
L50
(H40W)
(H20W)
G50
G70
H10N (B80)
H50N
H20W
(G63)
B80 H10W H40W
G63
H30W
(CODE 61 OPTION)
H50W
(G64) G64
(CODE 61 OPTION)
B83 B83 OR
B80
G63
(CODE 61 OPTION)
(G63)
G64
(CODE 61 OPTION) (B83)
(G64) (B83)
90000864E
84
736 BOMAG 008 911 71


Parts List
B80 ............... Plug ......................................................... 2 H50W ........... Plug ......................................................... 2

B83 ............... Plug ......................................................... 1 H60W ........... Charge relief valve plug .......................... 1
B83 ............... Speed sensor .......................................... 1 H62W ........... O-ring ...................................................... 1
H64W ........... Spring ...................................................... 1
G50 .............. Plug ......................................................... 2 H66W ........... Charge relief poppet ............................... 1
G70 .............. Plug ......................................................... 1 H68W ........... Lock nut ................................................... 1
G63 .............. Split flange screw .................................... 4
G64 .............. Screw - Shipping Cover .......................... 4 L30 ............... Seal carrier .............................................. 1
L35 ............... Seal carrier .............................................. 1
H10N ............ Loop flushing spool - defeat .................... 1 L40 ............... Lip seal .................................................... 1
H50N ............ Plug ......................................................... 2 L50 ............... O-ring ...................................................... 1
L60 ............... Retainer ................................................... 1
H10W ........... Shuttle valve spool .................................. 1 L70 ............... Screw ...................................................... 3
H20W ........... Spring guide ............................................ 2
H30W ........... Spring ...................................................... 2 L8 ................. Key .......................................................... 1
H40W ........... O-ring ...................................................... 2 L9 ................. Slotted nut ............................................... 1
Name Plates
Ames, Iowa, U.S.A. Neumünster, Germany Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ Model Code Typ
90M055 NC 0 N 90M055 NC 0 N
8 N 0 C6 W 00 Model Model
8 N 0 C6 W 00
Code Code
NNN 00 00 24 NNN 00 00 24
Model No. Ident Nr Model No. Ident Nr
Model Number 94 – 2029 Model Number 312918
Serial Number A – 91 – 26 – 67890 Serial Number N – 91 – 26 – 67890
Serial No. Fabr Nr Serial No. Fabr Nr
MADE IN U.S.A. MADE IN GERMANY
Place of Manufacture Place of Manufacture
Name Plate (U.S.A. Production) Name Plate (German Production)
85
008 911 71 BOMAG 737


Variable Motor
Minor Repair Parts
Y100 Y102
Y101
L35
Y40 (Early Production
075 Frame Size) (L70)
Y50
Y60 L70
E15 L60
E35 E26 (Y50) (L40)
L30
L40
B83
(B74)
B80
B83 L50
B76
H68W T100
T101
T30
H60W T40
(B74) T50
H62W T60
H64W (T50)
H66W M1PT Y80 Y71

H60N B74 Y72
Y70
M1NA, M1NB P700
(G50) M1NC, M1ND P702
(P400)
(H50N) G50 (B80)
(P401)
(H50W) (P402)
E25 P601 (P403)
(H40W) (B74)
P603
E35
(H30W) H10N
(H20W) (P400) P600
E15
(P401) P602
G70 H50N (P402)
(P403)
H10W
H20W
H30W
(G63) H40W H50W
G63
(G64) (CODE 61 OPTION)
P800
G64
(CODE 61 OPTION)
90000865E
86
738 BOMAG 008 911 71


Parts List
B74 ............... Plug ......................................................... 4 L30 ............... Seal carrier .............................................. 1

B76 ............... Plug ......................................................... 1 L35 ............... Seal carrier .............................................. 1
B80 ............... Plug ......................................................... 2 L40 ............... Lip seal .................................................... 1
B83 ............... Plug ......................................................... 1 L50 ............... O-ring ...................................................... 1
B83 ............... Speed sensor .......................................... 1 L60 ............... Retainer ................................................... 1
L70 ............... Screw ...................................................... 3
E15 ............... Cap .......................................................... 1
E25 ............... Set screw ................................................ 1 M1N ............. Control valve - electric ............................ 1
E35 ............... Nut - Seal Lock ....................................... 1 M1P .............. Control valve - hydraulic ......................... 1
G50 .............. Plug ......................................................... 2 P400 ............. Plug ......................................................... 2

G63 .............. Split flange clamp .................................... 4 P600 ............. Plug ......................................................... 1
G64 .............. Shipping cover screw .............................. 4 P601 ............. PCOR-Valve ............................................ 1
P700 ............. Special plug ............................................. 1
G70 .............. Plug ......................................................... 1 P800 ............. O-ring ...................................................... 1
H10N ............ Loop flushing spool - defeat .................... 1 T30 ............... Filter screen ............................................ 1
H50N ............ Plug ......................................................... 2 T40 ............... O-ring ...................................................... 1
H60N ............ Plug ......................................................... 1 T50 ............... Backup ring ............................................. 2
T60 ............... O-ring ...................................................... 1
H10W ........... Shuttle valve spool .................................. 1 T100 ............. Orifice plug .............................................. 1
H20W ........... Spring guide ............................................ 2
H30W ........... Spring ...................................................... 2 Y40 ............... O-ring ...................................................... 1
H40W ........... O-ring ...................................................... 2 Y50 ............... Backup ring ............................................. 2
H50W ........... Plug ......................................................... 2 Y60 ............... O-ring ...................................................... 1
H60W ........... Charge relief valve plug .......................... 1 Y70 ............... Orifice check valve .................................. 1
H62W ........... O-ring ...................................................... 1 Y71 ............... Nut - Seal Lock ....................................... 1
H64W ........... Spring ...................................................... 1 Y72 ............... O-ring ...................................................... 1
H66W ........... Charge relief poppet ............................... 1 Y80 ............... Plug ......................................................... 1
H68W ........... Lock nut ................................................... 1 Y100 ............. Orifice plug .............................................. 1
Y102 ............. Orifice check valve .................................. 1
L8 ................. Key .......................................................... 1
L9 ................. Slotted nut ............................................... 1
Name Plate
Ames, Iowa, U.S.A. Neumünster, Germany

Model Code Typ
90S055 NB 2 0
8 N 4 S1 W 01 Model Code
NNN 01 00 24
Model No. Ident Nr
Model Number 94 – 4002
Serial Number A – 91 – 26 – 67890
Serial No. Fabr Nr
MADE IN U.S.A.
Place of Manufacture
Name Plate (U.S.A. Production)
87
008 911 71 BOMAG 739

Hydraulic Power Systems

SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND is a world leader in the design SAUER-SUNDSTRAND specializes in integrating a full
and manufacture of Hydraulic Power Systems. Research range of system components to provide vehicle designers
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technology. Hydraulic Power Systems
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F000 685 F000 688 F000 690 F000 684
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F000 717 F000 687 F000 693
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Worldwide Service Support
SAUER-SUNDSTRAND provides comprehensive worldwide service for its

produkts through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.
Original
Ersatzteile http://www.sauer-danfoss.com
Genuine Parts
SAUER-SUNDSTRAND COMPANY SAUER-SUNDSTRAND GMBH & CO.

2800 East 13th Street Postfach 2460 D-24531 Neumünster
Ames IA 50010 U.S.A. Krokamp 35 D-24539 Neumünster Germany
Phone: (515) 239-6000 Fax: (515) 239-6618 Phone: (04321) 871-0 Fax: (04321) 871 122
SM-SPV/SMF/SMV90-E • 10/98 • 300047G
740 BOMAG 008 911 71

16.2 Vibration motor A2FM
008 911 71 BOMAG 741

742 BOMAG 008 911 71

Vibration motor A2FM 16.2
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics
RDE 91 001-03-R/05.03
Konstantmotor A2FM/E ersetzt / replaces 04.00
Fixed Displacement Motor A2FM/E

Baureihe / Series 61
Reparaturanleitung / Repair Instructions
008 911 71 BOMAG 743

16.2 Bosch Rexroth AG | Mobile Hydraulics
2 A2F | RDE 91motor
Vibration 001-03-R/05.03
A2FM
Hinweis / Inhalt
Notice / Contents
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.
INHALT Seite/ CONTENTS

Page
A2F A2F
Schnittbild 3-6 Sectional view

Allgemeine Reparaturhinweise 7 General repair instructions
Dichtsätze und Baugruppen 8-9 Seal kits and sub-assemblies
Triebwelle abdichten 10 Sealing of the drive shaft
Anschlußplatte abdichten 11-14 Sealing of the cover plate
Triebwerk ausbauen 15-16 Removal the rotary group
Überprüfungshinweise 17-18 Inspection guidelines
Triebwerk einbauen 19-21 Installing rotary group
Anziehdrehmomente 22-24 Tightening torques
Sicherheitsbestimmungen 25 Safety regulations
744 BOMAG 008 911 71

RDE 91 001-03-R/05.03
Vibration motor A2FM| A2F Mobile Hydraulics | Bosch Rexroth AG 16.23
Schnittbild
Sectional view
A2FM Pos.B
Pos.D
Pos.A
Meßpunkte: Measuring points:

Siehe Serviceinfo See service information
008 911 71 BOMAG 745

4 A2F | RDE 91motor
A2FM
Schnittbild
Sectional view
A2FM mit Spülventil /

A2FM with flushing valve
746 BOMAG 008 911 71

RDE 91 001-03-R/05.03
Schnittbild
Sectional view
A2FE
008 911 71 BOMAG 747

6 A2F | RDE 91motor
A2FM
Schnittbild
Sectional view
A2FE
748 BOMAG 008 911 71

RDE 91 001-03-R/05.03
Allgemeine Reparaturhinweise
General repair instructions
Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!
Alle Öffnungen der Hydraulikaggregate

verschließen.
Close all ports of the hydraulic aggregates.
Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.
Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.
Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.
Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen bzw. entlüften.
Before start-up fill up hydraulic aggregates with

hydraulic oil respectively deaerate.
008 911 71 BOMAG 749

8 A2F | RDE 91motor
A2FM
Dichtsätze und Baugruppen

Seal kits and sub-assemblies
Dichtsatz
Seal kit
Triebwerk, mechanischer Teil /

Rotary group, mechanical part
Triebwerk, mechanischer Teil;

muß abgestimmt werden Pos. "A".
(siehe Serviceinfo)
Rotary group, mechanical part;

has to be adjusted to item "A".
(see service info)
Lagersatz, komplett abgestimmt.

Pos. B (Stützscheibe und Sicherungsring
nicht tauschbar)
zusätzliche Abstimmung Pos. "A".
(siehe Serviceinfo)
Bearing set, matched

Item B (support disc and circlip are
not exchangeable)
Additional adjustment item "A".
(see service info)
750 BOMAG 008 911 71

RDE 91 001-03-R/05.03
Dichtsätze und Baugruppen
Seal kits and sub-assemblies
Triebwerk, hydraulischer Teil /

Rotary group, hydraulic part
Triebwerk, hydraulischer Teil;

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)
Rotary group, hydraulic part;

Adjustment of the hydraulic part Pos. "D".
(see service info)
Triebwerk komplett; - fertig vorabgestimmt -

Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)
Complete rotary group, - pre-adjusted -

Adjustment of the hydraulic part Pos. "D".
(see service info)
Spülventil
Flushing valve
Ventil
Valve
008 911 71 BOMAG 751

10 A2F | RDE 91motor
A2FM
Triebwelle abdichten
Sealing of the drive shaft
Bei nicht verzahnten Triebwellen: Paßfeder abneh-

men. Triebwelle abkleben,
For non-splined shafts: remove key.

Protect the drive shaft (e.g. tape).
Sicherungsring ausbauen, Verschlußring abdrücken
Remove circlip, prise off cover.
Sichtkontrolle
Wellendichtring (1), Verschlußring (2),
Triebwelle (3), Gehäuse (4), O-Ring (5).
Visual check
Shaft seal (1), cover (2), drive shaft (3),
housing (4), O-ring (5).
752 BOMAG 008 911 71

RDE 91 001-03-R/05.03
11
Triebwelle abdichten
Sealing of the drive shaft
Wellendichtring demontieren.
Remove shaft seal.
Neuen Wellendichtring lagerichtig mit

passender Büchse einpressen.
Press in the new shaft seal,ensuring that

it is correctly orientated, using a suitable bush.
Neuen O-Ring einlegen, auf bündiges Anliegen

achten. O-Ring sowie Dicht- und Staublippe des
Wellendichtringes einfetten. (siehe Serviceinfo)
Fit new O-ring, ensure that it is correctly located.

Grease the O-ring as well as the seal and dust lips
of the shaft seal. (see service information)
Sicherungsring einbauen.
Sitzkontrolle des Sicherungsringes in der Nut.
Fit circlip.
Check to ensure that the circlip is correctly located
within the groove.
008 911 71 BOMAG 753

A2FM
Anschlußplatte abdichten
Sealing of the cover plate
Lage der Anschlußplatte zum Gehäuse kenn-

zeichnen (Pfeil), Befestigungsschrauben lösen.
Mark the position of the cover plate with regard

to the housing (arrow), loosen the fixing screws.
Anschlußplatte um Verdrillstift schwenken (1)

und abheben (2).
Swing the connection plate about the locating

pin (1) and lift off (2).
754 BOMAG 008 911 71

RDE 91 001-03-R/05.03
13
Auf Montagestellung des Verdrillstiftes achten

(Pfeile).
Take the assembly position of the locating

pin (arrow) into account.
Pumpe, Drehrichtung rechts.

Saugseite / (Blick auf sphärische Fläche.)
Suction side Druckseite /
Pressure side Pump, clockwise rotation.
(viewed on spherical surface.)
Saugseite /
Druckseite / Pumpe, Drehrichtung links.
Suction side
Pressure side (Blick auf sphärische Fläche.)
Pump, anti-clockwise rotation.

(viewed on spherical surface.)
Motor, beide Drehrichtungen.

(Blick auf sphärische Fläche.)
Motor, bi-directional.
(Viewed on spherical surface.)
008 911 71 BOMAG 755

A2FM
Sichtkontrolle
O-Ring (1), Einstich (2), Platte (3).
Visual check
O-ring (1), Groove (2), Plate (3).
Neuen O-Ring einlegen, zuvor leicht einfetten.
Lightly grease and fit O-ring.
Anschlußplatte aufsetzen, auf Kennzeichnung und

Lage des Verdrillstiftes achten.
Place the cover plate onto the housing taking into

account the location mark and position of the
locating pin.
Befestigungsschrauben mit Drehmomenten-

schlüssel anziehen.
Tighten fixing screws using a torque wrench.
756 BOMAG 008 911 71

RDE 91 001-03-R/05.03
15
Triebwerk ausbauen
Removal the rotary group
Lagersatz / Bearing set
Demontage der Anschlußplatte.

Steuerplatte abheben.
Zylinder am Mittelzapfen mit Schraube befestigen.
Removal of the connection plate.

Lift off the control plate.
Secure the cylinder to the centre pin using a screw.
Gewindestift,Zylinderschraube /
Threaded pin,socket head screw
NG / Size (mm)
10; 12; 16 M3 x 35
23; 28; 32 M5 x 45
45 M5 x 50
56; 63 M5 x 55
80; 90 M5 x 60
107; 125; 131 M6 x 70
160; 180 M6 x 85
008 911 71 BOMAG 757

A2FM
Triebwerk ausbauen
Removal the rotary group
Verschlußring, O-Ring und Paßscheibe ausbauen.
Remove the cover, O-ring and shim.
Triebwerk mit Vorrichtung ausbauen.
Withdraw the rotary group using an extractor.
Befestigungsschraube ausbauen.
Zylinder abheben.
Remove the fixing screw.

Lift off the cylinder.
Rückzugplatte demontieren, Schrauben sind

eingeklebt.
Komplettes Triebwerk bei ca. 120o C im Ölbad
erwärmen. Danach Befestigungsschrauben lösen!
Disassemble the retaining plate, screws are locked

with an adhesive.
Heat up the complete rotary group in an oil bath
to approx 120o C, then remove the fixing screws.
758 BOMAG 008 911 71

RDE 91 001-03-R/05.03
17
Überprüfungshinweise
Inspection guidelines
Triebwelle
4 4 1. kein Passungsrost, nicht ausgeschlagen.
1 2
3 2. keine Einlaufspuren, riefenfrei.
3. Kalotten riefenfrei und keine Pittings.
4. Keine Laufspuren (Lagerdreher)
3
Drive shaft
1. No wear, or fretting
2. No traces of wear, free of scratches.
3. Cups free of wear and no pitting.
4. No traces of wear, (bearing rotation).
1
1. Axiales Kolbenspiel
1. Axial play of piston.
Alt / Old
Kolben
Riefenfrei, keine Pittings.
Piston
Neu / New
Free of scratches, no pitting.
1 2
Mittelzapfen
1. Riefenfrei, ohne Pittings.
2. Riefenfrei.
Center pin
1. Free of scratches, no pittings.
2. Free of scratches.
Rückzugplatte
Riefenfrei, keine Ausbrüche.
Retaining plate
Free of scratches, no wear.
008 911 71 BOMAG 759

A2FM
Überprüfungshinweise
Inspection guidelines
Zylinder/Steuerplatte
1. Bohrungen riefenfrei, nicht ausgelaufen.
2. Gleichmäßiges Tragbild, riß- und riefenfrei.
Cylinder / control plate

1. Bores unscratched, and no traces of wear.
2. Even load distribution, free of cracks and
grooves.
Gehäuse
Im Lagerbereich riefenfrei und keine
Einlaufspuren.
Housing
No traces of wear in the bearing area.
Nur kompletten Kolbensatz austauschen.
Only exchange the pistons as a complete set.
Zylinder und Steuerplatte nur gemeinsam

austauschen.
Only replace the cylinder and control plate as a pair.
760 BOMAG 008 911 71

RDE 91 001-03-R/05.03
19
Triebwerk einbauen
Installing rotary group
Triebwelle mit Lager vormontiert verwenden.
Use a pre-assembled drive shaft with bearings.
S Abstimmung Pos. A / Adjustment item A
A = A* + S
S = Nennmaß - Sicherungsring /Safety ring
A A*
Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
Fit retaining plate complete with pistons and

centre pin.
Uses screws with a Precote coating.
Druckfeder (1) und Abstimmscheibe (2) einbauen.
Fit the compression spring (1) and shim(2).
Zylinder in Neutralposition befestigen.
Fix the cylinder in the neutral position.
008 911 71 BOMAG 761

A2FM
Triebwerk einbauen
Triebwerk max. ausschwenken.
Swivel the rotary group to max.
Neuer Radialwellendichtring montiert?
Is the new shaft seal fitted?
Gehäuse auf ca. 80o C erwärmen.
Heat the housing to approx. 80o C.
Heißes Gehäuse bis zum Anschlag aufsetzen.
Push on the hot housing until the stop is reached.
Neue Montagestellung.
New assembly position.
762 BOMAG 008 911 71

RDE 91 001-03-R/05.03
21
Triebwerk einbauen
Paßscheibe, O-Ring einlegen. Verschlußring

montieren.
O-Ring, Zwischenraum Wellendichtring einfetten
(siehe Serviceinfo).
Fit the shim and O-ring. Then fit the cover.

Grease the O-ring as well as the seal and dust
lipsof the shaft seal.
Triebwerk gegen Verschlußring ziehen.

Kontrolle: Verschlußring spielfrei.
Pull the rotary group against the cover.

Check: to see that the cover is free of play.
Befestigungsschraube ausbauen.
Steuerplatte lagerichtig aufsetzen.
Fertigmontage
Abstimmung Pos. D - siehe Serviceinfo
Remove fixing screw. Fit the control plate into its

correct location.
Final assembly
For adjustment of Pos. D - see service info
Abstimmung Pos. D / Adjustment item D

Pos. D
Anschlüsse mit Staubschutz abdichten.

Korrosionsschutz (innen/außen). Fertig!
Seal connections to protect against dust.

Corrosion proctection (internal/external).
Assembly complete.
008 911 71 BOMAG 763

A2FM
Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques
1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)
Die Werte gelten für Schaftschrauben mit metri- The values stated are valid for bolts with metric
schem ISO-Gewinde nach DIN 13 Teil 13, sowie ISO threads to DIN 13 part 13, as well as head
Kopfauflagemaßen nach DIN 912 Zylinder- areas to DIN 912 socked head cap screws, DIN
schrauben, DIN 931 Sechskantschrauben mit 931 hexagon bolt or DIN 933 hexagon bolts with
Schaft bzw. DIN 933 Sechskantschrauben mit threads up to the head.
Gewinde bis Kopf.
Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240
764 BOMAG 008 911 71

RDE 91 001-03-R/05.03
23

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).
G
EOLASTIC-
Dichtung / Seal
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300
008 911 71 BOMAG 765

A2FM

7. Linsenschrauben 7. Oval head screw

mit Innen-TORX, Gewindevorbeschichtung mit "precote" with inner TORX, thread precoated with "precote"
Standard / Standard precote 80 - Rot / Red
precote 86 - Blau / Blue

Variante / Variant
*
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
siehe Stückliste / as to parts list
* mit Unterkopfbeschichtung - farblos

* with head bottom coating - colorless
Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7
766 BOMAG 008 911 71

RDE 91 001-03-R/05.03
25
Sicherheitsbestimmungen
Safety regulations
Allgemein General advice
● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.
Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck-Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. heavy injuries.
Daher sofort einen Arzt aufsuchen, da anderenfalls Therefore immediately consult a doctor as otherwise
schwere Infektionen entstehen können! heavy infections can be caused.
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr 2. When searching leakages use appropriate auxiliary devices
geeignete Hilfsmittel verwenden! because of the danger of accidents.
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt 3. Before working at the hydraulic equipment, lower pressure
drucklos machen und angebaute Geräte absenken! to zero and lower working arms of the rnachine.
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor 4. When working at the hydraulic equipment, absolutely stop
abstellen und Traktor gegen Wegrollen sichern motor and secure tractor against rolling away
(Feststellbremse, Unterlegkeil)! (parking brake, shim)!
5. Beim Anschließen von Hydraulikzylindern und -motoren ist 5. When connecting hydraulic cylinders and motor pay
auf vorgeschriebenen Anschluß der Hydraulikschläuche attention to correct connection of hydraulic flexible hoses.
zu achten! 6. In case of exchanging the ports, the tunctions are vice versa
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen (f. ex. lift-up/lower) - danger of accidents!
(z.B. Heben/Senken) - Unfallgefahr! 7. Check hydraulic flexible hoses regularly and replace them in
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und case of dammage or wear! The new hose pipes must comply
bei Beschädigung und Alterung austauschen! Die with the technical requirements of the machine manufacturer!
Austausch schlauchleitungen müssen den technischen
Anforderungen des Geräteherstellers entsprechen! Orderly disposal or recycling of oil, fuel and
filters!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!
008 911 71 BOMAG 767

A2FM
768 BOMAG 008 911 71

RDE 91 001-03-R/05.03
27
008 911 71 BOMAG 769

Bosch Rexroth AG
Mobile Hydraulics
Produktbereich Axialkolbenmaschinen
Werk / Plant Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
[email protected]
www.boschrexroth.com/brm
© 2003 by Bosch Rexroth AG, © 2003 by Bosch Rexroth AG,

Mobile Hydraulics, 89275 Elchingen Mobile Hydraulics, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Bosch Rexroth AG reproduziert oder
any form or by any means, without the unter Verwendung elektronischer
prior written authorization of Bosch Systeme gespeichert, verarbeitet,
Rexroth AG. In the event of vervielfältigt oder verbreitet werden.
contravention of the above provisions, Zuwiderhandlungen verpflichten zu
the contravening party is obliged to Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are zu beachten, dass unsere Produkte
subject to a natural process of wear einem natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.
Printed in Germany
RDE 91 001-03-R/05.03
770 BOMAG 008 911 71

16.3 Travel drive series 51
008 911 71 BOMAG 771

772 BOMAG 008 911 71

Travel drive series 51 16.3
saue
Series 51
Bent Axis
Variable Motors
Service Manual
008 911 71 BOMAG 773

saue
Bent Axis Variable Displacement Motors Series 51
General Description
Series 51 Variable Displacement Motors are bent Motors equipped with controls normally start at maxi-
axis design units, incorporating spherical pistons. mum displacement. This provides maximum starting
torque (high acceleration).
These motors are designed primarily to be combined
with other products in closed circuit systems to trans- The controls may utilize externally or internally sup-
fer and control hydraulic power. plied servo pressure. They may be overridden by a
pressure compensator which functions when the
Series 51 Motors have a large maximum / minimum motor is operating in motor and pump modes. A
displacement ratio (5 to 1) and high output speed defeat option is available to disable the pressure
capabilities. SAE flange and cartridge motor configu- compensator override when the motor is running in
rations are available. pump mode.
The pressure compensator option features a low

pressure rise (short ramp) to provide optimal power
A complete family of controls and regulators is avai-
utilization throughout the entire displacement range
lable to fulfill the requirements of a wide range of
of the motor. The pressure compensator is also
applications.
available as a stand-alone regulator.
● The Series 51 - Advanced Technology Today
● The Most Technically Advanced Hydraulic Units in the Industry
● SAE Flange and Cartridge Motors
● Cartridge Motors designed for Direct Installation in Compact

Planetary Drives
● Large Displacement Ratio (5:1)
● Complete Family of Control Systems
● Proven Reliability and Performance
● Optimum Product Configurations
● Compact, Lightweight
Front page: Option - hydraulic two-position control

Copyright 1992-1997, Sauer-Sundstrand Company.
All rights reserved. Contents subject to change. Printed in U.S.A. 0992H
2
774 BOMAG 008 911 71

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Contents
Introduction ......................................................................................................................................................4
Basic Hydraulic Circuits ...................................................................................................................................4
General Description of the Series 51 Variable Displacement Motors ..............................................................5
Functional Description ......................................................................................................................................6
Technical Specifications and Data - Variable Displacement Motors .............................................................. 20
Safety Precautions .........................................................................................................................................21
Gauge Installation ..........................................................................................................................................23
Start-Up Procedure and Maintenance ............................................................................................................25
Component Inspection and Adjustment .........................................................................................................27
Troubleshooting ............................................................................................................................................. 37
Exploded View of the Series 51 Variable Motor .............................................................................................41
Minor Repair and Replacement - Variable Motor ........................................................................................... 51
General .....................................................................................................................................................51
Shaft Seal (SAE Flange Configuration) ....................................................................................................52
Shaft Seal (Cartridge Configuration) .........................................................................................................53
Loop Flushing Shuttle Valve (Option)........................................................................................................54
Charge Pressure Relief Valve ...................................................................................................................55
Minimum Angle Servo Cover .................................................................................................................... 55
Hydraulic 2-Position Control (Type N2) .....................................................................................................56
Electrohydraulic 2-Position Controls (Types E1•E2 and F1•F2) ...............................................................57
Electric 2-Position Controls (Type S1) ......................................................................................................58
Hydraulic Proportional Control (Type HZ) .................................................................................................59
Hydraulic Proportional Control (Type HS) .................................................................................................60
Hydraulic Proportional Control with Maximum Angle Over-ride (Types H1•H2 or K1•K2) ........................61
Two Connection Hydraulic Proportional Control (Type HP) ......................................................................62
Two Connection Hydraulic Proportional Control for “Dual Path” Vehicles (Type HC) ...............................64
Electrohydraulic Proportional Control (Types EP and EQ)........................................................................68
Pressure Control Pilot (PCP) Valve for Electrohydraulic Proportional Control (Types EP and EQ) .......... 70
Multi-function Block ...................................................................................................................................71
Pressure Compensator Regulator (Type PC) ........................................................................................... 76
Control Orifices .........................................................................................................................................77
Plug / Fitting Torques ................................................................................................................................77
0-1 3
008 911 71 BOMAG 775

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Introduction
The purpose of this manual is to provide information Dirt or contamination is the greatest enemy of any
necessary for the normal servicing of the Series 51 type of hydraulic equipment. The greatest possible
family of variable displacement hydrostatic motors. cleanliness is necessary when starting up the sys-
tem, changing filters, or performing any other service
This manual includes unit and component descrip- procedure.
tion, troubleshooting, adjustments, and minor repair
procedures. By following the procedures in this For Technical Information on Series 51 motors, refer
manual, inspections and minor repairs may be per- to publication BLN-10042 or 368753.
formed without affecting the unit warranty.
For Fluid Quality Requirements, refer to publication
A Series 51 motor does occasionally require servic- BLN-9987 or 697581.
ing, and these units are designed to meet this require-
ment. Sauer-Sundstrand provides a complete repair serv-
ice for its products. Contact any Sauer-Sundstrand
Many repairs or adjustments can be completed with- Authorized Service Center for details. Sauer-Sund-
out removing the unit from the vehicle or machine, strand Authorized Service Center locations are listed
provided the unit is accessible and can be thoroughly in publication BLN-2-40527 or 698266.
cleaned before beginning any procedures.
Basic Hydraulic Circuits

CASE Closed Circuit
DRAIN
LINE The main ports of the pump are connected by hydrau-
lic lines to the main ports of the motor. Fluid flows in
either direction from the pump to the motor then back
to the pump in this closed circuit. Either of the hydrau-
INPUT PV MV OUTPUT lic lines can be under high pressure. The direction
and speed of fluid flow (and the motor output shaft
rotation) depends on the position of the pump swash-
plate. The system pressure is determined by the
machine load.
FLOW (BI-DIRECTIONAL) Open Circuit

RESERVOIR The outlet port of the pump is connected by a hydrau-
51000001 lic line to a directional control valve. The working ports
Fig. 0-1 - Basic Closed Circuit of this valve are connected to the main ports of the
motor. When the valve is actuated, fluid flows first
FLOW FLOW from the pump to the valve. The valve then directs the
(UNI-DIRECTIONAL) (BI-DIRECTIONAL) fluid to the motor in either direction. The direction of
fluid flow (and motor output shaft rotation) depends
CONTROL VALVE
on the direction the control valve is shifted. The speed

INPUT PUMP of fluid flow (and motor output shaft speed) depends
MV OUTPUT on pump output volume and the distance the control
valve is shifted. The system pressure is determined
by the machine load.
CASE Fluid returning from the motor is routed through the
DRAIN
RESERVOIR LINE
control valve to the reservoir. Additional components
may be necessary to provide dynamic braking and to
51000002 deal with over-running loads.
Fig. 0-2 - Basic Open Circuit
4 0-2
776 BOMAG 008 911 71

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General Description of the Series 51 Variable Displacement Motors
The Series 51 variable displacement hydraulic mo- Various hydraulic and electrohydraulic controls may
tors use spherical pistons and piston rings. The angle be mounted on the motor end cap to control the servo
between the cylinder block and the output shaft can piston and the motor displacement. Servo pressure
be set between 32° and 6°, providing a 5 to 1 oil may either be supplied internally from the motor, or
maximum to minimum displacement ratio. externally.
At maximum displacement, the motor will provide a For all controls except the N2 and PC, servo pressure
certain maximum output shaft torque and minimum oil is supplied to a four (4) way spool valve in the motor
speed corresponding to the pressure and flow sup- end cap. When a combination of pilot pressure (or
plied to the motor. Under the same input conditions force) from an external control assembly and internal
but at minimum displacement, the shaft speed will be spring force shifts this valve, servo pressure is routed
approximately five (5) times faster while the available to move the servo piston and change the motor’s
output torque will decrease to approximately one-fifth displacement.
(1/5) the full displacement value. The displacement
is changed by a servo piston which is connected to A synchronizing shaft, with spherical rollers, synchro-
the valve segment. nizes the rotation of the output shaft and the cylinder
block. The ball end of each piston runs in a socket
bushing, pressed into the output shaft. There are no
other parts used to connect the pistons to the shaft.
Two tapered roller bearings support the output shaft.
Minimum
Displacement Limiter
Hydraulic Pressure Compensator
Proportional Override
Control Valve Segment
Control
Pressure Bearing Plate
Port
Tapered Roller Bearings
Synchronizing
Piston Shaft
Servo Piston
Cylinder
Charge Pressure
Relief Valve
P001 196
Fig. 10-1 - Sectional view of Series 51 variable displacement motor (SAE Flange
Configuration) with Hydraulic Proportional Control
10 - 1 5
008 911 71 BOMAG 777

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Functional Description
Loop Flushing
Series 51 motors used in closed circuit applications
incorporate an integral loop flushing valve as stan-
dard equipment. Installations that require additional
fluid to be removed from the main hydraulic circuit
because of fluid cooling requirements, or circuits
requiring the removal of excessive contamination
from the high pressure circuit, can benefit from loop
flushing. Series 51 motors used in open circuit appli-
51000003 51000004
cations may have the optional loop flushing defeat
Fig. 10-2 - Loop Fig. 10-3 - Loop
components installed.
Flushing Flushing Defeat
Components Components Series 51 motors equipped with an integral loop
flushing valve also include a charge pressure relief
valve. The setting of the motor charge relief valve
affects the function of the flushing circuit. Higher
motor charge relief settings reduce the loop flushing
flow and increase the flow over the pump charge
pressure relief valve when the circuit is operating.
Lower motor charge relief settings increase the loop
flushing flow and may increase the motor case pres-
sure when the circuit is operating.
An appropriate combination of pump and motor charge

pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all condi-
tions of operation to maintain pump control perfor-
mance in closed loop systems.
NOTE: An optional orifice may be installed between

the motor charge relief and the motor case to
limit the maximum flushing oil flow.
6 10 - 2
778 BOMAG 008 911 71

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Functional Description (Continued)
Displacement Limiters
All Series 51 motors incorporate mechanical dis-
placement limiters. The minimum displacement of
the motor can be limited within the standard range by
a set screw in the motor housing. The maximum
displacement can be limited with spacers installed on
the servo piston.
51000005
Fig. 10-4 - Minimum Displacement Limiter
with Tamper Resistant Cap (Cartridge
Motor Configuration Shown)
51000006
Fig. 10-5 - Maximum Displacement Limiter
Screw
Controls - General
A wide range of control options is available for the
Series 51 motors. These include pilot operated
Electrohydraulic 2-Position Controls, Hydraulic Pro-
portional Controls (single or two [2] connection), and
Electrohydraulic Proportional Controls. A directly op-
erated Hydraulic 2-Position Control and a Pressure
Compensator regulator are also available.
The Series 51 variable motor servo piston (except 5100007
when equipped with N2 control or the PC regulator) Fig. 10-6 - Internal Servo Pressure Supply
may be operated either by servo pressure oil supplied Screen with Multi-function Block and/or
internally from the main ports of the motor, or by servo Control Removed (Plug for External
pressure oil supplied from an external source. (The Supply)
N2 control uses servo pressure supplied by an exter-
nal control valve. The PC regulator obtains servo
pressure from the main ports of the motor.)
Orifice plugs are installed in the control spool sleeve

in the end cap to regulate the flow of oil from the servo
piston to the motor housing. Orifice plugs may be
installed in the end cap to regulate the flow of servo
pressure supply oil to the control valve, and to regu-
late the flow of oil from the control valve to the servo
piston. 51000008
Fig. 10-7 - External Servo Pressure Supply
Fitting (Plug for Internal Supply)
10 - 3 7
008 911 71 BOMAG 779

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Hydraulic 2-Position Control (Type N2)
This is a two (2) position (maximum - minimum
displacement) control, consisting of a cover plate
mounted on the end cap. An external control valve
supplies servo pressure from an external source
directly to the servo piston. PCOR is not available
with the N2 control.
When servo pressure is supplied to port “Y1,” the

51000009 setting piston moves to the maximum motor displace-
Fig. 10-8 - Series 51 Motor with N2 Control ment position. When servo pressure is supplied to
port “Y2,” the setting piston moves to the minimum
motor displacement position.
Orifices may be installed in the external control valve

or its connections to regulate the speed of servo
piston movement.
51000010
Fig. 10-9 - N2 Control Components
L2 M6 (M4) Y1 Y2 (M3)
A
M1
max.
disp.
U4 (opt.)
M2
B
L1
51000011
Fig. 10-10 - N2 Control Schematic
8 10 - 4
780 BOMAG 008 911 71

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Electrohydraulic 2-Position Control (Types
E1•E2 and F1•F2)
A 12 or 24 VDC solenoid valve, mounted on the multi-
function block, connects the end of the control valve
spool in the end cap with pilot pressure (provided by
the shuttle spool in the multi-function block) or with
the motor case. The control valve in the end cap is
biased by a threshold spring, and controls oil flow to
the ends of the servo piston. Servo pressure may be
51000012
supplied from an external source or internally by the Fig. 10-11 - Series 51 Motor with E1•E2 or
shuttle spool in the multi-function block. PCOR is
F1•F2 Control
available with these controls.
With the E1 and E2 controls, energizing the solenoid

will cause the motor to shift to minimum displace-
ment. When the solenoid is not energized, the motor
is held at maximum displacement.
With the F1 and F2 controls, energizing the solenoid

causes the motor to shift to maximum displacement.
When the solenoid is not energized, the motor is held
at minimum displacement.
51000013
Fig. 10-12 - E1•E2 and F1•F2 Control
Components
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2
E1•E2
B1
U5
(plug for T7,
ext. servo T8 M9
T1
press.) X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
M8 M7
F1•F2
51000014
Schematic
10 - 5 9
008 911 71 BOMAG 781

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Electric 2-Position Control (Type S1)
A 12 VDC solenoid valve, mounted on the multi-
function block, directly operates the control valve
spool in the end cap. The control valve in the end cap
is biased by a threshold spring, and controls oil flow
to the ends of the servo piston. Servo pressure may
be supplied from an external source or internally by
the shuttle spool in the multi-function block. PCOR is
available with this control.
51000162
Fig. 10-14 - Series 51 Motor with S1 Control With the S1 control, energizing the solenoid causes
the motor to shift to maximum displacement. When
the solenoid is not energized, the motor is held at
minimum displacement.
51000163
Fig. 10-15 - S1 Control Components
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2
S1
B1
U5
(plug for T7,
ext. servo T8 M9
T1
press.) X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
51000085
Fig. 10-16 - S1 Control Schematic
10 10 - 6
782 BOMAG 008 911 71

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Hydraulic Proportional Control (Type HZ)
The HZ control consists of a cover plate mounted
directly on the end cap. A ball type shuttle valve
provides internal servo pressure supply to the control
valve in the end cap. PCOR is not available with the
HZ control.
Feedback springs (single spring for 060, 080 and

110) and a threshold spring are installed in the end
cap. The feedback springs and threshold spring 51000015
provide a force on the end of the control spool. The Fig. 10-17 - Series 51 Motor with HZ
force of the threshold spring is externally adjustable Control
with an adjusting screw. The feedback spring is
positioned between the control spool and a feedback
lug attached to the servo piston. The force of the
feedback spring increases as the motor’s displace-
ment decreases.
Pilot oil pressure from an external source is applied to

the end of the control spool opposite the feedback
and threshold springs. An increase in pilot pressure
(above the threshold pressure and within the modu-
lating pressure range) will result in a decrease in
51000016
motor displacement, while a decrease in pilot pres- Fig. 10-18 - HZ Control Components
sure will result in an increase in motor displacement.
L2 M6 M4 M3
A
M1
max.
disp.
U4 (opt.) T3
T2
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
B
Servo
Pressure
internal L1
X1 M7
51000017
Fig. 10-19 - HZ Control Schematic
10 - 7 11
008 911 71 BOMAG 783

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Hydraulic Proportional Control (Type HS)
The HS control consists of a cover plate (with a
hydraulic port) mounted on the multi-function block.
Servo pressure may be supplied from an external
source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.
The function of the HS control is identical to the

function of the HZ control.
51000018
Fig. 10-20 - Series 51 Motor with HS
Control
51000019
Fig. 10-21 - HS Control Components
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2
B1
T7,
U5 (plug for T8 M9
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
M7 X1 HS
H1•H2
M7 X1
K1•K2
M7 X1
51000022
Fig. 10-22 - HS, H1•H2, and K1•K2 Control
Schematic
12 10 - 8
784 BOMAG 008 911 71

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Hydraulic Proportional Control with
Electric Override (Types H1•H2 and K1•K2)
The function of the H1•H2 and K1•K2 controls is
similar to the function of the HS control. A 12 or 24
VDC solenoid valve is installed between the external
pilot pressure source and the control spool.
With the H1•H2 controls, energizing the solenoid

allows the control to function as an HS control. When
the solenoid is not energized, pilot pressure is blocked 51000020
and the end of the control spool is drained to the motor Fig. 10-23 - Series 51 Motor with H1•H2
case, causing the motor to shift to maximum displace- Control
ment.
With the K1•K2 controls, energizing the solenoid

blocks pilot pressure and drains the end of the control
spool to the motor case, causing the motor to shift to
maximum displacement. When the solenoid is not
energized, the control functions as an HS control.
51000167
Fig. 10-24 - Series 51 Motor with K1•K2
Control
51000021
Fig. 10-25 - H1•H2 and K1•K2 Control
Components
10 - 9 13
008 911 71 BOMAG 785

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Two Line Hydraulic Proportional Control
(Type HP)
This control consists of a valve block with two (2)
hydraulic ports mounted on the multi-function block.
The valve block incorporates a shuttle spool and a
pilot piston with centering springs. A pin transmits
force from the pilot piston to the control spool in the
end cap. Feedback springs (single spring for 060,
51000023
080, and 110) and a threshold spring are installed in
Fig. 10-26 - Series 51 Motor with HP the end cap. These springs function similar to the HS
control. Servo pressure may be supplied from an
Control
external source or internally by the shuttle spool in the
multi-function block. PCOR is available with this
control.
Two pilot pressures are provided to the control. The

shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback spring,
and the lower pressure to the opposite side of the pilot
piston. The rod transmits a force, proportional to the
difference of the pilot pressures, to the control spool.
51000024
An increase in the difference between the pilot pres-
Fig. 10-27 - HP Control Components sures will result in a decrease in motor displacement,
while a decrease will result in an increase in displace-
ment.
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2
B1
T7,
U5 (plug for T8 M9
X3 (M5)
Servo press,
external
M2
Servo B
Press,
internal
L1
X2 X1
51000025
Fig. 10-28 - HP Control Schematic
14 10 - 10
786 BOMAG 008 911 71

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for “Dual-Path” Vehicles (Type HC)
The HC control operates in a similar manner to the HP
control, however the HC control is optimized for use
in “dual-path” drive vehicles. This control consists of
a valve block with two (2) hydraulic ports mounted on
the end cap. The valve block incorporates a shuttle
spool and a pilot piston with centering springs. A pin
transmits force from the pilot piston to the control
51000158
spool in the end cap. Fig. 10-29 - Series 51 Motor with HC
A bleed valve is provided to eliminate any air which Control
might become trapped in the pilot piston oil passages.
Feedback springs are installed in the end cap. Servo

pressure is supplied internally by a ball type shuttle
valve in the control housing. PCOR is not available
with this control.
Two pilot pressures are provided to the control. The

shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback springs,
and the lower pressure to the opposite side of the pilot
piston. The pin transmits a force, proportional to the
difference of the pilot pressures, to the control spool.
An increase in the difference between the pilot pres- 51000111
sures will result in a decrease in motor displacement, Fig. 10-30 - HC Control Components
while a decrease will result in an increase in displace-
ment. The feedback springs in the end cap have L2 M6 M4 M3
differing spring rates and operate in parallel (060,
A
080, and 110) or series (160 or 250) to provide a linear M1
relationship between motor displacement and pilot
pressure differential. max.
disp.
U4 (opt.) T3
T2
T7,
T8 M9
T1
M5
M2
B
L1
X2 X1
51000160
Fig. 10-31 - HC Control Schematic
10 - 11 15
008 911 71 BOMAG 787

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Electrohydraulic Proportional Control
(Types EP and EQ)
This control consists of a valve block and PCP (Pres-
sure Control Pilot) valve mounted on the multi-func-
tion block. The valve block incorporates a pilot piston
with centering springs. A pin transmits force from the
pilot piston to the control spool in the end cap.
Feedback springs (single spring for 060, 080, and
110) and a threshold spring are installed in the end
51000026
cap. These springs function similar to the HS control.
Fig. 10-32 - Series 51 Motor with EP Control
Servo pressure may be supplied from an external
(EQ Similar) source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.
An external pilot pressure source is connected to the

inlet of the PCP valve, which produces differential
pilot pressures proportional to the current through it.
These pressures are applied to the pilot piston. The
operation of this control is similar to that of the HP
Control, with the motor displacement being propor-
tional to the current through the PCP valve.
An increase in current (above the threshold current)

will result in a decrease in motor displacement, while
a decrease will result in an increase in displacement.
51000027
Fig. 10-33- EQ Control Components (EP
Similar)
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2
B1
T7,
U5 (plug for T8 M9
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
M7 X1 M8
51000028
Fig. 10-34 - EP and EQ Control Schematic
16 10 - 12
788 BOMAG 008 911 71

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Multi-function Block Components
The Multi-function Valve Block includes a shuttle
valve which provides internally supplied servo pres-
sure, and an optional Pressure Compensator Over-
Ride (PCOR) function with optional brake pressure
defeat.
51000029
Fig. 10-35 - Multi-function Block (Without
Control)
Servo Pressure Supply
For internal supply, the multi-function block incorpo-

rates a shuttle spool with internal check ball valve that
routes oil from the main circuit ports of the motor to the
control valve in the end cap. “High side” pressure is
provided to the servo control valve in the end cap.
For external supply, the connection between the

shuttle spool and the servo control valve is blocked in
51000030
the end cap. The external pressure supply to the Fig. 10-36 - Multi-function Block with Servo
servo control valve connects to a port (“M5”) on the
Pressure Supply Shuttle Spool
end cap.
Pressure Compensator Over-Ride (PCOR)
The Pressure Compensator Over-Ride (PCOR) sys-

tem includes a spool valve located in the PCOR block
which is attached to the multi-function block. This
system increases the motor displacement at system
pressures above the PCOR valve setting. (Pressure
Compensator Over-Ride is not available with the N2
and HZ controls, or the PC regulator.)
For bi-directional PCOR operation, the shuttle valve

in the multi-function block routes system high pres-
sure to the PCOR spool valve. For single direction
51000031
PCOR operation, the PCOR spool valve is connected Fig. 10-37 - Multi-function Block with PCOR
to one (1) side of the closed loop through passages in Block and Spool Valve (K1•K2 Control
the multi-function block
Shown)
When system pressure exceeds the PCOR setting,
the spool valve moves to connect the displacement
reducing end of the servo piston to the motor case,
and the displacement increasing end of the servo
piston to system pressure. This increases the motor
displacement, which reduces the motor output speed.
When the PCOR valve closes, control of the servo
piston returns to the control spool in the motor end
cap.
10 - 13 17
008 911 71 BOMAG 789

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An optional “brake pressure defeat” spool may be
installed in the multi-function block. When used with
the PCOR, this spool assures that the PCOR does
not cause the motor displacement to increase during
deceleration (which could cause pump overspeed).
Pressure from a source such as the pump servos or
an external valve, shifts the defeat spool to block the
high pressure supply to the PCOR valve from the
“deceleration” side of the closed loop. Either bi-
51000032 directional or single direction PCOR operation can be
Fig. 10-38 - Multi-function Block with PCOR specified when PCOR defeat is installed.
Defeat Spool Components
Shuttle Valve Shuttle Valve PCOR Brake Pressure Defeat Operation
A1 T4 A1
Rotation High pressure Control pressure
Defeat
Spool
port on port
CW A XB
T5
CCW B XA
U7 U7
U6 U6
B1 T6
B1
PCOR PCOR
Valve Valve
XA XB
Standard with Defeat

Pressure Compensator Override
51000033
Fig. 10-39 - PCOR and PCOR with Defeat
Schematic
18 10 - 14
790 BOMAG 008 911 71

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Pressure Compensator Regulator (Type
PC)
In this regulator, the Pressure Compensator system
in the multi-function block assembly controls the
motor displacement. At system pressures below the
compensator setting, the servo piston is maintained
in the minimum motor displacement position. When
system pressure exceeds the POR setting, hydraulic
pressure acts on the servo piston to increase the
motor displacement.
With the Pressure Compensator regulator, an in- 51000034

crease in system pressure (above the setting pres- Fig. 10-40 - Series 51 Motor with PC
sure) will result in an increase in motor displacement Regulator
and output torque, and a decrease in motor shaft
speed.
51000035
Fig. 10-41 - PC Regulator Components
L2 M6 M4 M3
A
M1
max.
disp.
T5
U7
U4 (opt.)
U6 T7
T1
M9
M5
M2
B
L1
51000036
Fig. 10-42 - PC Regulator Schematic
10 - 15 19
008 911 71 BOMAG 791

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Technical Specifications and Data - Variable Displacement Motors
Design Hydraulic Fluid
Piston motor with variable displacement, bent axis Refer to Sauer-Sundstrand publication BLN-9887 or
construction. 697581.
Type of Mounting Temperature 1)
SAE four (4) bolt flange – SAE Flange Configuration. ϑ min = -40°C (-40°F), intermittent, cold start
Two (2) bolt flange – Cartridge Motor Configuration. ϑ nominal = 104°C (220°F), continuous
ϑ max = 115°C (240°F), intermittent
Pipe Connections
1)
at the hottest point, normally the case drain line.
Main pressure ports: SAE flange
Hydraulic fluid viscosity must be as shown below.
Remaining ports: SAE O-ring thread
Fluid Viscosity Limits
Direction of Rotation
ν min = 5 mm2/s (42 SUS) intermittent
Clockwise and counter-clockwise.
ν min = 6.4 mm2/s (47 SUS) min. continuous
Installation Position ν min = 13 mm2/s (70 SUS) optimum
ν max = 110 mm2/s (510 SUS) max. continuous
Installation position discretionary. The housing must ν max = 1600 mm2/s (7400 SUS) intermittent, cold start
always be filled with hydraulic fluid.
Filtration
System Pressure Range, Input
Acceptable contamination level: ISO Code 18/13 or
Max: 480 bar (6960 psi) better. Refer to Sauer-Sundstrand publication BLN-9887
Min: 10 bar (145 psi) or 697581.
Case Pressure
Max. Continuous: 3 bar (44 psi)
Intermittent (Cold start): 5 bar (73 psi)
Frame Size
Dimension 060 080 110 160 250
Displacement maximum cm3 60.0 80.7 109.9 160.9 250.0
in3 3.66 4.92 6.71 9.82 15.26
minimum cm3 12.0 16.1 22.0 32.2 50.0
in3 0.73 0.98 1.34 1.96 3.05
Continuous speed at max disp min-1 (rpm) 3600 3100 2800 2500 2200
at min disp min-1 (rpm) 5600 5000 4500 4000 3400
Max. speed at max disp min-1 (rpm) 4400 4000 3600 3200 2700
at min disp min-1 (rpm) 7000 6250 5600 5000 4250
Theoretical at max disp Nm / bar 0.95 1.28 1.75 2.56 3.98
torque lbf•in / 1000 psi 583 784 1067 1563 2428
at min disp Nm / bar 0.19 0.26 0.35 0.51 0.80
lbf•in / 1000 psi 117 156 214 313 486
Max. continuous Q max L / min 216 250 308 402 550
flow gal / min 57 66 81 106 145
Max. corner power Pcorner max kW 336 403 492 644 850
hp 450 540 660 864 1140
Mass moment J kg • m2 0.0046 0.0071 0.0128 0.0234 0.0480
of inertia lbf • ft2 0.1092 0.1685 0.3037 0.5553 1.1580
Weight m kg 28 32 44 56 86
(with control N2) lb 62 71 97 123 190
20 10 - 16
792 BOMAG 008 911 71

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Safety Precautions
● When Series 51 units are used in vehicular ● Use caution when dealing with hydraulic
hydrostatic drive systems, the loss of hy- fluid under pressure. Escaping hydraulic
drostatic drive line power in any mode of fluid under pressure can have sufficient
operation may cause a loss of hydrostatic force to penetrate your skin causing seri-
braking capacity. A braking system, redun- ous injury. This fluid may also be hot enough
dant to the hydrostatic transmission must, to burn. Serious infection or reactions can
therefore, be provided which is adequate to develop if proper medical treatment is not
stop and hold the system should the condi- administered immediately.
tion develop.
● Some cleaning solvents are flammable. To
● Certain service procedures may require the avoid possible fire, do not use cleaning
vehicle/machine to be disabled (wheels solvents in an area where a source of igni-
raised off the ground, work function discon- tion may be present.
nected, etc.) while performing them in order
to prevent injury to the technician and by-
standers.
20 - 1 21
008 911 71 BOMAG 793

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Notes
22 20 - 2
794 BOMAG 008 911 71

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Gauge Installation
Various pressure gauge readings can be a great Snubbers are recommended to protect pressure
asset in troubleshooting problems with the Series 51 gauges. Frequent gauge calibration is necessary to
motor or support system. insure accuracy.
Fig. 30-1 - Gauge Ports, Motor with N2 Control

Port "L1" Port Y2:
Servo press., external
(N2 Control Only) Gauge port M6:
Charge pressure
"X" Gauge port M3; 9/16 — 18 UNF-2B
Servo pressure
min. displacement Gauge port M2:
Port "B" system
pressure
A B
Gauge port M1:
Port "A" system M1
pressure Port Y1:
M2
Servo press., external
(N2 Control Only)
Port "L2"
Gauge port M4:
Servo pressure
max. displacement
Side Port End Cap Axial Port End Cap
Right Side View View in Direction "X"
51000037
Fig. 30-2- Gauge Ports, Motor with E1•E2, F1•F2, H1•H2, and K1•K2 Controls
Port X3:
servo press., external
Gauge port M5:
servo press., internal Control • E1/E2 • F1/F2
XA
Control • E1/E2•F1/F2 Control • H1/H2 • K1/K2
Gauge port M8 Gauge port M7
Control • H1/H2 control pressure
Control pressure port X1 View"T"
Control • K1/K2
Control pressure port X1
XA
XB XB
"T" 51000038
Fig. 30-3 - Gauge Ports, Motor with HS and HZ Controls
Port X3:
servo press., ext.
Gauge port M5: Gauge port M7:
servo press., int. Control pressure
XA
Gauge port M7:
Control pressure
View"U" View"U"
(HS) (HZ)
XA XB
Control pressure Control pressure
XB
port X1 port X1
"U" 51000039
30 - 1 23
008 911 71 BOMAG 795

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Gauge Installation (Continued)
Fig. 30-4 - Gauge Ports, Motor with HP Control
Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA
View"V"
XA XB
XB X1 X2 Ports X1, X2:

Control pressure
9/16 — 18 UNF-2B
"V" 51000040
Fig. 30-5 - Gauge Ports, Motor with EP•EQ Control
Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA
View"W"
XA XB
XB
MS-Connector (MS3102C) Packard
7/8 — 20 UNEF Connector
Manual override
Port X1:
External PCP
"W" supply pressure 51000041
Gauge Information
System 600 bar or 10,000 psi Gauge Motor 60 bar or 1000 psi Gauge
M1 Pressure M6 Charge
Port “A” 9/16 — 18 O-Ring Fitting Pressure 9/16 — 18 O-Ring Fitting
System 600 bar or 10,000 psi Gauge M7 Control 60 bar or 1000 psi Gauge
M2 Pressure M8 Test Port 9/16 — 18 O-Ring Fitting
Port “B” 9/16 — 18 O-Ring Fitting L1 Case 60 bar or 1000 psi Gauge
Servo 600 bar or 10,000 psi Gauge L2 Pressure 060, 080, 110:
M3 Pressure 1-1/16 — 12 O-Ring Fitting
(Min. Angle) 9/16 — 18 O-Ring Fitting 160, 250:
Servo 600 bar or 10,000 psi Gauge 1-5/16 — 12 O-Ring Fitting
M4 Pressure X1 Control 60 bar or 1000 psi Gauge
(Max. Angle) 9/16 — 18 O-Ring Fitting X2 Pressure 9/16 — 18 O-Ring Fitting
Servo 600 bar or 10,000 psi Gauge X3
M5 Supply 9/16 — 18 O-Ring Fitting or XA Defeat 60 bar or 1000 psi Gauge
(M9) Pressure Tee into Control Pressure Line XB Pressure Tee into Defeat Pressure
Line(s)
24 30 - 2
796 BOMAG 008 911 71

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Start-Up Procedure and Maintenance
Start-Up Precautions Fill the reservoir with recommended hydraulic fluid,
which should be passed through a 10 micron (nomi-
Cleanliness
nal, no bypass) filter prior to entering the reservoir.
Ensure that all system components, including fittings, The use of contaminated fluid will cause damage to
pipes, and hoses, are completely clean. If cloths are the components, which may result in unexpected
used for cleaning components, they must be made of vehicle/machine movement.
lint-free materials.
The inlet line leading from the reservoir to the pump
Follow the guidelines presented in Sauer-Sundstrand must be filled prior to start up. Check inlet line for
publication BLN-9887 or 697581 for required fluid properly tightened fittings and make sure it is free of
cleanliness levels at machine start-up. restrictions and air leaks.
Reservoir and Fluid Level Be certain to fill the pump and motor housing with
clean hydraulic fluid prior to start up. Fill the
The reservoir should be designed to accommodate
housing by pouring filtered oil into the upper case
maximum volume changes during all system operat-
drain port.
ing modes, and to promote de-aeration of the fluid as
it passes through the tank. The reservoir outlet (charge Install a 0 to 60 bar or 0 to 1000 psi pressure gauge
pump inlet) and the reservoir inlet (fluid return) must in the charge pressure gauge port to monitor the
always be below the normal fluid level. A sight glass charge pressure during start-up.
is the preferred method for checking fluid level.
The external control input signal should be discon-
The reservoir inlet (fluid return) should be positioned nected at the pump control during initial start-up. This
so that flow to the reservoir is directed into the interior will allow the pump to remain in its neutral position.
of the reservoir for maximum dwell and efficient de-
“Jog” or slowly rotate prime mover until charge pres-
aeration. A baffle (or baffles) between the reservoir
sure starts to rise. Start the prime mover and run at
inlet and outlet ports will promote de-aeration and
the lowest possible RPM until charge pressure is
reduce surging of the fluid.
established. Excess air may be bled from the high
No funnel-shaped eddying at the reservoir outlet pressure lines through the high pressure gauge ports.
(charge pump inlet) or formation of foam at the
Once charge pressure is established, increase speed
reservoir inlet (fluid return) is permitted.
to normal operating RPM. Note the charge pressure.
Start-Up Procedure If charge pressure is incorrect, shut down and deter-
mine cause for improper pressure.
The following start-up procedure should always be
followed when starting-up a new Series 51 installa- Shut down prime mover and connect external control
tion or when restarting an installation in which either input signal. Start prime mover, checking to be
the pump or motor has been removed from the certain pump remains in neutral. With prime mover at
system. normal operating speed, slowly check for forward and
reverse machine operation.
WARNING
Charge pressure should be maintained during for-
The following procedure may require the ve- ward or reverse operation. Continue to cycle slowly
hicle/machine to be disabled (wheels raised off between forward and reverse for at least five (5)
the ground, work function disconnected, etc.) minutes.
while performing the procedure in order to
prevent injury to the technician and bystand- Shut down prime mover, remove gauges, and plug
ers. Take necessary safety precautions before ports. Check reservoir level and add fluid if neces-
operating the vehicle/machine. sary.
Prior to installing the motor, inspect the unit for The transmission is now ready for operation.
damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses,
valves, fittings, heat exchanger, etc.) are clean prior
to filling with fluid.
30 - 3 25
008 911 71 BOMAG 797

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Start-Up Procedure and Maintenance (Continued)
Maintenance Changing the Fluid and Filter
Cleanliness
To insure optimum service life on Series 51 products,
The reservoir breather air filter (if equipped) must be regular maintenance of the fluid and filter must be
kept clean. Clean the area around the filler cap before performed.
opening the reservoir. The hydraulic fluid should be
The fluid and filter must be changed per the vehicle/
filtered before it enters the reservoir.
machine manufacturer’s recommendations. In the
Follow the guidelines presented in Sauer-Sundstrand absence of such recommendations, the following
publication BLN-9887 or 697581 for required fluid intervals may be used:
cleanliness levels during machine operation.
• System with a sealed type reservoir - 2000 hrs.
Recommended Fluids • System with a breathing type reservoir - 500 hrs.
Hydraulic fluids used with Sauer-Sundstrand prod- It may be necessary to change the fluid more fre-
ucts should be carefully selected with assistance quently if the fluid becomes contaminated with for-
from a reputable supplier, following the guidelines eign matter (dirt, water, grease, etc.) or if the fluid has
presented in Sauer-Sundstrand publication BLN-9887 been operating at temperature levels greater than the
or 697581. maximum recommended. Never reuse fluid.
Checking for Leaks The filter should be changed when changing the fluid,
or whenever the filter indicator shows that it is neces-
Check the system components for leakage at regular sary to change the filter.
intervals. Tighten any leaking connections while the
system is not under pressure. Replace any defective
seals and gaskets.
Check hydraulic hoses for damage or aging. When

installing replacements, be certain that the hoses are
clean and connected properly.
Checking the Fluid Level
Check the reservoir daily for proper fluid level, the

presence of water (noted by a cloudy or milky appear-
ance, or free water in bottom of reservoir), and rancid
fluid odor (indicating excessive heat).
26 30 - 4
798 BOMAG 008 911 71

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Component Inspection and Adjustment
WARNING
The following procedures may require the ve-

hicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the adjustments to prevent
injury to the technician and bystanders.
Charge Pressure Relief Valve Adjustment

An appropriate combination of pump and motor charge
pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all
conditions of operation to maintain pump control
performance in closed loop systems.
To measure motor charge pressure, install a 0 to 60

bar or 0 to 500 psi pressure gauge in the motor charge 51000042
pressure gauge port. Install a gauge to measure case Fig. 30-6 - Adjusting Charge Pressure
pressure. Operate the system with the prime mover Relief Valve
at normal operating speed and the pump at half
stroke (forward or reverse) when measuring motor
charge pressure.
In most applications, the motor charge relief valve is

set 2 to 4 bar (29 to 58 psi) below the setting of the
pump charge relief valve (measured with the pump in
its “neutral” or zero-angle position). This setting as-
sumes a reservoir temperature of 50° C (122° F), and
is referenced to case pressure.
51000043
Series 51 motors are equipped with an external screw
Fig. 30-7 - Tighten Charge Pressure Relief
adjustable charge pressure relief valve. To adjust the
charge pressure, loosen the lock nut (with a 1-1/16" Valve Lock Nut
hex wrench) and turn the adjustment plug with a large
screwdriver. Clockwise rotation of the plug increases
the setting, and counter-clockwise rotation decreases
the setting (at a rate of approximately 3.4 bar [50 psi]
per turn). The lock nut should be torqued to 52 Nm (38
ft•lbsf).
Once the desired charge pressure setting is achieved,

remove the gauges and reinstall the port plugs.
30 - 5 27
008 911 71 BOMAG 799

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Component Adjustment (Continued)
Minimum Displacement Limiter Adjustment
The minimum displacement is set at the factory, and
the adjustment screw is covered with a tamper-
resistant cap
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The sealing lock nut must be retorqued
510000434
Fig. 30-8 - Loosen Minimum Displacement after every adjustment to prevent an unex-
Limiter Lock Nut pected change in operating conditions and to
prevent external leakage during unit operation.
NOTE: Changes in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor, while maintaining the motor at
minimum displacement and monitoring the
motor output shaft speed. An increase in
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed.
To adjust the minimum displacement, first remove

51000045
Fig. 30-9 - Rotate Minimum Displacement and discard the cap covering the adjusting screw.
Adjusting Screw Using a 17 mm hex wrench for 060 and 080 frame
size motors or a 19 mm hex wrench for 110 through
250 frame size motors, loosen the lock nut retaining
Approximate Change in the minimum displacement limiter adjusting screw.
Minimum Displacement Using a 5 mm internal hex wrench for 060 and 080
Frame Per Revolution frame size motors or a 6 mm internal hex wrench for
Size of Adjusting Screw 110 through 250 frame size motors, rotate the adjust-
060 1.5 cc/Rev (.09 in3/Rev) ing screw to limit the minimum displacement of the
080 2.1 cc/Rev (.13 in3/Rev) motor.
110 3.1 cc/Rev (.19 in3/Rev) Rotating the adjusting screw clockwise will increase
180 4.0 cc/Rev (.24 in3/Rev) the minimum displacement of the motor, while rotat-
250 6.2 cc/Rev (.38 in3/Rev) ing the adjusting screw counter-clockwise will de-
crease the minimum displacement.
Min. Displacement Screw Size
Frame Range and Length For each full revolution, of the adjusting screw, the
Size cc/Rev (in /Rev)
3
mm (in) displacement will change according to the accompa-
nying chart.
060 12 to 29 (.73 to 1.77) M10x65 (2.56)
30 to 40 (1.83 to 2.44) M10x80 (3.15) Different minimum displacements may require differ-
080 16 to 35 (.98 to 2.14) M10x65 (2.56) ent length adjusting screws. The various lengths are
36 to 54 (2.20 to 3.20) M10x80 (3.15) shown in the accompanying chart.
110 22 to 46 (1.34 to 2.81 ) M12x70 (2.76) After establishing the desired minimum displacement
47 to 74 (2.87 to 4.52) M12x80 (3.15) setting, tighten the lock nut on the adjusting screw to
160 32 to 72 (1.95 to 4.39) M12x75 (2.95) 51 Nm (38 ft•lbsf) for 060 and 080 frame size motors
73 to 107 (4.45 to 6.53) M12x90 (3.54) or 86 Nm (63 ft•lbsf) for 110 through 250 frame size
250 50 to 90 (3.05 to 5.49) M12x75 (2.95) motors. Install a new tamper-resistant cap on the
91 to 130 (5.55 to 7.93) M12x90 (3.54) adjusting screw.
131 to 167 (7.99 to 10.19) M12x100 (3.94)
28 30 - 6
800 BOMAG 008 911 71

saue
Maximum Displacement Limiter
Adjustment
The maximum displacement of the Series 51 motors
can be limited by limiting the stroke of the setting
piston, and the resulting movement of the valve
segment. A displacement stop screw is installed on
the setting piston (under the minimum angle servo
cover) to limit the stroke of the piston.
Spacers may be installed on the displacement stop

screw to limit the stroke. A longer or shorter screw
must be used to retain a thicker or thinner spacer.
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The stop screw must be retorqued
after adjustment to prevent an unexpected
change in operating conditions.
NOTE: Changes in motor displacement can be de-
the motor, while maintaining the motor at 51000046
maximum displacement and monitoring the Fig. 30-10 - Remove Minimum Angle Servo
motor output shaft speed. An increase in Cover Screws
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed. Approximate Change in
Frame Maximum Displacement
To adjust the maximum displacement, first remove Size with Change in Spacer Thickness
the screws retaining the minimum angle servo cover cc/mm (in3/.1 in)
to the end cap with an 8 mm internal hex wrench (060,
080, 110, and 160 units), or a 10 mm internal hex 060 0.98 (.15)
wrench (250 units). Remove the minimum angle 080 1.14 (.18)
servo cover and O-rings. Remove the displacement 110 1.48 (.23)
limiter screw with an 8 mm internal hex wrench. 160 1.93 (.30)
Installing a thicker spacer on the end of the setting 250 2.63 (.41)
piston will reduce the maximum displacement of the
motor. Installing a thinner spacer will increase the
maximum displacement. The displacement will
change according to the accompanying chart.
Torque the displacement limiter screw to 54 Nm (40

ft•lbsf).
Install the minimum angle servo cover and its O-rings.

Install the cover screws and torque to 78 Nm (58
ft•lbsf) for 060, 080, 110, and 160 motors, or 110 Nm
(81 ft•lbsf) for 250 motors.
51000070
Fig. 30-11 - Torque Maximum Displacement
Limiter Screw
30 - 7 29
008 911 71 BOMAG 801

saue
Displacement Control Adjustments
NOTE: A change in motor displacement can be de-
the motor and monitoring the motor output
shaft speed while adjusting the control. An
increase in displacement will result in a de-
crease in shaft speed, while a decrease in
displacement will result in an increase in shaft
speed.
No adjustments are provided for the N2 control.
A minimum of 25 bar (360 psi) servo pressure is

required to change the motor displacement with the
motor shaft turning. A minimum of 70 bar (1015 psi)
servo pressure is required to change the motor dis-
placement with the motor shaft locked.
50000009
Fig. 30-12 - Hydraulic 2-Position Control,
Type N2)
Electrohydraulic 2-Position Control (Types E1•E2

and F1•F2) and Electric 2-Position Control (Type
S1)
These controls do not require adjustment.
CAUTION
Do not tamper with the adjusting screw in the

end cap (opposite the control).
50000012
Fig. 30-13 - Electrohydraulic 2-Position Pilot pressure for the E1•E2 or F1•F2 electric sole-
Control, Types E1•E2 and F1•F2 noid valve is internally supplied. When the solenoid is
energized, motor charge pressure should be present
at test ports M7 and M8. When the solenoid is not
energized, test port M8 should drop to case pressure.
The S1 control utilizes a direct acting solenoid to

operate the control valve spool in the end cap.
Servo pressure supply oil is usually provided inter-

nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
50000162 displacement with the motor shaft turning, and a
Fig. 30-14 - Electric 2-Position Control, minimum of 70 bar (1015 psi) is required with the
Type S1 motor shaft locked.
30 30 - 8
802 BOMAG 008 911 71

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Hydraulic Proportional Control (Types HZ, HS,
H1•H2, and K1•K2)
The control start pressure for these controls may be
adjusted with the adjusting screw on the end cap
(opposite the control block). Control start is that pilot
pressure at which the motor displacement starts to
decrease.
To check the control start setting, install a gauge to
monitor the pilot pressure (connect to port M7 or tee 51000015
into the pilot line connected to port X1), and the Fig. 30-15 - Hydraulic Proportional Control,
minimum angle servo pressure (port M3). If adjusting Type HZ
an H1 or H2 control, the override solenoid must be
energized. If adjusting a K1 or K2 control, the sole-
noid must not be energized.
NOTE: The pilot signal may be determined by prime
mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.
Increase the pilot signal to the required control start
pressure. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to 51000018
decrease. Fig. 30-16 - Hydraulic Proportional Control,
To adjust the control start pressure, loosen the lock Type HS
nut using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start pressure.
Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjust-
ing.
For the H1•H2 controls, the pilot signal pressure
supplied to port X1 should also be present at test port
M7 when the solenoid is energized. When the sole-
noid is not energized, test port M7 should drop to case
pressure.
51000020
For the K1•K2 controls, the pilot signal pressure Fig. 30-17 - Hydraulic Proportional Control
supplied to port X1 should also be present at test port with Electric Override, Type H1•H2 (K1•K2
M7 when the solenoid is not energized. When the Similar)
solenoid is energized, test port M7 should drop to
case pressure.
Shut down the prime mover. Remove the gauges and
install the gauge port plugs. Return the pump and
motor controls to their normal operation.
51000047
displacement with the motor shaft turning, and a Fig. 30-18 - Adjusting Control Threshold,
minimum of 70 bar (1015 psi) is required with the Types HS, HZ, H1•H2, and K1•K2
motor shaft locked.
30 - 9 31
008 911 71 BOMAG 803

saue
(Type HP)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
differential pilot pressure at which the motor displace-
ment starts to decrease.
To check the control start setting, install gauges to

51000023 monitor the pilot pressures (tee into the pilot lines
Fig. 30-19 - Two Line Hydraulic connected to ports X1 and X2), and the minimum
Proportional Control, Type HP angle servo pressure (port M3).
NOTE: The pilot signals may be determined by prime

Increase the pilot signal differential to the required

control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
51000047 The differential control start pressure should be the
Fig. 30-20 - Adjusting Control Threshold same no matter which pilot pressure is higher. Differ-
(Type HP) ences in control operation when the pilot pressure
differential is reversed indicate a problem with the
shuttle spool in the control block.
To adjust the control start differential pressure, loosen

the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw clockwise increases the control
start pressure. Torque the lock nut to 9 Nm (6.6 ft•lbsf)
after adjusting.


displacement with the motor shaft turning, and a
minimum of 70 bar (1015 psi) is required with the
motor shaft locked.
32 30 - 10
804 BOMAG 008 911 71

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for “Dual Path” Vehicles (Type HC)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the
control housing. Control start is that differential pilot
pressure at which the motor displacement starts to
decrease.
To check the control start setting, install gauges to

monitor the pilot pressures (tee into the pilot lines 51000158
connected to ports X1 and X2), and the minimum Fig. 30-21 - Two Line Hydraulic
angle servo pressure (port M3). Proportional Control, Type HC
NOTE: The pilot signals may be determined by prime

Increase the pilot signal differential to the required

control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
The differential control start pressure should be the 51000159
same no matter which pilot pressure is higher. Differ- Fig. 30-22 - Adjusting Control Threshold
ences in control operation when the pilot pressure (Type HC)
differential is reversed indicate a problem with the
shuttle spool in the control block.
To adjust the control start differential pressure, loosen

the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw counter-clockwise (CCW) increases
the control start pressure. Torque the lock nut to 9 Nm
(6.6 ft•lbsf) after adjusting.

Servo pressure supply oil is provided internally from

the main system ports of the motor.
30 - 11 33
008 911 71 BOMAG 805

saue
(Types EP and EQ)
The control start current for the EP and EQ controls
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
current supplied to the PCP (Pressure Control Pilot)
valve at which the motor displacement starts to de-
crease.
51000026 To check the threshold setting, install instruments to
Fig. 30-23 - Electrohydraulic Proportional monitor the PCP current, and the minimum angle
Control, Type EP (EQ Similar) servo pressure (port M3).
NOTE: The current supplied to the PCP may be

determined by prime mover speed, other
shaft speeds, control pressures, or other elec-
trical signals, depending upon the design of
the vehicle / machine control circuit.
Increase the PCP current to the required control start

current. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to
decrease.
51000047
Fig. 30-24 - Adjusting Control Threshold To adjust the control start current, loosen the lock nut
(Type EP•EP) using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start current.
Torque the lock nut to 9 Nm (6.6 ft•lbsf) after adjust-
ing.
PCP supply pressure oil is provided externally. PCP

supply pressure must be a minimum of 20 bar (290
psi) and no more than 70 bar (1015 psi).


displacement with the motor shaft turning, and a
minimum of 70 bar (1015 psi) is required with the
motor shaft locked.
34 30 - 12
806 BOMAG 008 911 71

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Pressure Compensator Over-Ride (PCOR)
and Pressure Compensator Regulator
(Type PC) Adjustment
The PCOR or PC regulator valve setting may be
adjusted with the adjusting screw on the PCOR/PC
valve block attached to the multi-function block. The
regulator start pressure is that system pressure at
which the PCOR or PC regulator starts to increase
the motor displacement.
In order to measure the regulator start pressure
setting of the PCOR or the PC regulator, the motor
output shaft must be loaded to increase the system 51000031
working pressure. This can accomplished by apply- Fig. 30-25 - PCOR Block on Multi-Function
ing the vehicle’s brakes or by loading the work func- Block (K1•K2 Control Shown)
tion.
WARNING
The following procedures may require the ve-

hicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the adjustment to prevent
injury to the technician and bystanders.
Install gauges to monitor system pressure (connect
to ports M1 and M2), the minimum angle servo
pressure (port M3), and the maximum angle servo
pressure (port M4).
51000034
Start the prime mover and operate at normal speed.
Fig. 30-26 - Pressure Compensator
Provide a signal to the pump control to provide a
Regulator (Type PC)
constant flow of hydraulic fluid to the motor. Provide
a signal to the motor control to maintain the motor at
its minimum displacement.
Increase the load on the motor to increase the system
pressure to the required regulator start pressure. The
maximum angle servo pressure (M4) will increase
and the minimum displacement servo pressure (M3)
will decrease as the PCOR or PC regulator operates.
The servo pressures will equalize, and the maximum
angle servo pressure continue to increase, as the
motor displacement starts to increase.
51000048
During the transition from minimum to maximum Fig. 30-27 - System Pressure Gauge Ports
displacement, an additional 10 bar (145 psi) increase (Side Port End Cap)
in system pressure may be noted.
Once the motor is at maximum displacement, further
increases in load will result in increasing system
pressure until the maximum system pressure (deter-
mined by the system relief valve or pump pressure
limiter) is reached.
30 - 13 35
008 911 71 BOMAG 807

saue
Allow the pump to return to its neutral position.
Repeat the procedure for the other side of the closed
circuit if so configured. The PCOR or PC regulator
must operate at the same start pressure as noted
previously. Any noticeable difference in operation
from side to side may indicate a problem with the
pressure supply shuttle spool or brake pressure de-
feat spool in the multi-function block.
NOTE: Some motors may be configured for the
PCOR or PC regulator to function on only
one (1) side of the closed loop. Refer to the
nomenclature on the motor nameplate.
In order for the PCOR or PC regulator to function
properly on motors equipped with a brake pressure
defeat spool, the defeat spool must be positioned
correctly. The control pressure for the defeat spool
should be applied to the appropriate port (XA or XB)
as shown in the following table to shift the defeat
spool and permit PCOR or PC regulator operation.
Maximum pressure across the brake pressure defeat
ports XA and XB is 50 bar (725 psi).
51000049 Pressure Compensator Override Defeat Operation
Fig. 30-28 - Loosen PCOR/PC Lock Nut Rotation High system Control
pressure port pressure on port
CW A XB
CCW B XA
The PCOR or PC regulator valve is screw adjustable.
To adjust, loosen the locknut with a 1-1/16" hex
wrench. Turn the adjusting screw with a large screw-
driver until the desired pressure setting is estab-
lished. Clockwise rotation of the adjustment screw
will increase the pressure setting at a rate of approxi-
mately 70 bar (1000 psi) per turn.
51000050
Fig. 30-29 - Rotate PCOR/PC Adjusting CAUTION
Screw A stop pin is installed in the adjusting screw to
prevent “overtravel” of the PCOR/PC valve
spool. The stop pin must protrude (distance
"X" “X”) 19 mm (.75 in.) from the spring seat for
settings of 270 to 370 bar (3900 to 5350 psi), or
24 mm (.94 in.) for settings of 110 to 260 bar
(1600 to 3750 psi). Refer to the appropriate
Service Parts Manual for further information.
While holding the adjusting screw from turning, torque
the lock nut to 52 Nm (38 ft•lbsf). Recheck the PCOR
or PC regulator setting.
51000051
Fig. 30-30 - PCOR/PC Adjusting Screw Stop
Pin motor controls to their normal operation.
36 30 - 14
808 BOMAG 008 911 71

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Troubleshooting
Fault-Logic Diagrams • Closed Circuit
Check Oil Level Check System Check Pump Check Prime Mover
OK OK OK Speed
in Reservoir Relief Valve Inlet Pressure
Pressure Low
Low Low OK
Settings
Fill to Proper Defective Inspect Inlet Filter Adjust

Level and Replace if
Adjust or Necessary
Replace
Replace Check System Check Charge and

Transmission OK Internal Leakage OK Control Pressures
(Pump and Motor)
High Incorrect
Repair as Required Repair as Required

SYSTEM RESPONSE IS SLUGGISH
Check Oil Air in System OK Check Pump Inspect Shaft Inspect Shaft
Level in
OK Inlet Pressure
OK Couplings
OK Alignment
Reservoir
Loose Fitting Low Defective Defective
Low
Fill to Proper Purge Air and Inspect Inlet Filter Repair or Align Shafts
Level Tighten and Replace if Replace
Fittings Necessary
EXCESSIVE NOISE AND/OR VIBRATION
Check Oil Level Inspect Heat Check Charge Check Pump Inlet
in Reservoir
OK Exchanger
OK Pressure
OK Pressure
Low Defective Incorrect Low OK
Fill to Proper Clean, Repair Repair as Inspect Inlet Filter

Level or Replace Required and Replace if
Necessary
Replace Check System Check for Internal Check System Relief

Transmission OK Pressure OK System Leakage OK Pressure Settings
(Pump and Motor)
High High Low
Reduce Load on Repair as Required Adjust or Replace

Transmission
SYSTEM OPERATING HOT
30 - 15 37
008 911 71 BOMAG 809

saue
Troubleshooting (Continued)
Fault-Logic Diagrams • Closed Circuit (Continued)
Check Charge Check Pump Interchange System Replace

Pressure OK Control System OK Relief Valves and/or OK Transmission
Charge Check (Pump and
Decays in One Defective Valves Motor)
Direction (Forward
Problem Changes
or Reverse) Only
Direction
Inspect and Repair Repair or Replace Repair or Replace

Loop Flushing Appropriate Valve
Valve
MOTOR OPERATES NORMALLY IN ONE DIRECTION ONLY
Check Inlet Check Outlet Motor at Incorrect Repair or Replace

Pressure at OK Pressure at OK (Minimum) Displacement OK Motor
Motor Motor
Low High / Low Incorrect
Correct System Correct System Check Control Supply

Pressure and/or Repair
LOW MOTOR OUTPUT TORQUE Displacement Control
Check Oil Check Charge Check Pump

Level in OK Pressure OK Output Flow OK Check Motor Displacement
Reservoir
Low Incorrect Improper Incorrect OK
Fill to Proper Repair Charge Repair Pump Check and Repair

Level System Control and/or Control System and
Pump Displacement Controls
(Pump and Motor)
Repair or Replace
Motor
IMPROPER MOTOR OUTPUT SPEED
38 30 - 16
810 BOMAG 008 911 71

saue
Notes
30 - 17 39
008 911 71 BOMAG 811

saue
Notes
40 30 - 18
812 BOMAG 008 911 71

saue
Exploded View of the Series 51 Variable Motor
The following information is for general parts identi-
fication ONLY. Refer to the applicable Service Parts
List when ordering service parts.
Base Unit
L35
W10 OPTION
WNNT L40
W50
L50
B71
W25 B80
B71A B80
L70 L80
L75
L40
L50
B70
B70A
B70A
Y10
B70
Y20
W25
Y30
Y20
W50
Y10 Y10
W10 B70A
OPTION Y20
WNNS B70
Y30
Name Plate
saue
Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ
51V160 RF1N
E1A2 ANE1 NNN Model Code
050AA210322
Model No. Ident Nr
Model Number
516-40104 786673
Serial Number N 91 25 67890
Serial No. Fabr Nr
MADE IN GERMANY
Place of Manufacture
Name Plate (German Production)
40 - 1 41
008 911 71 BOMAG 813

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Exploded View of the Series 51 Variable Motor (Continued)
End Cap
(....) = Applies to the indicated
G30 frame size(s).
G24
G30A
J70
G26
J60 G38
J50 G36
M18/M98 F10N, F10A–G
M16/M96 F20A–G
K90
K50
J40
K10
OR
K16 K70 OR
(250) K90N
G20
G20A K80
Q40 K90A
K14
K16 G50
(060—160)
G12 G50A G12
G12A G30 G30A K18N
(250) (250)
G80
(060, 080) G12A OR
G80A K16
G30 K18
(060, 080) (060—160) K16
(250)
G30A (250)
G30
(250) G30A K14
G20A
M11/T3A1-A9
T3B0-B6 G20
G12 T3C2-C7
G12A S20 OR
G12A
G12 S10
M11/T1A1-A9
T1B0-B6 (060, 080,
T1C2-C7 G30A 110)
G18 (250) OR S10
G90 (160, 250)
G12A G30
Y40 G12 (250)
N1U5 J30
T8A1-A9
Y50 T8B0-B6 J10A-D
T8C2-C7
J20/S70
G30A
G30 T7A1-A9
G42
G36 T7B0-B6
T7C2-C7
M11/T2A1-A9 G44
T2B0-B6
T2C2-C7 G38
F33
G38
G38
G42 F32
42 40 - 2
814 BOMAG 008 911 71

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Multi-Function Valve
N28 Q50
N28A N84
N84A
N52 OR
N32 N34
N34A
N72 N46/T5
N66 N72A N52/T4
N66A
N34
N34A N84
N30
N34
N34A OR
N52/T6
N34A N84A
N34
N34
N34A
N1A1-A6 N28
OR N28A
N90A
N66A
N90 OR N66
N26A
N26
N34
N34A
N58
N24
N82
N11
N29
Z10 & Z20
N82 N22 & N20

U7 N24
U6 N11 & N21
N14
N16
N18
N27A
N27 N29
N23
N27A
N23A
N27
Q60
40 - 3 43
008 911 71 BOMAG 815

saue
Controls
M28
M30
M24
M38
M36
M10 M30
M18
M28
M32A M32 M26 M14
M32
M24
M26
M30 M28
M1HS
M1HP
M16 M18
M16
M20 M22
M1EP•EQ
M14 M18 M16 M16
M12 M14
M12
EP•EQ M10 HS M18
M10
M36
HP
M16 M1S1
M10
M20 M14
M22
M1E1•E2•E5 M22A S1
M1F1•F2
M1H1•H2
M1K1•K2 M18A
M14
M18
M2E5
E1•E2•E5 / F1•F2 / H1•H2 / K1•K2
44 40 - 4
816 BOMAG 008 911 71

saue
Controls (Continued)
(....) = Applies to the indicated
frame size(s).
S50
S30
S20
S40
S60
S11T
(060, 080,
110)
OR
S11T
S10 (160, 250)
(060, 080, S10
110) (160, 250)
S10T S10T
M10 (060, 080, (160, 250)
M12 110)
S70
M44 M32
M34
M34A
M14
M40 M1HC
M1N2 M16
M38 M47
M16A M14 M46
N2
M18
M50A
M18A
M50
M10 M34A M48A
M18 M12 M11 M34
M18A M48
(060, 080, 110) M26
M18A M34A
M22 M10
M18 M16A J10 M34
M1HZ M16 M25
HZ
M24
M22
M20
M14
M12
M28 M18
M16
HC
40 - 5 45
008 911 71 BOMAG 817

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PC Regulator
T7
F33
F32
M84
M28
M84A
M28A
M52
M34
M34A
M72 T5
M66 T4
M66A M72A
M34
M34A
M30
M34
M34A
T6 M84
M34A M84A
M34
M34 M34A
M10 M28
M28A
M90A
M90 M28A
M26 M28
M26A
M34A
M34
M58
Z10 & Z20
M24 M82 M22 & M20

U7
U6
M1PC & M21
M14
M16
M18
M27A
M27 M29
M23
M27A
M23A
M27
Q60
46 40 - 6
818 BOMAG 008 911 71

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Item Description Quantity Item Description Quantity
B000 COMMON PARTS GROUP (SAE FLNG) J00A-K CONTROL START SETTING
B80 O-RING 1 J10A-K SPRING-HEL COMP- CONT START 1
L35 FLANGE- SAE 1 J20 SEAT-SPRING 1
L40 SEAL- SHAFT 1 J30 SEAT-SPRING 1
L50 O-RING 1 J40 SCREW-ADJUSTING 1
L70 SCREW- SOC HD 8 J50 O-RING 1
J60 NUT-ADJUSTING SCREW 1
C000 COMMON PARTS GROUP (CARTRIDGE) J70 NUT-LOCK 1
L40 SEAL- SHAFT 1
L50 O-RING 1 J00N CONT START N/A (FOR 2 POS CONT)
L75 COVER- SEAL 1
L80 RING- RETAINING 1 M0EP CONTROL- ELHYD PRP, PACKARD
M0EQ CONTROL- ELHYD PRP, MS
F••• MAXIMUM DISPLACEMENT F32 BUSHING- VALVE ASSY 1
F10 SPACER- MAX DISPL LMTR 1 M1EP PCP VALVE, PACKARD CONN 1
F20 SCREW-SOC HD - MAX DISPL LMTR 1 M1EQ PCP VALVE, MS CONN 1
M10 HOUSING- CONTROL 1
G00A END CAP-AXIAL (160-250) M12 SCREW- SOC HD 4
G00B END CAP-AXIAL, CODE 61 (160-250) M14 COVER 1
G00R END CAP-SIDE, LOOP FL M16 GASKET 1
G00S END CAP-SIDE, LOOP FL, CODE 61 M18 SCREW- SOC HD 4
G12 PLUG-STR THD HEX 7 M24 PISTON- SHUTTLE, DELTA P 1
G14 PLUG-EXP 1 M26 SPRING- HEL COMPRESSION 1
G16 PLUG-MANDREL 2 M28 PIN 1
G18 SCREW-SET, FLAT PT 2 M30 O-RING 1
G20 PLUG- SPECIAL 2 M32 PLUG-SOC HD 2
G20N PLUG- STR THD HEX 2 M34 PLUG-MANDREL 6
G24 SCREW-SOC HD 4 M36 O-RING 1
G26 COVER-SERVO PISTON 1 M38 O-RING 1
G30 PLUG-STR THD HEX 3 M40 CONTROL SCREEN FILTER 1
G36 O-RING 2 M42 PLUG-SOC HD 1
G38 O-RING 4 M44 PLUG-PLASTIC 1
G42 O-RING 2 N90 PLUG-STR THD HEX 1
G44 O-RING 1
G50 PLUG-ST THD HEX 2 M0E1/E2 CONTROL- ELHYD 2 POS
G70 COVER-PORT 2 M0F1/F2 CONTROL- ELHYD 2 POS, MAX ANG
G90 CONTROL SCREEN FILTER 1 F32 BUSHING- VALVE ASSY 1
K10 ADJ PLUG ASSY-CHG RLF 1 M1E1 VALVE ASSY- SOLENOID,12V 1
K14 SPRING-HELICAL COMP 2 M1E2 VALVE ASSY- SOLENOID,24V 1
K16 GUIDE-SPRING (060 — 160) 2 M10 HOUSING-CONT, ELHYD, 2 POS (E) 1
K16 GUIDE-SPRING (250) 2 M10 HOUSING-CONT, ELHYD, 2 POS (F) 1
K18 SHUTTLE VALVE SPOOL 1 M12 PLUG-EXP 7
K18N LOOP FLUSH SPOOL- DEFEAT 1 M14 SCREW-SOC HD 4
K50 O-RING 1 M16 O-RING 2
K70 SPRING-HELICAL COMPRESSION 1 M18 PLUG-STR THD HEX 1
K80 POPPET-CHG RELIEF 1 M20 O-RING 1
K90 NUT-HEX LOCK 1 M22 PLUG-STR THD HEX 1
K90N PLUG- ST THD HEX 1 N90 PLUG-STR THD HEX 1
40 - 7 47
008 911 71 BOMAG 819

saue
M0HC CONTROL- HYD PRPNL 2LN, DUAL PATH M0HS CONTROL- HYD PRP, 1 LN
F32 BUSHING- VALVE ASSY 1 F32 BUSHING-VALVE ASSY 1
M1HC HOUSING- HYD PRPNL (2LN),DUAL 1 M1HS HOUSING- VALVE, HYD PRPRNL 1 LN 1
M10 SCREW-SOC HD 4 M10 SCREW-SOC HD 4
M11 WASHER, FLAT (060, 080, 110) 4 M12 O-RING 1
M12 COVER 1 M14 PLUG-STR THD HEX 1
M14 GASKET 1 M16 PLUG-PLASTIC 1
M16 NUT-SEAL LOCK 1 N90 PLUG-STR THD HEX 1
M18 SCREW-SET, FL PT 1
M20 GUIDE- SPRING 1 M0HZ CONTROL- HYD PRP, 1 LN, CMPCT
M22 SPRING-HELICAL COMPRESSION 1 F32 BUSHING- VALVE ASSY 1
M24 PISTON- DELTA P 1 M1HZ HOUSING- VALVE, HYD PRP, 1 LN, CPT 1
M25 SEAT- SPRING 1 M10 VALVE ASSY- DBL CHECK 1
M26 PIN 1 M12 SCREW- SOC- DRILLED 1
M28 SCREW-SOC HD 4 M14 CONTROL SCREEN FILTER 2
M32 CONTROL SCREEN FILTER 2 M16 PLUG-STR THD HEX 2
M34 PLUG-SOC HD 4 M18 PLUG-STR THD HEX 3
M38 VALVE- BLEED 1
M40 NUT- SEAL LOCK 1 M0H1/H2 CONTROL- HYD PRP, 1 LN, MAX ANG
M44 VALVE, SHUTTLE- DELTA P 1 M0K1/K2 CONTROL- HYD PRP, 1 LN, MIN ANG
M46 SEAT- BALL CHECK 1 F32 BUSHING-VALVE ASSY 1
M47 BALL- SHUTTLE 1 M1H1 VALVE ASSY-SOLENOID,12V 1
M48 PLUG-STR THD HEX 1 M1H2 VALVE ASSY-SOLENOID,12V 1
M50 PLUG-STR THD HEX 1 M10 HSG-CONT,ELHYD, 2 POS 1
M12 PLUG-EXP 8
M0HP CONTROL- HYD PRPNL 2LN, W/BLD M14 SCREW-SOC HD 4
F32 BUSHING- VALVE ASSY 1 M16 O-RING 2
M1HP HOUSING- HYD PRPNL (2LN),W/BLD 1 M18 PLUG-STR THD HEX 1
M10 COVER 1 M20 O-RING 1
M12 GASKET 1 M22 PLUG-PLASTIC 1
M14 PISTON-SHUTTLE, DELTA P 1 N90 PLUG-STR THD,SOC HD 1
M16 SPRING-HELICAL COMPRESSION 1
M18 PIN 1 M0N2 CON-HYD, 2 POS, DIRECT
M24 O-RING 1 M1N2 COVER 1
M26 VALVE SHUTTLE,DELTA P 1 M10 PLUG 1
M28 PLUG-SEALING 1 M11 SCREW- SET,FLT PT 3
M30 O-RING 2 M12 O-RING 1
M32 PLUG-SEALING 1 M14 SCREW-SOC 4
M34 PLUG-EXP 6 M16 GASKET 1
M36 SCREW-SOC HD 4 M18 PLUG 1
N90 PLUG-STR THD HEX 1
48 40 - 8
820 BOMAG 008 911 71

saue
M0PC REGULATOR- PRESS COMP N0A1-6 SVO PRS SPLY, PCOR, DFT
F32 PLUG- VALVE BUSHING BORE 1 N1A1-6 HOUSING-MULTI FUNCTION BLOCK 1
F33 O-RING 1 N11 HOUSING-VALVE 1
M1PC HOUSING- VALVE 1 N14 NUT-HEX LOCK 1
M10 HOUSING- MULTI FUNCTION BLOCK 1 N16 O-RING 1
M14 NUT-HEX LOCK 1 N18 SPRING-HELICAL COMPRESSION 1
M16 O-RING 1 N20 SEAT-SPRING, PCOR 1
M18 SPRING-HELICAL COMPRESSION 1 N21 BUSHING-VALVE 1
M20 SEAT-SPRING, PC 1 N22 SPOOL-PCOR VALVE 1
M21 BUSHING-VALVE 1 N23 PLUG-STR THD HEX 1
M22 SPOOL-PC VALVE 1 N24 O-RING 5
M23 PLUG-STR THD HEX 1 N26 PLUG-SOC HD (W/PCOR) 1
M26 PLUG-SOC HD 1 N26 PLUG-STR THD HEX (WO/PCOR) 1
M27 PLUG-STR THD HEX 10 N27 PLUG-STR THD HEX 17
M28 PLUG-STR THD HEX 4 N28 PLUG-PLASTIC (W/DFT) 2
M29 SCREW-SOC 4 N28 PLUG-STR THD HEX (WO/DFT) 2
M30 SPOOL, BI-DIRECTIONAL CHECK 1 N29 SCREW-SOC 4
M34 PLUG-STR THD HEX 10 N30 SPOOL, BI-DIRECTIONAL CHECK 1
M36 SCREW-SET,FLT PT 5 N32 PISTON 1
M38 PLUG-EXP 11 N34 PLUG-STR THD HEX 10
M50 PLUG-EXP 8 N36 SCREW-SET,FLT PT 5
M52 CONTROL SCREEN FILTER 2 N38 PLUG-EXP (060 - 110 ONLY) 11
M54 PLUG-EXP 1 N50 PLUG-EXP (060 - 110 ONLY) 6
M58 SCREW-SOC HD 4 N52 CONTROL SCREEN FILTER 2
M62 PLUG-EXP 1 N54 PLUG-EXP 1
M66 PLUG-STR THD HEX 2 N58 SCREW-SOC HD 4
M72 PLUG-STR THD,SOC HD 1 N62 PLUG-EXP 1
M82 O-RING 1 N66 PLUG-STR THD HEX (060-110) 2
M84 PLUG-STR THD HEX 2 N66 PLUG-STR THD HEX (160-250) 1
M86 SCREW-FL PT 1 N72 PLUG-STR THD,SOC HD 1
M90 PLUG-STR THD HEX 1 N74 SCREW-SET, FL PT 3
M96 GASKET 1 N82 O-RING 1
M98 PLUG 1 N84 PLUG, SPECIAL 2
N24 O-RING 5 N84 PLUG-STR THD HEX 2
N86 SCREW-SET 1
M0S1 CONTROL- ELECTRIC 2 POS, DIRECT U5 PLUG- SOC (EXT SUPPLY) 1
F32 BUSHING- VALVE ASSY 1 U6 ORIFICE, PCOR DAMPING 1
M1S1 SOLENOID,12V 1 U7 ORIFICE, PCOR DAMPING 1
M10 ADAPTER PLATE- SOLENOID 1
M14 SCREW-SOC HD 4 N0NN SERVO PRESS SPLY- NONE
M16 O-RING 1
M18 O-RING 1 P0AA SYS PRESS PROTECT- NONE
M20 PIN 1
M22 O-RING 1
N90 PLUG-STR THD HEX 1
40 - 9 49
008 911 71 BOMAG 821

saue
S00D-G CONTROL RAMP- HP, HS, H1/H2, K1/K2 Y••• MINIMUM DISPLACEMENT
S10 GUIDE-SPRING (160-250) 1 Y10 SCREW- SET, FLT PT 1
S10D-G CONT RAMP SPRING (060-110) 1 Y20 NUT- HEX, SEAL LOCK 1
S10D-G CONT RAMP SPRING ASSY (160-250) 2 Y30 TAMPER RESISTANT CAP 1
S20 GUIDE-SPRING 1
S70 SEAT-SPRING 1 Z000 PRS COMP SET- NONE
S00N CONTROL RAMP-NONE Z0•• PCOR / PRESS COMP SETTING

Z10 ADJUSTER- THREADED 1
S00T CONTROL RAMP- HC Z20 PIN-STRAIGHT 1
S10 GUIDE-SPRING 1
S10T CONT RAMP SPRING 1
S11T CONT RAMP SPRING 1
S20 GUIDE-SPRING 1
S30 NUT- ADJUSTING SCREW 1
S40 O-RING 1
S50 NUT- LOCK 1
S60 SCREW- ADJUSTING 1
S70 SEAT-SPRING 1
S00U-Z CONTROL RAMP- EP/EQ

S10 GUIDE-SPRING (160-250) 1
S10U-Z CONT RAMP SPRING (060-110) 1
S10U-Z CONT RAMP SPRING ASSY (160-250) 1
T0A0 CON ORIFICE (A0)- NONE
T0A1 CON ORIFICE (A1)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 SCREW 2
T5 ORIFICE 1
T6 SCREW 1
T7 ORIFICE 2
T8 ORIFICE 1
U3 SCREW-FL PT 1
T0A2 CON ORIFICE (A2)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 ORIFICE 2
T5 SCREW 1
T6 ORIFICE 1
T7 ORIFICE 2
T8 ORIFICE 1
WNNN SPCL HDW-NONE

A10 SPEED SENSOR 51V 0
B70 PLUG-SOC HD 1
B71 PLUG-PLASTIC 1
50 40 - 10
822 BOMAG 008 911 71

saue
Minor Repair and Replacement - Variable Motor
Charge Pressure
Relief Valve
Loop Flushing
Valve
Shaft
Seal
Control
Orifices
Multi-function
Block
Control
Minimum Displacement
Limiter
51000052
Variable Displacement Motor (SAE Flange Configuration)
Fig. 50-1 - Minor Repairs
Minor Repairs may be performed, following the proce- Protect all exposed sealing surfaces and open cavi-
dures in this section, without voiding the unit war- ties from damage and foreign material.
ranty. Although specific products are illustrated,
these procedures apply to all units in the Series 51 It is recommended that all gaskets and O-rings be
family. replaced. All gasket sealing surfaces must be cleaned
prior to installing new gasket. Lightly lubricate all O-
General rings with clean petroleum jelly prior to assembly.
Cleanliness is a primary means of insuring satisfac-
tory transmission life, on either new or repaired units.
Cleaning parts by using a solvent wash and air drying
is adequate, providing clean solvent is used. As with
any precision equipment, the internal mechanism
and related items must be kept free of foreign mate-
rials and chemicals.
50 - 1 51
008 911 71 BOMAG 823

saue
Minor Repair and Replacement - Variable Motor (Continued)
Shaft Seal (SAE Flange Configuration)
Lip type shaft seals are used on the Series 51 motors.
Replacement of the shaft seal usually requires re-

moval of the motor from the machine.
Remove the screws holding the flange to the housing,

using a 6 mm internal hex wrench (060 and 080 units),
an 8 mm internal hex wrench (110 units), a 10 mm
internal hex wrench (160 units), or a 12 mm internal
hex wrench (250 units).
Remove the flange from the housing using a suitable

puller. Care must be taken so as to not damage the
housing bore or shaft.
51000178 51000179 CAUTION
Fig. 50-2 - Remove Fig. 50-3 - Remove
Screws Holding Flange (SAE) Do not allow the output shaft to move out of the
Flange to Housing housing while removing the flange. After the
(SAE) flange is removed, do not attempt to remove
the shaft from the housing. If the output shaft
moves out of the housing, the synchronizing
shaft and rollers could fall out of position,
requiring major disassembly of the unit.
Remove the old seal from the flange. Once removed,

the seal is not reusable.
Inspect the flange and the new seal for any damage
or nicks.
Using an arbor press, press the new seal into the

flange. Be careful not to damage seal.
NOTE: The outside diameter of the seal may be

51000053 51000054 lightly coated with a sealant (such as Loctite
Fig. 50-4 - Remove Fig. 50-5 - New Seal High Performance Sealant #59231) prior to
Old Seal from Flange Installed in Flange installation. This will aid in preventing leaks
(SAE) (SAE) caused by damage to the seal bore in the
flange.
Inspect the sealing area on the shaft for rust, wear, or

contamination.
52 50 - 2
824 BOMAG 008 911 71

saue
Install a new O-ring on the flange. Prior to assembly,
lubricate the flange O-ring and the I.D. of the seal with
petroleum jelly.
Protect the seal lip from damage during installation by

wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.
Assemble the flange and seal over the shaft and into
the housing bore. Install four (4) of the flange screws,
51000055 51000056
and tighten them evenly to pull the flange into posi- Fig. 50-6 - Install Fig. 50-7 - Torque
tion. Take care to not damage the O-ring or seal lip
Flange onto Housing Flange Screws (SAE)
during installation.
(SAE)
Install the flange screws and torque evenly to 32 Nm
(24 ft•lbsf) for 060 and 080 motors, 63 Nm (46 ft•lbsf)
for 110 motors, 110 Nm (81 ft•lbsf) for 160 motors,
and 174 Nm (128 ft•lbsf) for 250 motors.
Shaft Seal (Cartridge Configuration)

Lip type shaft seals are used on the Series 51 motors.
These seals can be replaced without major disas-
sembly of the unit. However, replacement of the shaft
seal requires removal of the motor from the wheel
drive or track drive gearbox.
Remove the seal carrier retaining ring from the hous-

ing.
Carefully pull the seal cover out of the housing. Care

must be taken so as not to damage the housing bore
or shaft.
Remove the O-ring from the housing.
Remove the old seal from the carrier. Once removed,

the seal is not reusable. 51000057 51000058
Inspect the carrier and the new seal for any damage
Carrier Retaining Seal Carrier
or nicks.
Ring (Cartridge) (Cartridge)
Using an arbor press, press the new seal into the
carrier. Be careful not to damage seal.
NOTE: The outside diameter of the seal may be

lightly coated with a sealant (such as Loctite
High Performance Sealant #59231) prior to
installation. This will aid in preventing leaks
caused by damage to the seal bore in the seal
carrier.
51000059 51000060
Inspect the sealing area on the shaft for rust, wear, or
Fig. 50-10 - Seal Fig. 50-11 - Seal
contamination.
Carrier Removed Installed in Carrier
(Cartridge) (Cartridge)
50 - 3 53
008 911 71 BOMAG 825

saue
Install the carrier O-ring into the groove in the hous-
ing. Prior to assembly, lubricate the carrier O-ring and
the I.D. of the seal with petroleum jelly.
Protect the seal lip from damage during installation by

wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.
Assemble the carrier and seal over the shaft and into
the housing bore. Take care to not damage the O-ring
51000061 51000057
Fig. 50-12 - Install Fig. 50-13 - Install or seal lip during installation.
Seal Carrier Carrier Retaining Install the seal carrier retaining ring.
(Cartridge) Ring (Cartridge)
Loop Flushing Shuttle Valve (Option)
Using an 11/16" wrench, remove the hex plugs from
both sides of end cap.
Remove springs and spring seat washers. Note the
orientation of the washers.
NOTE The 250 frame size motors use thicker spring
seat washers.
51000062 51000063 Remove flushing valve spool.

Shuttle Valve Plugs Valve Spool
Inspect parts for damage or foreign material.
51000066
Fig. 50-16 - Loop Flushing Shuttle Valve
Components
Install flushing valve spool in end cap, then install the

spring seat washers (thick washers on 250 frame size
motors) on each end of the spool. The step on the
spring seat washers should face out, toward the
springs.
Install the spool springs and hex plugs. Torque the
plugs to 41 Nm (30 ft•lbsf).
51000064 51000065
Fig. 50-17 - Install Fig. 50-18 - Install
Valve Spool and Plugs and Springs
Washers
54 50 - 4
826 BOMAG 008 911 71

saue
Charge Pressure Relief Valve
Before removing the screw adjustable relief valve
plug, mark the plug, lock nut, and end cap to allow
maintaining the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut (with a 1-1/16"
hex wrench), and unscrewing the plug with a large
screwdriver.
Remove the spring and relief valve poppet. 51000067 51000068

Inspect the poppet and mating seat in the end cap for Charge Relief Valve Charge Relief Valve
damage or foreign material. Plug
Install the poppet and spring. Install the plug with its
and torque the lock nut to 52 Nm (38 ft•lbsf).
Check and adjust, if necessary, the charge pressure.
51000069
Fig. 50-21 - Charge Relief Valve
Components
Minimum Angle Servo Cover

Thoroughly clean external surfaces prior to removal
of cover.
Remove the four (4) screws retaining the cover to the

end cap with an 8 mm internal hex wrench (060, 080,
110, and 160 units) or a 10 mm internal hex wrench
(250 units). Remove the cover. Remove the O-rings
between the cover and end cap.
51000046 51000006
Install new O-rings on the end cap and retain with Fig. 50-22 - Remove Fig. 50-23 - Install
petroleum jelly. Install the cover onto the end cap and Servo Cover Screws Servo Cover
install the screws. Torque the screws to 78 Nm (58
ft•lbsf) for 060, 080, or 110 units, or 110 Nm (81 ft•lbsf)
for 160 or 250 units.
The plug in the cover may be removed with a 7/16"

hex wrench. Torque this plug to 9 Nm (7 ft•lbsf).
50 - 5 55
008 911 71 BOMAG 827

saue
of cover plate.
Remove the four (4) screws retaining the cover plate

(160 and 250 units). Remove the cover plate.
51000071 51000072 Remove the solid plug from the valve sleeve bore in
Fig. 50-24 - Remove Fig. 50-25 - Remove the end cap. (An 8 mm threaded hole is provided in
Cover Plate Screws Cover Plate the plug for a puller screw.) Remove the O-ring from
the plug.
Remove the O-rings from the end cap.
Install new O-rings on the end cap and retain with

petroleum jelly.
Install a new O-ring on the solid plug and install the

solid plug into the end cap.
51000168
Fig. 50-26 - Remove Valve Sleeve Bore
Plug Install the cover plate onto the end cap and install the
screws. Torque the screws to 78 Nm (58 ft•lbsf) for
060, 080, or 110 units, or to 110 Nm (81 ft•lbsf) for 160
or 250 units.
Set screws are installed in control orifice holes in the

end cap to plug the valve sleeve bore passages. To
gain access to the screw plugs, remove the outer
plugs from the end cap with a 7/16" or 11/16" hex
wrench. Remove the screw plugs with a 3 mm internal
hex wrench. When installing, torque the screw plugs
51000010
to 4 Nm (35 in•lbsf). Torque the 5/16" outer plugs to
Fig. 50-27 - N2 Control Components 9 Nm (7 ft•lbsf), and the 9/16" outer plugs to 37 Nm (27
ft•lbsf). Refer to the “Control Orifices” topic for addi-
tional information.
The special plug and seal washer on the end cap

opposite the control may be removed with a 13 mm
hex wrench. When installing, torque this plug to 20
Nm (15 ft•lbsf).
51000073 51000074
Fig. 50-28 - Torque Fig. 50-29 - Torque
Cover Plate Screws Plug in End Cap
56 50 - 6
828 BOMAG 008 911 71

saue
Electrohydraulic 2-Position Controls
(Types E1•E2 and F1•F2)
Thoroughly clean external surfaces prior to removing
the control.
The solenoid may be removed from the valve by

removing the nut with a 3/4" hex wrench. The
solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.
51000075 51000076
E1•E2 or F1•F2 Solenoid Valve
Control Solenoid
Remove the screws retaining the valve housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.
The plugs on the control housing may be removed

with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ft•lbsf).
51000013
Components
Install new O-rings onto the valve housing. Install the

valve housing onto the multi-function block, and
install the screws. Torque the screws to 6.4 Nm (4.7
ft•lbsf).
51000077
Fig. 50-33 - Install E1•E2 or F1•F2 Control
Valve Housing
When installing the solenoid valve into the valve

housing, the valve should be torqued to 20 Nm (15
ft•lbsf). When installing the solenoid onto the valve,
torque the nut to 15 Nm (11 ft•lbsf.).
51000078 51000079
Solenoid Valve Solenoid
50 - 7 57
008 911 71 BOMAG 829

saue
Electric 2-Position Controls (Type S1)
the control.
Remove the screws retaining the solenoid and sole-

noid adapter plate to the multi-function block with a 4
mm internal hex wrench. Remove the solenoid and
the solenoid adapter plate from the multi-function
block.
51000164 51000165
Fig. 50-36 - Remove Fig. 50-37 - Remove Remove the solenoid pin from the multi-function
S1 Control Screws Adapter Plate and block.
Solenoid
Install new O-rings onto the adapter plate and the
solenoid.
51000163
Fig. 50-38 - S1 Control Components
Install the solenoid pin into the hole in the multi-

function block.
51000086
Fig. 50-39 - Install S1 Control Solenoid Pin
Install the adapter plate with O-rings onto the multi-

function block.
Install the solenoid with O-ring onto the adapter plate.
Install the screws and torque to 6.4 Nm (4.7 ft•lbsf).
51000165 51000166
Fig. 50-40 - Install Fig. 50-41 - Torque
Adapter Plate and Control Solenoid
Solenoid Screws
58 50 - 8
830 BOMAG 008 911 71

saue
Hydraulic Proportional Control (Type HZ)
of control.
Remove the four (4) screws retaining the valve hous-

ing to the end cap with an 8 mm internal hex wrench
(060, 080, and 110 units) or a 10 mm internal hex
wrench (160 and 250 units). Remove the valve hous-
ing. Remove the O-rings between the valve housing
and end cap, and the O-ring on the valve spool 51000080 51000081
sleeve. Fig. 50-42 - Remove Fig. 50-43 - Remove

HZ Control Housing HZ Control Housing
The plugs on the control housing may be removed Screws
with a 7/16" or 11/16" hex wrench. When reinstalling,
torque the 5/16" plugs to 9 Nm (7 ft•lbsf), and the 9/16"
plugs to 37 Nm (27 ft•lbsf)
The valve housing is equipped with filter screens in
51000016
Fig. 50-44 - HZ Control Components
the passages between the housing and the end cap.

Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end cap.
Units with external servo pressure supply have a plug 51000082 51000083
installed in the end cap passage leading to the valve Fig. 50-45 - HZ Fig. 50-46 - End Cap
spool sleeve. This plug may be removed with a 2.5 Control Housing O-Rings Installed
mm internal hex wrench. When installing this plug, Screens
torque to 2 Nm (18 in•lbsf).
Install a new O-ring onto the valve spool sleeve in the

end cap. Install new O-rings onto the end cap.
Install the valve housing onto the multi-function block,

and install the screws.
Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080,

or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250
units. 51000081 51000084
Fig. 50-47 - Install HZ Fig. 50-48 - Torque
Control Housing HZ Control Valve
Housing Screws
50 - 9 59
008 911 71 BOMAG 831

saue
Hydraulic Proportional Control (Type HS)
of control.

51000087
Fig. 50-49 - Remove HS Control Housing
Screws
The plug on the control housing may be removed with

an 11/16" hex wrench. When reinstalling, torque the
plug to 37 Nm (27 ft•lbsf).
Install a new O-ring onto the valve housing.
51000019
Fig. 50-50 - HS Control Components

and install the screws.
Torque the screws to 6.4 Nm (4.7 ft•lbsf).
51000088
Fig. 50-51 - Torque HS Control Housing
Screws
60 50 - 10
832 BOMAG 008 911 71

saue
Hydraulic Proportional Control with
Maximum Angle Over-ride (Types H1•H2 or
K1•K2)
the control.
The solenoid may be removed from the valve by

removing the nut with a 3/4" hex wrench.
51000089 51000090
H1•H2 or K1•K2 Solenoid Valve
Control Solenoid
The solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.


with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ft•lbsf).
51000091
Fig. 50-54 - Remove Control Housing
Screws
Install new O-rings onto the valve housing.

and install the screws. Torque the screws to 6.4 Nm
(4.7 ft•lbsf).
51000021
Fig. 50-55 - H1•H2 and K1•K2 Control
Components
When installing the solenoid valve into the valve

housing, the valve should be torqued to 20 Nm (15
ft•lbsf).
When installing the solenoid onto the valve, torque

the nut to 15 Nm (11 ft•lbsf.).
51000092 51000093
Solenoid Valve Solenoid
50 - 11 61
008 911 71 BOMAG 833

saue
Two Connection Hydraulic Proportional
Control (Type HP)
of control.
Hold the control housing in position, and remove the

screws retaining the cover and control housing to the
Remove the housing cover and gasket. Remove the
51000094 51000095 valve housing with shuttle valve assembly and pilot
Fig. 50-58 - Remove Fig. 50-59 - Remove piston from the multi-function block.
HP Control Housing Control Housing
Screws Remove the O-rings from the valve housing. Remove
the pilot piston and spring from the valve housing.
Remove the pilot piston pin from the multi-function

block.
Remove the inner shuttle spool plug from the valve

housing. (A 5 mm threaded hole is provided in the
inner plug for a puller screw.) Remove the shuttle
spool from the valve housing. Remove the outer
shuttle spool plug. Remove the O-rings from the
51000096 51000086 plugs.
Shuttle Spool Plug Pilot Piston Pin
Install new O-rings on the shuttle spool plugs.
Install new O-rings on the valve housing and retain

with petroleum jelly.
51000024
Fig. 50-62 - HP Control Components
62 50 - 12
834 BOMAG 008 911 71

saue
Install the pilot piston pin in the multi-function block.
Install the outer (thin) shuttle piston plug with the large
chamfer toward the shuttle valve bore. Install the
shuttle spool into its bore and install the inner (thick)
plug with the large chamfer toward the shuttle valve
bore.
51000097 51000098
Fig. 50-63 - Pilot Fig. 50-64 - Install
Piston Pin Installed Shuttle Spool and
Plugs
Position the valve housing (with O-ring) on the multi-
function block.
Install the pilot piston into the housing and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.
51000099 51000100
Control Housing Pilot Piston
Install the small spring in the outer end of the pilot

piston.
Install the control cover and gasket. Align the control

assembly with the multi-function block and install the
four (4) screws.
Torque the control screws to 6.4 Nm (4.7 ft•lbsf).
51000101 51000102
Spring Cover, Gasket, and
Screws
50 - 13 63
008 911 71 BOMAG 835

saue
Two Connection Hydraulic Proportional
Control for “Dual Path” Vehicles (Type HC)
Bleed Valve
Loosen the seal lock nut on the bleed valve with a 10

mm hex wrench, and remove the valve with a 4 mm
internal hex wrench.
Install the bleed valve and torque to 3 Nm (27 in•lbsf).

51000103 51000175
Fig. 50-69 - Remove Fig. 50-70 - Install
HC Control Bleed HC Control Bleed
Valve Valve
Install the seal lock nut and torque to 19 Nm (14
ft•lbsf).
Servo Pressure Shuttle Valve
Remove the servo pressure shuttle plug with an

11⁄16" hex wrench. Remove the shuttle ball seat with
a 5 mm internal hex wrench and remove the ball.
51000176 51000104
Fig. 50-71 - Install Fig. 50-72 - Remove
HC Control Bleed Servo Pressure Ball
Valve Seal Nut Shuttle Valve
Install the servo pressure shuttle ball.
Install the shuttle ball seat and torque to 11 Nm (8

ft•lbsf). Install the shuttle passage plug and torque to
37 Nm (27 ft•lbsf).
51000123 51000174
Servo Pressure Servo Pressure
Shuttle Ball Valve Shuttle Ball Seat
Control Pressure Shuttle Valve
Remove the shuttle spool plugs with a 1/4" internal

hex wrench. Remove the control pressure shuttle
spool.
Install the control pressure shuttle spool.
Install the shuttle spool plugs and torque to 20 Nm (15

ft•lbsf).
51000105 51000122
Control Pressure Shuttle Spool Plugs
Shuttle Spool
64 50 - 14
836 BOMAG 008 911 71

saue
Pilot Piston and Control Housing
Thoroughly clean external surfaces prior to disas-

sembly of control.
Remove the four (4) screws retaining the cover to the

control housing with a 4 mm internal hex wrench.
Remove the housing cover and gasket (with the

adjusting screw and seal lock nut).
51000177 51000106
HC Control Housing HC Control Housing
Cover Screws Cover
Remove the control start adjustor spring seat and
spring from the pilot piston.
Remove the pilot piston from the control housing.
Remove the pilot piston pin seat and pin from the
control housing (or pilot piston).
Remove the control start spring from the control

housing.
51000107 51000108
Adjustment Spring Pilot Piston Pin and
and Pilot Piston Control Start Spring
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the control housing to
the end cap with an 8 mm internal hex wrench (060,
(160 and 250 units).
Remove the control housing from the end cap. Re-

move the O-rings between the control housing and
the end cap, and the O-ring on the valve spool sleeve.
51000109 51000110
Screws
50 - 15 65
008 911 71 BOMAG 837

saue
with a 7/16" hex wrench or a 1/4" internal hex wrench.
When reinstalling, torque the 5/16" plugs to 9 Nm (7
ft•lbsf), and the 9/16" plugs to 20 Nm (15 ft•lbsf).
51000111
Fig. 50-83 - HC Control Components
The control housing is equipped with filter screens in

the passages between the housing and the end cap.
(0.08 in.) below the machined surface of the valve
housing or end cap.
51000112 51000113
Fig. 50-84 - HC Fig. 50-85 - End Cap Install a new O-ring onto the valve spool sleeve in the
Control Housing O-Rings Installed for end cap. Install new O-rings onto the end cap.
Screens HC Control
Install the valve housing onto the end cap, and install
the screws (with flat washers on 060, 080, and 110
units).
Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080,

and 110 units, or to 110 Nm (81 ft•lbsf) for 160 and
250 units.
51000110 51000114
Screws
66 50 - 16
838 BOMAG 008 911 71

saue
Install the control start spring into the control housing.
Install the pilot piston pin. The end of the pin must
engage the recess in the end of the control valve
spool.
51000115 51000116
HC Control Start Pilot Piston Pin
Spring
Install the pilot piston pin seat.
spring and spring seat. The end of the piston with the
deeper bore and the cross drilled hole should engage
the start spring and pin seat.
51000117 51000118
Pilot Piston Pin Seat HC Control Pilot
Piston
Install the adjustor spring in the outer end of the pilot
piston.
Install the adjustor spring seat.
51000119 51000120
HC Control Start HC Control Start
Adjuster Spring Adjuster Spring Seat
Install the control cover and gasket (with adjusting
screw and seal lock nut).
Torque the control cover screws to 6.4 Nm (4.7

ft•lbsf).
51000106 51000121
HC Control Cover Control Cover
and Gasket Screws
50 - 17 67
008 911 71 BOMAG 839

saue
(Types EP and EQ)
of control.
The Pressure Control Pilot (PCP) valve may be

removed from the control valve housing, as de-
scribed under the following heading.
51000124 51000125 Remove the screws retaining the control housing

Fig. 50-96 - Remove Fig. 50-97 - Remove cover and control valve housing to the multi-function
PCP Valve EP•EQ Control block with a 4 mm internal hex wrench. Remove the
Housing Screws housing cover and gasket.
Remove the valve housing with the pilot piston from

the multi-function block.
Remove the O-rings from the valve housing. Remove

the pilot piston and spring from the valve housing.
Remove the pilot piston pin from the multi-function

block.
51000126 51000086
EP•EQ Control Pilot Piston Pin
Housing
Install new O-rings on the valve housing and retain
with petroleum jelly.

with a 1/4" internal hex wrench. When reinstalling,
torque the 9/16" plugs to 20 Nm (15 ft•lbsf).
51000027
Fig. 50-100 - EQ Control Components (EP
Similar)
68 50 - 18
840 BOMAG 008 911 71

saue
Install the pilot piston pin in the multi-function block.
Position the valve housing (with O-rings) on the multi-

function block.
51000097 51000127
Fig. 50-101 - Pilot Fig. 50-102 - Install
Piston Pin Installed Control Housing
pin. The end of the piston with the cross drilled hole
should engage the pin.
Install the small spring in the outer end of the pilot

piston.
51000128 51000129
Pilot Piston Spring
Install the control cover and gasket. Align the control

assembly with the multi-function block and install the
four (4) screws.
Torque the control screws to 6.4 Nm (4.7 ft•lbsf).
Reinstall the PCP valve, if removed.
51000130 51000131
Fig. 50-105 - Torque Fig. 50-106 - Install
Cover, Gasket, and PCP Valve
Screws
50 - 19 69
008 911 71 BOMAG 841

saue
Pressure Control Pilot (PCP) Valve for
(Types EP and EQ)
Thoroughly clean external surfaces of control.
Using a 4 mm internal hex wrench, remove the four

(4) screws and remove the PCP valve.
Check surfaces for nicks or damage. Clean internal

51000132 51000133 screens.
Fig. 50-107 - Remove Fig. 50-108 - PCP
PCP Valve Screws Valve Components
Install new O-rings on the PCP housing and retain

with petroleum jelly. Position the PCP on the control
valve housing and install the screws.
Torque the screws to 5.4 Nm (48 in•lbsf).
51000124 51000131
PCP onto Control PCP Valve Screws
70 50 - 20
842 BOMAG 008 911 71

saue
Multi-function Block
Removal and Installation
Remove the external control assembly as described
in the instructions for the specific control.
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the multi-function block
51000087 51000134
(160 and 250 units).
Remove the multi-function block from the end cap. External Control (HS Multi-function Block
Remove the O-rings between the multi-function block Shown) Screws
and the end cap, and the O-ring on the valve spool
sleeve.
The multi-function block is equipped with filter screens
in the passages between the block and the end cap.
(0.08 in.) below the machined surface of the multi- 51000135 51000136
function block or end cap. Fig. 50-113 - Remove Fig. 50-114 - Multi-
Multi-function Block function Block
Units with external servo pressure supply have a plug
Screens
installed in the end cap passage leading to the valve
spool sleeve. This plug may be removed with a 2.5
mm internal hex wrench. When installing this plug,
torque to 2 Nm (18 in•lbsf).
Install a new O-ring onto the valve spool sleeve in the
end cap.
Install new O-rings onto the end cap.
Install the multi-function block onto the end cap, and
install the screws. 51000083 51000135
Torque the screws to 78 Nm (58 ft•lbsf) for 060, 080, Fig. 50-115 - End Fig. 50-116 - Install
or 110 units, or to 110 Nm (81 ft•lbsf) for 160 or 250 Cap O-Rings Multi-function Block
units. Installed
Reinstall the external control assembly as described
in the instructions for the specific control.
51000137 51000088
Fig. 50-117 - Torque Fig. 50-118 - Install
Multi-function Block External Control (HS
Screws Shown)
50 - 21 71
008 911 71 BOMAG 843

saue
Servo Pressure Supply Shuttle Spool
Remove the servo pressure supply shuttle spool plug

from the multi-function valve with a 9/16" hex wrench.
NOTE: If a pressure compensator valve block is

installed, the opposite end of the shuttle
spool bore in the multi-function valve is
plugged with an internal hex head plug lo-
cated under the valve block. If a pressure
51000138 51000139
Fig. 50-119 - Remove Fig. 50-120 - Remove compensator valve block is not installed, the
opposite end of the shuttle spool bore is
plugged with a hex head plug.
Supply Spool Plug Supply Shuttle Spool
Remove the servo pressure supply shuttle spool from
the multi-function valve block.
Inspect the shuttle spool for burrs or scoring. The

spool must slide free in its bore. The shuttle ball in the
spool must be free to move.
51000030
Fig. 50-121 - Multi-function Block with
Servo Pressure Supply Shuttle Spool
Install the shuttle spool into the multi-function block.
Install the hex head plug into the multi-function valve

and torque to 37 Nm (27 ft•lbsf).
NOTE: If an internal hex head plug was removed

from the opposite end of the shuttle spool
bore, torque it to 20 Nm (15 ft•lbsf).
51000139 51000140
Supply Shuttle Spool Supply Spool Plug
72 50 - 22
844 BOMAG 008 911 71

saue
Blocking Plate for Multi-function Block Without
PCOR
The blocking plate may be removed by removing the

four (4) screws with a 5 mm internal hex wrench.
Remove the O-rings from the plate.
Install new O-rings on the blocking plate and retain

with petroleum jelly. Install the plate on the multi-
function block and install the screws. Torque the
51000170 51000171
screws to 11 Nm (8 ft•lbsf). Fig. 50-124 - Remove Fig. 50-125 - Torque
Blocking Plate (Less Blocking Plate
PCOR) Screws (Less PCOR)
Pressure Compensator Valve for Pressure
Compensator Over-Ride (PCOR) and Pressure
Compensator Regulator (Type PC)
Loosen the adjusting screw lock nut with a 1-1/16"

hex wrench. Remove the adjusting screw from the
valve block with a large screwdriver.
Remove the pressure compensator valve spring and

the spool assembly from the block.
51000142 51000143
PCOR•PC Adjustor PCOR•PC Spring
and Spool Valve
Remove the valve block plug with a 1" hex wrench.
Remove the four (4) screws retaining the valve block

to the multi-function block with a 5 mm internal hex
wrench. Remove the valve block and O-rings.
51000144 51000145
PCOR•PC Plug PCOR•PC Valve
Block
Install new O-rings on the pressure compensator
valve block and retain with petroleum jelly. Install a
new O-ring on the adjusting screw.
The plugs on the valve block may be removed with a

7⁄16" hex wrench. When reinstalling, torque the 5⁄16"
plugs to 9 Nm (7 ft•lbsf).
51000146
Fig. 50-130 - Pressure Compensator Valve
Block Components
50 - 23 73
008 911 71 BOMAG 845

saue
Install the valve block on the multi-function block and
install the screws. Torque the screws to 11 Nm (8
ft•lbsf).
Install the valve block plug and torque to 54 Nm (40

ft•lbsf).
51000147 51000148
PCOR•PC Valve PCOR•PC Valve Plug
Block
Install the pressure compensator spool assembly
and the valve spring.
Install the adjusting screw and lock nut. Perform the

PCOR or PC regulator pressure adjustment as de-
scribed under “Component Adjustment."
51000143 51000142
PCOR•PC Spring PCOR•PC Adjusting
and Spool Valve Screw
PCOR and PC Regulator Orifices
To gain access to the PCOR or PC regulator orifices,

remove the three (3) plugs located between the
defeat spool stop plugs on the multi-function block,
using a 7/16" hex wrench. Remove the PCOR brake
pressure defeat spool (if installed). Remove the ori-
fice plug(s) and plain plug(s) with a 2.5 mm internal
hex wrench.
51000149
Fig. 50-135 - PCOR and PC Regulator Refer to the appropriate Service Parts Manual for
information on orifice locations and sizes.
Orifices
Install the orifice plug(s) and plain plug(s), and torque
to 4 Nm (35 in•lbsf). Install the outer plugs and torque
to 6 Nm (4 ft•lbsf). Reinstall the PCOR defeat spool (if
removed).
Additional orifices are installed in the passages under

the pressure compensator valve block.
51000172
Fig. 50-136 - PCOR and PC Regulator
Orifices
74 50 - 24
846 BOMAG 008 911 71

saue
PCOR Brake Pressure Defeat Spool
Remove the PCOR defeat spool bore plugs or fittings

with a hex wrench.
Remove the PCOR defeat spool stop plugs with a

7⁄16" hex wrench. Remove the defeat spool.
NOTE: The defeat spool may be removed from

either end of its bore in the multi-function block.
51000150 51000151
PCOR Defeat Spool PCOR Defeat Spool
Plug or Fitting Stop Plug
Inspect the defeat spool for burrs or roughness. The
spool must slide freely in its bore. Inspect the pins in
the stop plugs for damage.
51000032
Fig. 50-139 - Multi-function Block With
PCOR Defeat Spool Components
Install the PCOR defeat spool into its bore in the multi-
function block.
Install the spool stop plugs into the multi-function

block. Torque the stop plugs to 6 Nm (4 ft•lbsf).
Install the defeat spool bore plugs or fittings and

torque to 27 Nm (20 ft•lbsf).
51000152 51000153
PCOR Defeat Spool PCOR Defeat Spool
Stop Plug
50 - 25 75
008 911 71 BOMAG 847

saue
Pressure Compensator Regulator (Type
PC)
The PC regulator utilizes the multi-function block and
pressure compensator valve to control the motor
displacement.
Service procedures for these components are in-
cluded in the “Multi-function Block” section of this
manual.
51000035
Fig. 50-142 - PC Regulator Components
A valve sleeve bore plug is installed in the motor end

cap in place of the valve spool sleeve. Remove the
plug from the valve sleeve bore in the end cap. (An 8
mm threaded hole is provided in the plug for a puller
screw.) Remove the O-ring from the plug.
A single servo drain orifice is installed in the valve
sleeve bore plug. This orifice limits oil flow from the
maximum displacement end of the servo piston to the
motor case.
51000169 51000173
Fig. 50-143 - Remove Fig. 50-144 - Servo Install a new O-ring on the valve sleeve bore plug.
Valve Sleeve Bore Drain Orifice (T7) Install the bore plug into the end cap.
Plug
The special plug and seal washer on the end cap
opposite the multi-function block may be removed
with a 13 mm hex wrench. When installing, torque this
plug to 20 Nm (15 ft•lbsf).
76 50 - 26
848 BOMAG 008 911 71

saue
Control Orifices
Orifices are installed in the motor end cap to regulate
oil flow to the servo control valve and the servo piston.
To gain access to these orifice plugs, remove the

three (3) plugs located on the motor end cap nearest
the multi-function block or control, using a 7⁄16" or
9⁄16" hex wrench. Remove the orifice plugs (plain
plugs for N2 control) with a 3 mm internal hex wrench.
51000154 51000155
Install the orifice plugs, and torque to 4 Nm (35 Fig. 50-145 - Servo Fig. 50-146 - Servo
in•lbsf). Torque the 5⁄16" outer plugs to 9 Nm (7 Pressure Supply Orifice for Maximum
ft•lbsf), and the 9⁄16" outer plug to 37 Nm (27 ft•lbsf). Orifice (T1) Displacement (T2)
Orifices are also installed in the servo control valve
sleeve to control oil flow from the servo piston to the
motor case.
51000156 51000157
Fig. 50-147 - Servo Fig. 50-148 - Servo
Orifice for Minimum Drain Orifices (T7
Displacement (T3) and T8)
Plug / Fitting Torques
If any plugs or fittings are removed from the unit
during servicing, they should be torqued as indicated
in the accompanying table.
Item Torque
Pressure Gauge Ports 37 Nm
(9/16—18 O-Ring Hex) (27 ft•lbsf)
Construction Plugs 20 Nm
(9/16—18 O-Ring Int. Hex) (15 ft•lbsf)
Construction Plugs 9 Nm
(5/16—24 O-Ring) (7 ft•lbsf)
Screw Plugs 4 Nm
(M6 Int. Hex) (35 in•lbsf)
50 - 27 77
008 911 71 BOMAG 849

78
850
DO NOT REMOVE UNTIL CONTROL VALVE AND
16.3
SPRINGS ARE REMOVED!

Remove as an assembly to preserve adjustment.
INSTALL BEFORE INSTALLING SPRINGS AND
CONTROL VALVE!
J70 For Proportional Controls
J60 [Except HC]
J40 (060 — 110 Frame Sizes)
For Proportional Controls
Items T1, T2, and T3: [Except HC]
3 mm internal hex wrench; (160 — 250 Frame Sizes)
J50
Torque to 5 Nm (44 lbsf•in)
4 mm internal S20
hex wrench T2
saue
S10
S20
J30
J10
S10 S70
BOMAG
J30
J10
T1 S70
T3
Remove Item T1 BEFORE removing Item F32! T7
Install Item T1 AFTER installing Item F32! F32
J30
Install O-ring J10 F33
a
Genuine
on adjustor screw J20 T8

Service Parts
13 mm hex wrench
Torque to 20 Nm Items T7 and T8:
(15 lbsf•ft) For 2-Position Controls 2.5 mm int. hex wrench
4-Way Valve and Feedback Springs
10 mm hex wrench [Except N2] Torque to 2 Nm (18 lbsf•in)

Torque to 9 Nm (6.6 lbsf•ft) 5 mm threaded holes
after adjustment for puller screws
FOR 2-POSITION CONTROLS,
Sheet 1 of 2
Install O-rings
DO NOT DISTURB ADJUSTMENT! on valve sleeve
Series 51 MV
Travel drive series 51
008 911 71
DO NOT REMOVE UNTIL CONTROL VALVE AND
008 911 71
SPRINGS ARE REMOVED!
Remove as an assembly to preserve adjustment (060 — 110).
INSTALL BEFORE INSTALLING SPRINGS AND
CONTROL VALVE!
S50
S30
Travel drive series 51
For 060 — 110 Frame Sizes

S60
Items T1, T2, and T3: For 160 — 250 Frame Sizes
S40 3 mm internal hex wrench;
4 mm internal
hex wrench T2 S20
saue
S11T
S10
S20 S10T
BOMAG
S70
S11T
T1 S10
T3 S10T
S70
Remove Item T1 BEFORE removing Item F32!
T7
Install Item T1 AFTER installing Item F32!
F32
Install O-ring
a
Genuine
on adjustor screw F33

Service Parts
T8
13 mm hex wrench
Torque to 20 Nm Items T7 and T8:
(15 lbsf•ft) 2.5 mm int. hex wrench
10 mm hex wrench
Torque to 9 Nm (6.6 lbsf•ft) 5 mm threaded holes
Sheet 2
after adjustment. for puller screws

Install O-rings
4-Way Valve and Feedback Springs - HC Control
on valve sleeve
Series 51 MV
79
16.3
851
saue
Hydraulic Power Systems
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SAUER-SUNDSTRAND is a world leader in the design SAUER-SUNDSTRAND specializes in integrating a full
and manufacture of Hydraulic Power Systems. Research range of system components to provide vehicle
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F000 692 F000 691 F000 686
Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors/
Pumps and Motors Variable Motors Compact Wheel Drives
F000 685 F000 688 F000 690 F000 684
Medium Duty Axial Piston Microcontrollers and Hydrostatic Transmission

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F000 689 F000 687 F000 693
Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts
Worldwide Service Support
SAUER-SUNDSTRAND provides comprehensive worldwide service for its

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strategically located in all parts of the world.
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SAUER-SUNDSTRAND COMPANY SAUER-SUNDSTRAND GMBH & CO.

saue 2800 East 13th Street • Ames IA 50010 • U.S.A.
Phone: (515) 239-6000 • FAX: (515) 239-6618
Postfach 2460 • D-24531 Neumünster
Krokamp 35 • D-24539 Neumünster • Germany
TWX: 9105201150 Phone: (04321) 871-0 • FAX: (04321) 871 122
SM-VMV51E • 11/97 • 300 043A
BLN-10043 • November 1997
852 BOMAG 008 911 71

16.4 Transmission CR
008 911 71 BOMAG 853

854 BOMAG 008 911 71

Transmission CR 16.4
3ERIES#2
#OMPACT
2OLLER$RIVE
3ERVICE-ANUALAND
2EPAIR)NSTRUCTION
008 911 71 BOMAG 855

3ERIES#2n#OMPACT2OLLER$RIVE
3ERVICE-ANUALAND2EPAIR)NSTRUCTION
)NTRODUCTION
).42/$5#4)/. 4HISBROCHUREREPRESENTSINFORMATIONFORNORMALSERVICEASWELLASANINSTRUCTIONFOR
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TORQUEOF.M;LBFsIN=FOR#2AND.M;LBFsIN=FORTHE#2
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BERETURNEDTO3AUER $ANFOSS.EUMàNSTER
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856 BOMAG 008 911 71

#ONTENTS
#/.4%.43 )NTRODUCTION
-ODEL#ODE
$ESCRIPTION
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4ECHNICAL&EATURES
3CHEMATIC
$ESIGN
4YPEOF-OUNTING
$IRECTIONOF2OTATION
)NSTALLATION0OSITION
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/UTLINE$RAWINGS
2OLLER$RIVE'EARBOXWITH#ARTRIDGE-OTORn#2
2OLLER$RIVE'EARBOXWITH#ARTRIDGE-OTORn#2
2EPAIR)NSTRUCTION
'ENERAL
$ISASSEMBLY
'EARAND0LANET#ARRIERS$ISASSEMBLY
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!SSEMBLY
'EARAND0LANET#ARRIERS
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3CREW4ORQUE
%XPLODED6IEWS
%XPLODED6IEWn#2!
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#ROSS3ECTION6IEWn#2!
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$+-(03$,2EV!n
008 911 71 BOMAG 857

-ODEL#ODE
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3ERIESOR0RODUCT 2EVISIONSTATUSOFUNIT
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#2 #OMPACT 2OLLER
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3PECIALHARDWAREFEATURES
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/UTPUTTORQUE
4"
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! 4$
; LB FsIN =
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; LB FsIN =
. M

; LB FsIN = 3HAFTSPLINEMOTOR 2 A T IO
# 7XXX M
# $ ). M
TEETH
3PINDLEANDMOTORCONFIGURATION M
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WITH MECH BRAKE RELEASE
! M M
#
WITH SPECIAL BRAKE RELEASE
! M
+
WITH SPECIAL BRAKE RELEASE "RAKE
! M
+ / NOT AVAILABLE BRAKE
WITH SPECIAL BRAKE RELEASE WITH BRAKE
! M +
# STATIC BRAKE TORQUE INPUT SHAFT .M ; LBFsIN=
.OT AVAILABLE
M /PTIONAL
$+-(03$,2EV!n
858 BOMAG 008 911 71

$ESCRIPTION0OWER&LOW$IAGRAM
$%3#2)04)/. 2OLLER$RIVESCONSISTOFTWO ORTHREE SIMPLEPLANETARYSTAGESCONNECTEDINSERIES

%ACHPLANETARYSTAGECONSISTSOFASUNPINIONINPUT GEARANINTERNALTOOTHRINGGEARAND
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878 BOMAG 008 911 71

16.5 Axle DANA 193
008 911 71 BOMAG 879

16.5 Axle DANA 193
880 BOMAG 008 911 71

Axle DANA 193 16.5
008 911 71 BOMAG 881

16.5 Axle DANA 193
882 BOMAG 008 911 71

Axle DANA 193 16.5
008 911 71 BOMAG

1 883
16.5 Axle DANA 193
PRINTED IN ITALY
Copyright By DANA ITALIA S.p.A.
Vietata la riproduzione anche parziale di testo ed illustrazioni
Realizzazione a cura dell'Ufficio Post Vendita della DANA ITALIA S.p.A.
Impaginazione: TEMAS s.r.l. - Gallarate (Va)
Stampa: Agosto 1999 (N.L. 7416)
Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have
not been tested and submitted for approval.
Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilitaÁ per l'utilizzo di componenti non originali o accessori
non collaudati ed approvati.
AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder
nicht abgenommenem und genehmigtem ZubehoÈr abgelehnt.
Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o
bien de accesorios no ensayados y aprobados.
Le constructeur se reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous
deÂclinons toute responsabiliteÂ pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.
884 BOMAG
2 008 911 71
Axle DANA 193 16.5
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
INTRODUCTION ..........................................................5 DIFFERENTIAL UNIT

GB MAINTENANCE AND LUBRICANTS . Removal and disassembly ....................................................44
. Definition of viewpoints............................................7 . Assembly and installation .....................................................54
. Data plate ..............................................................................7 REDUCTION GEAR AND BEVEL PINION
. Maintenance points ................................................................7 . Disassembly.........................................................................68
. Maintenance intervals.............................................................8 . Installation and adjustment ...................................................74
. Adjustment and checks ..........................................................8
. Conversion tables...................................................................9 SPECIAL TOOLS ......................................................................82
. Tightening torques .................................................................9
. Screw-locking, sealing, and lubricating materials ...................10
NOTES ON SAFETY PRECAUTIONS ........................................13
CHECKING WEAR AND REPLACING THE BRAKING DISKS
. Disassembling the braking units............................................14
. Assembling the braking units ................................................20
. Mechanical and manual release of the axle ...........................28
PLANETARY REDUCTION AND AXLE SHAFT
. Disassembly.........................................................................30
. Assembly .............................................................................38
INTRODUZIONE .......................................................5 GRUPPO DIFFERENZIALE

ITA . Rimozione e smontaggio.......................................................44
MANUTENZIONE E LUBRIFICANTI
. Definizione viste ..................................................7 . Assemblaggio ed installazione ..............................................54
. Targa matricola ......................................................................7 RIDUTTORE E PIGNONE CONICO
. Punti di manutenzione ............................................................7 . Smontaggio..........................................................................68
. Intervalli di manutenzione .......................................................8 . Installazione e registrazione..................................................74
. Registrazione e controlli .........................................................8 ATTREZZI SPECIALI.................................................................82
. Tabelle di conversione............................................................9
. Coppie di serraggio ................................................................9
. Materiali per bloccaggio viti, tenuta e lubrificazione................10
NOTE RIGUARDANTI LA SICUREZZA ......................................13
CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO
. Smontaggio gruppi di frenatura .............................................14
. Assemblaggio dei gruppi di frenatura ....................................20
. Sbloccaggio meccanico manuale dell'assale..........................28
RIDUTTORE EPICICLOIDALE E SEMIASSE
. Smontaggio..........................................................................30
. Assemblaggio ......................................................................38
VORAUSSETZUNG .................................................5 DIFFERENTIAL

D . Abmontieren und zerlegen ....................................................44
WARTUNG UND SCHMIERSTOFFE
. Definition der Ansichten......................................7 . Montieren und installieren.....................................................54
. Kennummernschild.................................................................7 REDUZIERER UND KEGELRAD
. Wartungsstellen .....................................................................7 . Abmontieren ........................................................................68
. Wartungsintervalle..................................................................8 . Installieren und einstellen .....................................................74
. Einstellungen und Kontrollen ..................................................8 SONDERWERZZEUGE ..............................................................82
. Umrechnungstabellen.............................................................9
. Anziehdrehmomente...............................................................9
. Material zur Blockierung von Schrauben und
fuÈr Dichtungen und Schmiermittel .........................................10
BEMERKUNGEN ZUR SICHERHEIT...........................................13
VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN
AUSWECHSELN
. Bremsaggregate abmontieren ...............................................14
. Bremsaggregate montieren ...................................................20
. Achse mechanisch manuell entsichern ..................................28
PLANETENGETRIEBE UND HALBACHSE
. Abmontieren ........................................................................30
. Montieren ............................................................................38
008 911 71 BOMAG

3 885
16.5 Axle DANA 193
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
PROLOGO................................................................ 5 GRUPO DIFERENCIAL

ESP MANTENIMIENTO Y LUBRICANTES . Remocion y desmontaje ....................................................... 44
. Definicion vistas................................................... 7 . Montaje e instalacion ........................................................... 54
. Matricula ............................................................................... 7 REDUCTOR Y PINÄON CONICO
. Puntos de manutencion.......................................................... 7 . Remocion ............................................................................ 68
. Intervalos de manutencioÁn...................................................... 8 . Instalacion y ajuste .............................................................. 74
. Ajuste y controles .................................................................. 8 HERRAMIENTAS ESPECIALES................................................. 82
. Tablas de conversion ............................................................. 9
. Pares de torsion .................................................................... 9
. Materiales para el bloqueo, estanqueidad y lubricacion ......... 10
NORMAS CONCERNIENTES A LA SEGURIDAD ....................... 13
CONTROL DEL DESGASTE Y SUSTITUCION DE LOS
DISCOS DEL FRENO
. Montaje de los grupos de frenado......................................... 14
. Desmontaje de los grupos de frenado................................... 20
. Desbloqueo manual de los axal ............................................ 28
REDUCTOR EPICICLOIDAL Y SEMIEJES
. Desmontaje ......................................................................... 30
. Montaje ............................................................................... 38
INTRODUCTION ....................................................... 5 GROUPE DIFFERENTIEL

F ENTRETIEN ET LUBRIFIANTS . Depose et demontage .......................................................... 44
. DeÂfinition vues ..................................................... 7 . Assemblage et installation .................................................... 54
. Plaque d'immatriculation ........................................................ 7 REDUCTEUR ET PIGNON CONIQUE
. Points d'entretien................................................................... 7 . Depose................................................................................ 68
. Intervalle de service ............................................................... 8 . Installation et reglage ........................................................... 74
. Reglages et controles............................................................. 8 OUTILS SPECIAL ..................................................................... 82
. Tableaux de conversion ......................................................... 9
. Couples de serrage................................................................ 9
. MateÂriaux pour le blocage vis, eÂtancheÂiteÂ et lubrification........ 10
NOTES EN MATIERE DE SECURITE......................................... 13
CONTROLE D'USURE ET SUBSTITUTION DES
DISQUES DE FREINAGE
. Desassemblage des groupes de freinage .............................. 14
. Assemblage des groupes de freinage ................................... 20
. Deblocage mecanique manuel de l'essieu............................. 28
REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU
. Demontage.......................................................................... 30
. Assemblage......................................................................... 38
886 BOMAG
4 008 911 71
Axle DANA 193 16.5
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, pullers and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la DANA ITALIA S.p.A..
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of DANA ITALIA mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
S.p.A.. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Abzieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
008 911 71 BOMAG
5 887
16.5 Axle DANA 193
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos de
Spiele, Vorspannungen und Drehmomente strengstens ein- las herramientas especificas necesarias para la ejecucioÂn de las
gehalten werden. intervenciones de mantenimiento figuran al final del manual; los
recambios se pueden pedir al fabricante de la maÂquina o
È LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern directamente al Service Center o a Distribuidores autorizados de
GU DANA ITALIA S.p.A..
die Einheiten gehoÈren. Der Einfachheit halber sind die
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer
= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
DANA ITALIA S.p.A. bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
El rendimiento y la duracioÂn de los oÂrganos mecaÂnicos
fournis par le constructeur du veÂhicule. En deÂcrivant les
ESP depende, ademaÂs que del constante y correcto opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mantenimiento, tambieÂn de la intervencioÂn inmediata enleveÂ du veÂhicule.
en caso de averõÂas o anomalõÂas.
Al proponer este manual, ha sido considerada la suposicioÂn de una IMPORTANT: Pour faciliter le travail en sauvegardant en
revisioÂn general del grupo, pero es el mecaÂnico quien tiene que meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
valorar la necesidad de montar cada uno de los componentes en teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
caso de reparacioÂn. El manual es una guõÂa raÂpida y segura que telles que des eÂtais ou banc de support, maillets en plastique
permite intervenciones precisas por medio de fotografõÂas y de ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
planos que muestran las distintas fases de las operaciones. A
continuacioÂn figuran todas las informaciones y advertencias Avant de proceÂder au deÂmontage des parties et vidanger
necesarias para ejecutar un montaje correcto, para las comproba- l'huile, il vaut mieux nettoyer soigneusement le pont, en
ciones y el montaje de cada uno de los componentes. Para enlevant incrustations et blocs de gras.
remover el puente diferencial del vehõÂculo hay que consultar los
manuales de los fabricantes del vehõÂculo. En la descripcioÂn de las PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
operaciones siguientes se supone que el puente ya ha sido sacado doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
del vahõÂculo. approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
IMPORTANTE: Para facilitar el trabajo salvaguardando al mismo particulier, de toutes les parties en mouvement (paliers,
tiempo las superficies mecanizadas y la seguridad de los
operadores, se aconseja que se usen equipos y herramientas engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
adecuados como caballetes y bancos de soporte, martillos de bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
plaÂstico o de cobre, palancas adecuadas, extractores y llaves sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
especõÂficas. substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
Antes de desmontar las partes y descargar el aceite, es effectue une reÂvision ou une reÂparation des composants. Au
conveniente que se haga una limpieza minuciosa del puente moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
sacando las incrustaciones y acumulaciones de grasa. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
conique, la substitution de l'un de ses engrenages comporte
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados eÂgalement la substitution de l'autre. En phase de montage, il
tienen que ser limpiados minuciosamente con productos adecua-
dos y restaurados o sustituidos en el caso de que presenten danÄos, faut respecter scrupuleusement les jeux, les preÂcharges et les
desgaste, rajaduras, agarrotamientos, etc. En particular, compro- couples prescrits.
bar la integridad de todas las partes en movimiento (cojinetes,
engranajes, par coÂnico, ejes) y de estanqueidad (anillos OR, VALIDITE: Le manuel fournit la validiteÂ des groupes sous
detenedor de aceite) sujetas a mayores solicitaciones y desgaste. forme de matricule. Pour une meilleure interpreÂtation, les
Se aconseja, de todas formas, que se sustituyan los oÂrganos de validiteÂs sont indiqueÂes comme:
estanqueidad cada vez que se ejecute la revisioÂn o reparacioÂn de
los componentes. = jusqu'aÁ l'immatriculation
Al volver a montar, los segmentos de compresioÂn tienen que estar
lubricados en los bordes de estanqueidad. En el caso del par = aÁ partir de l'immatriculation et apreÁs
coÂnico, la sustitucioÂn de uno de sus engranajes comporta tambieÂn
la sustitucioÂn del otro. Al montar hay que tener en cuenta Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
escrupulosamente los juegos, las precargas y los pares descriptos.
deÂmontage et d'assemblage sont pareilles dans toutes les
VALIDEZ: El manual suministra la validez de los grupos en forma versions.
de matrõÂcula. Para poder tener una interpretacioÂn correcta, la
validez estaÂ indicada: INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
Les dessins des installations speÂcifiques neÂcessaires pour
= hasta la matrõÂcula effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
= desde la matrõÂcula en adelante constructeur de la machine ou directement aux Centres de
Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ DANA ITALIA
S.p.A..
888 BOMAG
6 008 911 71
Axle DANA 193
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
16.5
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES
LEFT SIDE RIGHT SIDE

LATO SINISTRO LATO DESTRO
LINKE SEITE RECHTE SEITE
LADO IZQUIERDO LADO DERECHO
COTE GAUCHE COTE DROITE
D1240138
DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION
Type and model unit - modification index
1
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - AÈ nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modeÂle de ensemble - tableau des modifications
1 2 Serial number
2
Numero di serie
Seriennummer
3 NuÂmero de serie
Numero de serie
MFG. BY CLARK-HURTH COMPONENTS S.P.A. Lubricant
3
38062 Arco (Trento) Lubrificante
Schmieroel
MADE IN ITALY Lubricante
Lubrificant
D1240011
MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN
3 1 1 1 3
2 2 2 2
2
1
Oil filling plug - Tappo di carico
EinfuÈllstopfen - Tapon de carga
Bouchon de ravitaillement
2
Oil draining plug - Tappo di scarico
1 3 Ablasstopfen - Tapon de descarga
Bouchon de vidange
2
3
Check level plug - Tappo controllo livello
È lpegelkontrolle -
Stopfen zur O
Tapon de contrl de nivel - Jauge de niveau
D1240139
008 911 71 BOMAG

7 889
16.5 Axle DANA 193
MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE
OPERATION - OPERAZIONE - FREQUENCY - PERIODICITAÁ

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
ARBEITSVORGANG - - ZEITABSTAND -
LUBRICANTES - LUBRIFIANTS
OPERACION - OPERATION FRECUENCIA - PERIODICITE
Differential monthly
Differenziale mensile
Im differential monatlich . SAE85W90 (API GL4 - MIL L-2105)
. Check levels: Diferencial cada mes With additives for oil-bath brakes
. Controllo livelli: Differentiel mensuel Con additivi per freni a bagno d'olio
. È
Olstandkontrolle: Mit Zusatzmittel fuÈr Bremsen in OÈ lbad
. Control niveles: Planetary reduction every 200 hours
Con aditivos para frenos de banÄo de aceite
. ControÃle niveaux: Riduzione epicicloidale ogni 200 ore
Avec adjuvants pour freins en bain d'huile
Planetengetrieb alle 200 Std.
ReduccioÂn epicicloidal cada 200 horas . SAE85W90 (API GL5 - MIL 2105-B)
Reduction epicycloidale toutes les 200 heures With additives for oil-bath brakes, for units pre-
Differential every 800 hours ] senting hypoid crown wheel and pinion and /or
Differenziale ogni 800 ore self-locking differential gear
Im differential alle 800 Std. Per esecuzioni con coppia conica ipoide e/o con
Diferencial cada 800 horas differenziale autobloccante, con additivi per freni
Differentiel toutes les 800 heures a bagno d'olio
Bei AusfuÈhrungen mit Kegel- und Telleradpaar
. Oil change: Planetary reduction every 1000 hours ]
und/oder Selbstsperrdifferential, mit Zusatzmit-
. Cambio olio: Riduzione epicicloidale ogni 1000 ore È lbad
È lwechsel: teln fuÈr Bremsen in O
. O Planetengetrieb alle 1000 Std.
Para ejecuciones con par coÂnico hipoide y/o con
. Cambio aceite: ReduccioÂn epicicloidal cada 1000 horas
diferencial autobloqueante con aditivos para fre-
. Vidange huile: Reduction epicycloidale toutes les 1000 heures
nos de banÄo de aceite.
Self-locking differential gear every 700 hours ] r Pour exeÂcutions avec couple conique hypoõÈde et/
Differenziale autobloccante ogni 700 ore ou diffeÂrentiel autobloquant, avec adjuvants pour
Selbstsperrdifferential alle 700 Std. freins en bain d'huile
Diferencial autobloqueante cada 700 horas
Differentiel autobloquant toutes les 700 heures
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas
de trabajo - Initialement apreÁs 100 heures de travail
r When it starts sounding noisy - Anche ai primi cenni di rumorositaÁ - Auch falls ungewoÈhnliche GeraÈusche zu bemerken sind - TambieÂn al primer
indicio de ruido - MeÃme aux premiers signaux de bruit
OPERATION - OPERAZIONE - MEMBER - ORGANO - CONDITIONS - CONDIZIONI - FREQUENCY - PERIODICITAÁ - LUBRICANTS - LUBRIFICANTI -
ARBEITSVORGANG - ELEMENT - BEDINGUNG - ZEITABSTAND - SCHMIERSTOFFE -
OPERACION - OPERATION ORGANO - ORGANE CONDICIONES - CONDITIONS FRECUENCIA - PERIODICITE LUBRICANTES - LUBRIFIANTS
Normal work monthly
Lavori normali mensile
Normale Arbeit monatlich
Greasing Articulations Trabajos normales cada mes
Ingrassaggio Snodi TaÃches ordinaires mensuel
Schmieren Gelenk MOLIKOTE
Engrase RoÂtula Awkward work Weekly
Graissage Articulations Lavori gravosi Settimanale
Schwere Arbeit WoÈchentlich
Trabajos pesados Semanal
TaÃches extraordinaires Hebdomadaire
ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES
UNIT - GRUPPO - OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
AGGREGAT - ARBEITSVORGANG - ZEITABSTAND - BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
GRUPO - GROUPE OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS
Negative brake Adjustment every 1000 hours ]
Freno negativo Registrazione ogni 1000 ore Only for mineral oil use e.g. ATF Dexron II. Make sure
Federspeicherbremse Einstellen alle 1000 Std. that master cylinder seals are suitable for mineral oil.
Freno negativo Ajuste cada 1000 horas Usare esclusivamente olio minerale ATF Dexron II. Ac-
Frein neÂgatif ReÂglage toutes les 1000 hours certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Service brake Adjustment every 500 hours È l verwenden, z.B.: ATF Dexron II.
Nur mineralisches O
Freni di servizio Registrazione ogni 500 ore
Achtung: Dichtringe des Hauptbremszylinders muÈs-
Hilfsbremse Einstellen alle 500 Std. È l geeignet sein.
sen fuÈr dieses O
Frenos de ejercicio Ajuste cada 500 horas
Usar exclusivamente aceite mineral ATF Dexron II.
Freins de service ReÂglage toutes les 500 hours
Asegurarse de que las juntas del cilindro principal
Wheel nuts Tightening every 200 hours son adecuadas para este aceite.
Dadi ruota Serraggio - ogni 200 ore Utiliser exclusivement huile mineÂrale ATF Dexron II.
Radmuttern Festziehen alle 200 Std. VeÂrifier que les joints du maõÃtre-cylindre, soien compa-
Tuercas rueda Apriete cada 200 horas tibles avec cette huile.
Ecrous de roue Serrage toutes les 200 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100
horas de trabajo - Initialement apreÁs 100 heures de travail
890 BOMAG
8 008 911 71
Axle DANA 193 16.5
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN

TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
Units of pressure - UnitaÁ di pressione - Druckeinheiten

Unidad de presioÂn - UniteÂs de pression: 1 Atm%1 bar%105 PA%14.4 PSi
Units of weight - UnitaÁ di peso - Gewichtseinheiten Units of torque - UnitaÁ di coppia - Drehmomenteinheiten
Unidad de peso - UniteÂs de poids Unidad de par - UniteÂs de couple
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE
Unit - UnitaÁ di misura - Meûeinheiten - Unidad de medida - UniteÂs de mesure: Nm

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS 8.8 10.9 12.9
TAMAN Ä O TORNILLO
MESURE VIS Normali Normali Normali Normali Normali Normali
+ Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270
M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0
COARSE PITCH - PASSO GROSSO - GROûER
SCHRITT - PASO GRUESO - GROS PAS
M8 x 1,25 23,8-26,2 25,6-28,4 34,2-37,8 36,7-40,5 39,0-43,0 43,7-48,3

M10 x 1,5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1,75 82-91 90-100 116-128 126-139 139-153 152-168
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263
M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2,5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2,5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2,5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3,5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
FINE PITCH - PASSO FINE - KLEINER SCHRITT
M8 x 1 25,7-28,3 27,5-30,5 36,2-39,8 40,0-44,0 42,8-47,2 47,5-52,5

M10 x 1,25 49,4-54,6 55,2-61,0 71,5-78,5 78,0-86,0 86,0-94,0 93,0-103,0
M12 x 1,25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1,5 86-95 94-104 120-132 133-147 143-158 159-175
PASO FINO - PAS FIN
M14 x 1,5 143-158 157-173 200-222 219-242 238-263 261-289

M16 x 1,5 214-236 233-257 302-334 333-368 361-399 394-436
M18 x 1,5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1,5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1,5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082
008 911 71 BOMAG

9 891
16.5 Axle DANA 193
SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -
MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION
1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
I materiali per il bloccaggio, tenuta e lubrificazione specifica indicati nel manuale, sono quelli usati in fabbrica.
Die Materialien zur Blockierung von Schrauben, fuÈr Dichtungen und Schmiermittel, die im Handbuch aufgefuÈhrt sind, sind
dieselben die auch vom Hersteller verwendet werden.
Los materiales para el bloqueo, estanqueidad y lubricacioÂn especõÂfica indicados en el manual, son los que se usan en la faÂbrica
Les mateÂriaux de blocage, d'eÂtancheÂiteÂ et de lubrification speÂcifieÂs indiqueÂs dans ce manuel sont ceux employeÂs aÁ l'usine.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar
products marketed by different brand names with different trade marks.
Di questi materiali, vengono riportate le applicazioni tipiche che li distinguono, in modo da poterli sostituire con prodotti similari
commercializzati da altre marche e quindi con altre sigle.
Von diesen Materialien werden die typischen Anwendungen genannt, um sie mit aÈhnlichen Materialien zu ersetzen, die unter
anderen Namen und Kennzeichnungen im Handel erhaÈltlich sind.
De estos materiales damos las aplicaciones tõÂpicas que los distinguen, de manera que se puedan sustituir con productos similares
comercializados por otras marcas y por tanto con otras siglas.
De ces mateÂriaux ne sont reporteÂes que les applications typiques qui les distinguent de telle sorte qu'ils puissent eÃtre substitueÂs
par des produits semblables se trouvant dans le commerce sous d'autres marques et par conseÂquent sous d'autres sigles.
DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength loc-
king. Before using it, completely remove any lubricant by using the specific activator.
. Prodotto anaerobico adatto a prevenire l'allentamento di viti, dadi e tappi. Usato per la frenatura a media re-
sistenza. Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
. Anaerobes Produkt, um das Lockern von Schrauben, Muttern und Stopfen zu verhindern. FuÈr mittlere Wi-
derstandskraÈfte geeignet. Darf erst aufgetragen werden, wenn die FlaÈchen von Schmiermittel richtig sauber
Loctite 242
sind. Dazu das entsprechende Produkt verwenden.
. Producto anaeroÂbico apto para prevenir el aflojamiento de tornillos, tuerca y tapones. Usado para el frenado
de media resistencia. Tiene que ser usado soÂlo despueÂs de haber quitado todo residuo de lubricante con el
activador especõÂfico.
. Produit anareÂobic servant aÁ preÂvenir le relaÃchement des vis, eÂcrous et bouchons. UtiliseÂ pour le freinage
demi reÂsistant. Il doit eÃtre utiliseÂ apreÁs avoir enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
. Prodotto alternativo al 242 che, essendo oleocompatibile, non richiede l'attivazione di superfici lubrificate.
. Alternatives Produkt zu Loctite 242. Da es oÈlkompatibel ist muÈssen die geschmierten FlaÈchen nicht aktiviert
Loctite 243 werden.
. Producto alternativo al 242 que, siendo oleocompatible, no requiere la activacioÂn de superficies lubricadas.
. Produit en alternance avec le 242 lequel eÂtant oleÂocompatible ne requiert aucune activation des surfaces
lubrifieÂes.
. Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any
lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80ëC approx.
. Prodotto anaerobico adatto per la frenatura ad altissima resistenza di viti e dadi. Deve essere usato dopo aver
asportato ogni traccia di lubrificante con l'attivatore specifico.
La rimozione delle parti, puoÁ richiedere un riscaldamento a circa 80ëC.
. Anaerobes Produkt fuÈr hohe WiderstandskraÈfte fuÈr Schrauben und Muttern geeignet. Zuerst die FlaÈche sorg-
Loctite 270
faÈltig aktivieren. Um die FlaÈchen zu saÈubern, diese auf ca. 80ëC erwaÈrmen.
. Producto anaeroÂbico apto para el frenado de alta resistencia de tornillos y tuercas. tiene que ser usado de-
spueÂs de haber quitado todo residuo de lubricante con el activador especõÂfico.
La remocioÂn de las partes, puede requerir un calentamiento a unos 80ëC.
. Produit anareÂobic apte au freinage aÁ treÁs haute reÂsistance des vis et des eÂcrous. Il doit eÃtre utiliseÂ apreÁs avoir
enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts,
for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a max.
diametrical clearance of 0.25 mm.
. Prodotto anaerobico adatto per la frenatura e sigillatura ad alta resistenza di parti filettate, bulloni e prigionieri
di grandi dimensioni, protezione antimanomissione e sigillatura di tubazioni; puoÁ sigillare accoppiamenti con
gioco diametrale massimo di 0,25 mm.
. Anaerobes Produkt zum Bremsen und Siegeln von groûen Gewinden, Muttern und Stiftschrauben , sehr
Loctite 275 widerstandsfaÈhig, verschleierungsbestaÈndig, und zum Siegeln von Rohrleitungen geeignet; kann Kupplun-
gen mit einer maximalen Lagerluft von 0,25 mm siegeln.
. Producto anaerobico apto para el frenado y selladura a alta resistencia de tornillos, tuercas y prisioneros de
grandes dimensiones, protecion anti manomision y selladura de tubaciones ; puede sellar encolcados con
juego diametral.
. Produit anaeÂrobie adapteÂ au freinage et au scellage aÁ haute reÂsistance des parties fileteÂes, boulons et pri-
sonniers de grandes dimensions, protection anti-alteÂration et scellage de tuyauteries; il peut sceller des ac-
couplements ayant un jeu diameÂtral maximal de 0,25 mm.
892 BOMAG
10 008 911 71
Axle DANA 193 16.5
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can
seal clearances between flanges up to 0.2 mm.
. Prodotto anaerobico adatto alla tenuta ermetica di fluidi tra assiemi flangiati e di viti a foro comunicante con i
fluidi. PuoÁ sigillare giochi tra le flange fino a 0,2 mm.
. Anaerobes Produkt zur Abdichtung von FluÈssigkeiten an Flanschen und Schrauben mit LoÈcher, die mit FluÈs-
Loctite 510
sigkeiten in Kontakt stehen. Kann ein Spiel zwischen Flanschen bis 0,2 mm abdichten.
. Producto anaeroÂbico apto para le estanqueidad de fluidos entre grupos bridados y de tornillos de orificio co-
municante con los fluidos. Puede sellar juegos entre las bridas hasta 0,2 mm.
. Produit anareÂobic apte aÁ la tenue eÂtanche des fluides entre les pieÁces aÁ brides et des vis aÁ trou en contact
avec les fluides. Il peut sceller un jeu parmi les flasques jusqu'aÁ 0,2 mm.
. Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using
it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather dif-
ficult, so heating may be necessary for larger diameters.
. Prodotto anaerobico sigillante rapido per la tenuta di filettature di raccordi conici o cilindrici fino a M80.
Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
Dopo la polimerizzazione presenta una moderata difficoltaÁ di smontaggio per cui puoÁ richiedere, per i diametri
maggiori, un riscaldamento.
. Anaerobes Produkt zum schnellen Siegeln und Abdichten von Kegel- oder Zylinderkupplungen bis M80.
Darf erst aufgetragen werden, nachdem mit einem spezifischen Wirkstoff jede Spur von Schmiermittel ab-
getragen worden ist.
Loctite 577
Nach der Polymerisation koÈnnte das Abmontieren etwas schwierig sein weshalb groÈûere Durchmesser
zuerst erhitzt werden muÈssen.
. Producto anaerobico sellante rapido para el estanqueido de tornillos de empalme conico o cilindrico hasta
M80. Debe de ser utilisado despues de haber quitado cada mancha de lubrificante con activador especifico.
Despues de la polimeracion presenta una moderada dificultaÁde desmontaje por lo tanto puede necesitar, para
los diametros majores, un calientamiento.
. Produit anaeÂrobie collage rapide assurant l'eÂtancheÂiteÂ des filetages des raccords coniques ou cylindriques
jusqu'aÁ M80. Il doit eÃtre utiliseÂ apreÁs qu'on ait enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
Une certaine difficulteÂ de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessiteÂ de
devoir chauffer preÂalablement pour de plus amples diameÁtres.
. Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue to-
gether parts with clearance ranging between 0.1 and 0.25 mm.
. Adesivo anaerobico per l'incollaggio rapido ad alta resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco tra 0,1 e 0, 25 mm.
. Anaerober Klebstoff fuÈr groûe WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 638
ben). Kann Einzelteil mit einem Radialspiel zwischen 0,1 mm und 0,25 mm zusammenkleben.
. Adhesivo anaeroÂbico para el encolado raÂpido de alta resistencia de juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego entre 0,1 mm y 0,25 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide et hautement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre). Il peut servir aÁ coller des pieÁces avec un jeu allant de 0,1 aÁ 0,25 mm.
. Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue
together parts with radial clearance below 0.1 mm.
. Adesivo anaerobico per l'incollaggio rapido a media resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco radiale inferiore a 0,1 mm.
. Anaerober Klebstoff fuÈr mittlere WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 648 ben). Kann Einzelteil mit einem Radialspiel von weniger als 0,1 mm zusammenkleben.
. Adhesivo anaeroÂbico para encolado raÂpido de media resistencia juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego radial inferior a 0,1 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide moyennement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre).
Il peut servir aÁ coller des pieÁces avec un jeu radial infeÂrieur aÁ 0,1 mm.
. Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer
diameter of sealing rings for rotating shafts with outer metal reinforcement.
(AREXONS) . Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.
Repositionable jointing
compound for seals Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica
Mastice per guarnizioni esterna.
riposizionabile . Klebstoff fuÈr Gummidichtung auf LoÈsemittelbasis, trocknet durch Verdampfung.
Klebstoff fuÈr verstellbare Wird am aÈuûeren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet.
Dichtungen . Pasta para juntas de sellado para juntas elaÂsticas a base de disolvente, deshidratante por evaporacioÂn.
Pasta para juntas Se utiliza para la estanqueidad en el diaÂmetro externo de segmentos de compresioÂn, para ejes giratorios con
reposicionable
armadura metaÂlica exterior.
Mastic pour garnitures aÁ
remettre en place . Mastic adheÂsif aÁ base de solvants pour garnitures eÂlastiques, seÂchant par eÂvaporation.
Il sert garder eÂtanche le diameÁtre exteÂrieur des bagues d'eÂtancheÂiteÂ des arbres rotatifs ayant une arma-
ture meÂtallique externe.
008 911 71 BOMAG

11 893
16.5 Axle DANA 193
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and
physical elements. Polymerises with non-corrosive dampness.
Silicone . Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi
Silicone ambientali e fisici. Polimerizza con umiditaÁ non corrosiva.
. HalbfluÈssiger Klebstoff zum Befestigen, FuÈllen und zum Schutz von Bestandteilen vor aÈuûeren Einwirkun-
Silikon
gen. Polymerisiert durch nicht korrosive Feuchtigkeit
Silicona . Material adhesivo semifluido usado para el sellado, llenado y para la proteccioÂn de componentes de elemen-
Silicone tos ambientales y fõÂsicos. Polimeriza con humedad no corrosiva.
. Produit adheÂsif semi-fluide utiliseÂ pour le scellage, remplissage et protection des eÂleÂments ambiants et phy-
siques. PolymeÂrise aÁ une humiditeÂ non corrosive.
. Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
. Grasso sintetico con elevato grado di adesivitaÁ, additivato con composti siliconici.
(TECNO LUPE/101) Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso.
Silicone-based grease Usato quando si richiedono frequenti interventi di registrazione.
Grasso al silicone . Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert.
Wird auf Stellschrauben mit Loch, die mit oÈlhaltigen FluÈssigkeiten in Kontakt stehen, angebracht.
Silikonfett Wird verwendet, wenn die Schraub oÈfters eingestellt werden muû.
Grasa a la silicona . Grasa sinteÂtica con elevado grado de adhesioÂn, aditivada con componentes silicoÂnicos.
Graisse au silicone Aplicada en tornillos de ajuste de orificio comunicante con fluidos de tipo oleoso.
Se usa cuando se requieren frecuentes intervenciones de ajuste.
. Graisse syntheÂtique ayant un degreÂ d'adheÂsiviteÂ eÂleveÂ, adjuveÂ de composeÂs au silicone.
AppliqueÂ sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux.
UtiliseÂ quand il y a besoin de reÂglages freÂquents.
. Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent
sticking and oxidation of parts that are not lubricated on a regular basis.
. Composto lubrificante contenente bisolfuro di molibdeno, usato per la lubrificazione di perni snodo e per pre-
venire incollamenti ed ossidazioni di particolari non lubrificati in modo continuo.
Molikote . Schmierstoff mit MolybidaÈndisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxy-
(DOW CORNING) dation von nicht dauergeschmierten Einzelteilen verwendet.
. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacioÂn de roÂtulas y para pre-
venir encoladuras y oxidaciones de piezas no lubricadas de manera continua.
. ComposeÂ lubrifiant contenant du bisulfure de molybdeÁne, utiliseÂ pour lubrifier les axes d'articulation et preÂ-
venir collages et oxydations des pieÁces qui ne sont pas continuellement lubrifieÂes.
. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly
(Lithium-based) Grease . Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio.
Grasso (al Litio) . Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Mon-
(Lithium) Fett tage verwendet.
Grasa (al Litio) . Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje.
Graisse (au Lithium) . AppliqueÂ sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de
montage.
894 BOMAG
12 008 911 71
Axle DANA 193 16.5
NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR

SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
1 - During all operations described in this manual, the LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den
GB axle should be fastened onto a trestle, while the oÈrtlich geltenden Vorschriften entsorgt werden.
other parts mentioned should rest on supporting 9- Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum,
benches. Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen
2 - When removing one of the arms, an anti-tilting safety trestle Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw.
should be placed under the other arm. verwenden.
3 - When working on an arm that is fitted on the machine, make sure 10 - Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in
that the supporting trestles are correctly positioned and that the einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
machine is locked lengthways. bei der Arbeit nicht abmontiert werden muÈssen.
4 - Do not admit any other person inside the work area; mark off the Nur die beschriebenen Teile abmontieren.
area, hang warning signs and remove the ignition key from the 11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
machine. Seite einer Person, die zur Achse schaut und zwar dem Antrieb
5 - Use only clean, quality tools; discard all worn, damaged, low- entgegengesetzt.
quality or improvised wrenches and tools. Ensure that all 12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
dynamometric wrenches have been checked and calibrated. die Teile an denen der Lack ggf. beschaÈdigt worden ist,
6 - Always wear gloves and non-slip rubber shoes when performing anstreichen.
repair work. 1 - Las operaciones descritas se refieren al eje blo-
7 - Should you stain a surface with oil, remove marks straight away. ESP queado en un caballete y a algunas partes apoyadas
8 - Dispose of all lubricants, seals, rags and solvents once work has en el banco de trabajo.
been completed. Treat them as special waste and dispose of them 2- Cuando se saca un brazo del eje, colocar debajo del otro un
according to the relative law provisions obtaining in the country caballete de seguridad antivuelco.
where the axles are being overhauled. 3- Si se trabaja con un eje montado en la maÂquina, asegurarse de
9 - Make sure that only weak solvents are used for cleaning haber colocado caballetes soporte y de haber inmovilizado
purposes; avoid using turpentine, dilutants and toluol-, xylol- longitudinalmente la maÂquina.
based or similar solvents; use light solvents such as Kerosene, 4- No permitir que personas extranÄas entren en la zona de trabajo;
mineral spirits or water-based, environment friendly solvents. delimitar esta zona, colgar carteles de aviso de hombres
10 - For the sake of clarity, the parts that do not normally need to be trabajando y sacar las llaves de arranque de la maÂquina.
removed have not been reproduced in some of the diagrams. 5- Usar soÂlo y exclusivamente herramientas limpias y de buena
11 - The terms RIGHT and LEFT in this manual refer to the position of cualidad; descartar llaves o herramientas gastadas o danÄadas, de
the operator facing the axle from the side opposite the drive. calidad mediocre o improvisadas. Asegurarse de que las llaves
12 - After repair work has been completed, accurately touch up any dinamomeÂtricas han sido controladas y calibradas.
coated part that may have been damaged. 6- Durante las operaciones de reparacioÂn, llevar siempre guantes y
calzado antideslizamiento.
1 - Le operazioni descritte sono riferite all'assale bloc- 7- Limpiar inmediatamente las zonas que pudieran estar sucias de
ITA cato su cavalletto ed alcuni particolari appoggiati su aceite.
un banco di lavoro.
8- Los lubricantes, las juntas, los trapos para la limpieza y los
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro disolventes usados hay que eliminarlos como desechos especia-
braccio un cavalletto di sicurezza antiribaltamento. les y, de todas formas, de acuerdo con las normativas vigentes en
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di el paõÂs en el que se revisan los ejes.
aver sistemato dei cavalletti di sostentamento e di aver immobi- 9- Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en
lizzato longitudinalmente la macchina. absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
4 - Non permettere che persone estranee entrino nella zona di lavoro; silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs
delimitare questa zona, appendere dei cartelli di avviso di lavori in minerales o disolventes ecoloÂgicos a base de agua.
corso ed asportare le chiavi di avviamento della macchina. 10 - Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; de algunos grupos faltan algunas piezas que por lo general se
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ pueden dejar montadas. Sacar soÂlo las partes descritas.
od improvvisati. Assicurarsi che le chiavi dinamometriche siano 11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
state controllate e tarate. refieren a la persona que mira el eje del lado opuesto a la toma de
6 - Durante le operazioni di riparazione, indossare sempre guanti e movimiento.
scarpe antiscivolo. 12 - Al final de las reparaciones, para evitar oxidaciones, retocar
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. cuidadosamente las partes pintadas que estuvieran danÄadas.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e 1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu
comunque secondo le normative vigenti nel Paese ove vengono F bloqueÂ sur chevalet et de quelques pieÁces poseÂes
revisionati gli assali. sur un eÂtabli de travail.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica- 2- Quand on enleÁve un essieu monteÂ sur la machine, ajuster sous
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; l'autre bras un chevalet de seÂcuriteÂ contre tout basculement.
usare solo solventi leggeri quali cherosene, ragie minerali o 3- Si on oeuvre sur un essieu monteÂ sur la machine, s'assurer
solventi ecologici a base d'acqua. d'avoir ameÂnageÂ des chevalets de soutien et d'avoir bloqueÂ la
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni machine en longueur.
gruppi mancano dei particolari che, normalmente, possono essere 4- Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de
lasciati montati. Rimuovere solo i particolari descritti. travail; deÂlimiter cette zone, mettre des pancartes de signalisation
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla de travaux en cours et enlever les cleÂs de contact de la machine.
persona che guarda l'assale dal lato opposto alla presa di moto. 5- N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cleÂ
12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ou autres outils useÂs, abõÃmeÂs, de mauvaise qualiteÂ ou improviseÂs.
ritoccare con cura le parti verniciate eventualmente danneggiate. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂteÂ controÃleÂes et
calibreÂes.
1 - Die beschriebenen VorgaÈnge werden an der Achse 6- Pendant les opeÂrations de reÂparation, endosser toujours gants et
D vorgenommen, wenn diese auf einem Bock blockiert chaussures antideÂrapantes.
ist. Zur Bearbeitung der Einzelteile, werden diese 7- Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile.
auf die Werkbank gelegt. 8- Les lubrifiants, les garnitures, les eÂventuels chiffons servant au
2- Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs
den zweiten Arm legen. comme rebut speÂcial conformeÂment aux lois en vigueur dans le
3- Werden Arbeiten an der Achse vorgenommen, wenn diese noch pays ouÁ les essieux sont en reÂvision.
an der Maschine montiert ist, BoÈcke zur Halterung unter die 9- Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol,
Achse stellen und die Maschine der LaÈnge nach blockieren. xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne,
4- Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau.
waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und 10 - En ce qui concerne la clarteÂ en matieÁre d'illustration et exposition,
mit Schilder kennzeichnen, die auf die laufenden Arbeiten sur les figures de certains groupes, il y a des pieÁces manquantes
hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. qui normalement peuvent rester monteÂes.
5- Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈ- Enlever uniquement les pieÁces deÂcrites.
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher- 11 - Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se
stellen, daû die Dynamometer gepruÈft und geeicht worden sind. rapportent aÁ la personne regardant l'essieu du coÃteÂ opposeÂ aÁ celui
6- Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. de la prise de mouvement.
7- Mit OÈ l beschmutzte Stellen, sofort reinigen. 12 - A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation
8- Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und nuisible, retoucher soigneusement les parties vernies eÂventuelle-
ment abõÃmeÂes.
008 911 71 BOMAG
13 895
16.5 Axle
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DANA
DISCHI 193
FRENO - VERSCHLEISS
SIMBOLI KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE USURE ET SUBSTITUTION DES DISQUES FREINS
Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts T1
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice S
Attenzione, indicazione importante
Achtung, wichtiger Hinweis F1241070 F1241071
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
GB a bar GB b
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc. CHECKING WEAR Introduce tool T1 between the disks and check shim "S".
Controler, regler p.e. couples, mesures, pressions ecc. CAUTION! Perform operations on both arms. Minimum size of "S": 4.5 mm.
T=Special tool P=page Remove the oil-level plug (1).
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale P
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly
Sostituire ad ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage
Unlock - lock e.g. split pin, locking plate, etc.
Togliere-mettere la sicura F1241072 F1241073
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
bar GB c GB d
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung) ADJUSTING THE BRAKES Remove screw (2) and safety plate (3).
Colocar el seguro, pegar (mastique lõÂquido) Connect an external pump to the union piece "P" of the negative
Mettre la securite, coller (mastic liquide) brake and introduce a pressure of 15 ± 30 bar to eliminate the
Guard against material damage, damage to parts pressure of the Belleville washers (11).
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje)
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈl, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
Inserire pressione nel circuito idraulico F1241074 F1241075
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique GB e GB f
To clean
Pulire Turn the brake clearance adjustment pinion (4) clockwise and as REPLACING THE BRAKING DISKS
Reinigen
Limpiar far as the limit stop. Sling the arm (6) to be removed and connect it to a hoist.
Nettoyer Release pressure and disconnect the tubes. Loosen and remove screws (7) and nuts (8).
Lubricate - grease NOTE. Remove the lower plug (5) and drain the oil.
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
896 Lubrifier - Graisser BOMAG 008 911 71
14
Axle DANA 193 16.5
CONTROLLO USURA Introdurre l'attrezzo T1 tra i dischi e controllare lo

ITA ATTENZIONE! Eseguire le operazioni per i due ITA spessore "S".
bracci. "S" minimo: 4,5 mm
Asportare il tappo (1) di livello olio.
VERSCHLEISS KONTROLLIEREN Werkzeug T1 zwischen den Scheiben einsetzen und

D D die StaÈrke "S" kontrollieren.
ACHTUNG! Die VorgaÈnge an beiden Armen vorneh-
men. "S" Minimum: 4,5 mm
È
OleinfuÈllstopfen (1) abnehmen.
a b
CONTROL DESGASTE Introducir la herramienta T1 entre los discos y
ESP ESP controlar el espesor "S".
ATENCION! Efectuar las operaciones por los dos
ejes. «S» minimo: 4,5 mm.
Sacar el tapon (1) de nivel aceite.
CONTROLE USURE Introduire l'outil T1 entre les disques et controÃler la

F F cale "S".
ATTENTION! Effectuer les opeÂrations aux deux bras.
Enlever le bouchon (1) du niveau d'huile. "S" minimum: 4,5 mm
REGISTRAZIONE FRENI Asportare la vite (2) e la piastrina di sicurezza (3).

ITA Collegare al raccordo "P" del freno negativo una pompa ITA
esterna ed immettere una pressione di 15v30 bar per
eliminare la pressione delle molle a tazza (11).
BREMSEN EINSTELLEN Schraube (2) und SicherheitsplaÈttchen (3) abnehmen.

D AnschluûstuÈck "P" der Federspeicherbremse an eine D
aÈuûere Pumpe anschlieûen und Druck bei 15v30 bar
einlassen, um Tellerfedern (11) zu entlasten.
c d
REGISTRACION FRENOS Sacar el tornillo (2) y la placa de securidad (3).
ESP Conectar al empalme «P» del freno negativo una ESP
pompa esterna y introducir una presion de 15v30 bar
para eliminar la presion de los muelles a taza (11).
REGLAGE DES FREINS Enlever les vis (2) et la plaquette de seÂcuriteÂ (3).
F Brancher au raccord "P" du frein neÂgatif une pompe F
externe et envoyer une pression de 15v30 bar pour
eÂliminer la pression des ressorts belleville (11).
Ruotare in senso orario il pignone (4) di regolazione SOSTITUZIONE DISCHI FRENO

ITA gioco freni fino a fondo corsa. ITA Imbragare il braccio (6) da asportare e collegarlo ad un
Rilasciare la pressione e scollegare i tubi. mezzo di sollevamento.
NOTA. Rimuovere il tappo inferiore (5) e scaricare l'olio. Allentare ed asportare le viti (7) ed i dadi (8).
Das Kegelrad (4) zur Einstellung des Bremsspiels bis BREMSSCHEIBEN AUSWECHSELN
D zum Endanschlag drehen. D Den abzunehmenden Arm (6) anschlagen und an eine
Druck ablassen und die Leitungen abtrennen. Hebezeug befestigen.
BEMERKUNG. Unteren Stopfen (5) abnehmen und das O È l. Schrauben (7) und Muttern (8) lockern und abschrauben.
e f
Girar en sentido horario el pinon (4) de regulacioÁn SUBSTITUCION DISCOS FRENOS.
ESP juego frenos hasta final carrera. ESP Atar el eje (6) de sacar y conectarlo a un medio de
Dejar la presion y desconectar los tubos. levantamiento.
NOTA. Remover el tapon inferior (5) y descargar el aceite. Aflojar y sacar los tornillos (7) y las tuercas (8).
Tourner le pignon de reÂglage du jeu des freins (4) dans Substitution des disques frein
F le sens des aiguilles d'une montre jusqu'en fin de F Elinguer le bras (6) aÁ enlever et brancher celui-ci aÁ un
course. moyen de relevage.
LibeÂrer la pression et deÂbrancher les tubes. Desserrer et enlever les vis (7), les eÂcrous (8).
REMARQUE: Enlever le bouchon infeÂrieur (5) et vidanger l'huile.
008 911 71 BOMAG

15 897
16.5 Axle
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO DANA
- VERSCHLEISS 193
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
F1241076 F1241077
GB a GB b
Remove arm (6) together with brakes and axle shafts; lay down the Loosen screws (9) in an alternate manner and remove them.
arm vertically.
F1241078 F1241079
GB c GB d
Move the cylinder (10) outwards while supporting the Belleville Remove the cylinder (10) complete with piston (12).
washers (11).
Remove the Belleville washers (11) and note down direction of
assembly.
F1241080 F1241081
bar GB e GB f
Slowly introduce low-pressure compressed air through the con- Remove O-rings (13) and (14) from the piston (12).
nection member for the negative brake, in order to extract the NOTE. The O-rings (13) and (14) must be replaced each time the
piston (12). unit is disassembled.
CAUTION! Hold the piston (12) back, as it may be suddenly ejected
and damaged.
898 BOMAG
16 008 911 71
Axle DANA 193 16.5
Rimuovere il braccio (6) completo di freni e semiassi; Allentare in modo alternato le viti (9) ed asportarle.
ITA deporre il braccio in modo verticale. ITA
Den Arm (6) samt Bremsen und Halbachsen ab- Abwechselnd die Schrauben (9) lockern und ab-
D nehmen; den Arm senkrecht ablegen. D schrauben.
a b
Remover el eje (6) completo de frenos y semi-ejes; Aflojar de manera alternada los tornillos (9) y sacarlas.
ESP colocar el eje de manera vertical. ESP
Enlever le bras (6) complet de freins et demi-essieux; Desserrer les vis (9) en alternance, puis les enlever.
F deÂposer le bras en vertical. F
Spostare verso l'esterno il cilindro (10) sostenendo le Rimuovere il cilindro (10) completo di pistone (12).
ITA molle a tazza (11). ITA
Rimuovere le molle (11) ed annotare il senso di
montaggio.
Den Zylinder (10) nach auûen verstellen und dabei die Zylinder (10) samt Kolben (12) abnehmen.
D Tellerfedern (11) stuÈtzen. D
Federn (11) abnehmen und die Montagerichtung
notieren.
c d
Desplazar hacia el esterior el cilindro (10) sosteniendo Remover el cilindro (10) completo de piston (12).
ESP los muelles a taza (11). ESP
Remover los muelles (11) y anotar el sentido de
montaje.
DeÂplacer le cylindre (10) vers l'exteÂrieur en soutenant Enlever le cylindre (10) complet de piston (12).
F le ressort belleville (11). F
Enlever le ressort (11) et prendre note du sens de son
montage.
Immettere lentamente aria compressa a bassa pres- Rimuovere dal pistone (12) gli anelli OR (13) e (14).
ITA sione attraverso l'attacco per il freno negativo per ITA
NOTA. Gli anelli OR (13) e (14) devono essere
estrarre il pistone (12). sostituiti ad ogni smontaggio.
ATTENZIONE! Trattenere il pistone (12) che puoÁ essere espulso
velocemente ed essere danneggiato.
Langsam Druckluft bei Niederdruck durch den An- Kolben (12) und O-Ringe (14) und (14) abnehmen.
D schluû der Federspeicherbremse einlassen, um den D
BEMERKUNG. Die O-Ringe (13) und (14) muÈssen
Kolben (12) heraus zu druÈcken. jedesmal ausgewechselt werden, wenn das Teil zer-
ACHTUNG! Den Kolben (12) halten, da er ploÈtzlich heraus springen legt wird.
e und beschaÈdigt werden koÈnnte. f
Introducir lentamente aire comprimida a baja presioÁn Remover del piston (12) los anillos OR (13) y (14).
ESP atraves el empalme por el freno negativo para sacar el ESP
NOTA. Los anillos OR (13) y (14) deben de ser
piston (12). sobstituidos cada desmontaje.
ATENCION! Tener el piston (12) que puede ser expulso rapida-
mente y estropearse.
Envoyer lentement de l'air comprimeÂ aÁ basse pression Enlever le piston (12), les anneaux O'RING (13) et
F aÁ travers le raccord du frein neÂgatif pour extraire le F (14).
piston (12). REMARQUE. Les anneaux O'RING (13) et (14) sont aÁ
ATTENTION! Tenir le piston (12) qui pourrait eÃtre expulser substituer aÁ chaque deÂmontage.
rapidement et endommager.
008 911 71 BOMAG

17 899
16.5 Axle
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO DANA
- VERSCHLEISS 193
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
F1241082 F1241083
GB a GB b
Remove checking and guiding screws (15) from the pressure plate Remove the pressure plate (16).
(16). CAUTION! Note down the direction of assembly; flow regulator wall
NOTE. Loosen screws (15) in sequence and proportionally. "A" and oil drain holes must face the oil drain plug.
F1241084 F1241085
GB c GB d
Remove springs (17). Remove braking discs (18) and (19), noting down direction of
NOTE. Accurately check the condition of springs. They should not assembly.
be warped. NOTE. If disks are not to be replaced, avoid changing their
Any deformation of the springs requires spring replacement. position.
F1241086 F1241087
GB e GB f
Remove pinion (4) complete with O-ring (20). Unscrew and extract the braking disk clearance adjustment crown
NOTE. The O-ring must be replaced each time the unit is wheel (21).
disassembled.
900 BOMAG
18 008 911 71
Axle DANA 193 16.5
Rimuovere le viti (15) di ritegno e guida dello Rimuovere lo spingidisco (16).

ITA spingidisco (16). ITA
ATTENZIONE! Annotare il senso di montaggio; la
NOTA. Allentare le viti (15) in modo sequenziale ed in parete frangiflusso "A" e gli scarichi olio, devono
uguale misura. essere rivolti verso il tappo di scarico olio.
Befestigungsschrauben (15) und die FuÈhrung der Druckplatte (16) abnehmen.

D Druckplatte (16) abnehmen. D
ACHTUNG! Montagerichtung notieren; der Strahlreg-
BEMERKUNG. Abwechselnd Schrauben (15) im È lablaûoÈffnungen muÈssen in Richtung
ler "A" und die O
gleichen Maû lockern. È
des Olablaûstopfens gerichtet sein.
a b
Remover los tornillos (15) de retencioÁn y guõÁa del Remover el empuja-disco (16).
ESP empuya-disco (16). ESP
ATENCION. Anotar el sentido de montaje; la pared
NOTA. Aflojar los tornillos (15) de manera secuencial rompe-flujo "A" y los descarge aceite, deben de ser
y en la misma mesura. dirijidos hacia el tapon de descarga aceite.
Enlever vis (15) de fixation et guide du plateau de Enlever le plateau de pression (16).
F pression (16). F
ATTENTION! Prendre noter du sens du montage; la
REMARQUE: Desserrer les vis (15) en seÂquence et en paroi brise-jet "A" et les eÂcoulements d'huile sont
eÂgale mesure. tourneÂs vers le bouchon de vidange d'huile.
Rimuovere le molle (17). Rimuovere i dischi di frenatura (18) e (19) annotando

ITA ITA l'ordine di montaggio.
NOTA. Controllare attentamente lo stato delle molle
che non devono essere deformate. NOTA. Se i dischi non devono essere sostituiti, evitare
Ogni deformazione deve portare alla sostituzione. lo scambio di posizione.
Federn (17) abnehmen. Bremsscheiben (18) und (19) abnehmen und Monta-
D D gerichtung notieren.
BEMERKUNG. Die Federn sorgfaÈltig kontrollieren; sie
duÈrfen nicht verformt sein. Sollte dies der Fall sein, BEMERKUNG. Falls die Scheiben ausgewechselt
Federn auswechseln. werden muÈssen, ihre Position nicht verwechseln.
c d
Remover los muelles (17). Remover los discos de frenadura (18) y (19) anotando
ESP ESP el orden de montaje.
NOTA. Controlar atentamente el estado de los
muelles que no deben de ser deformes. NOTA. Si los discos no deben de ser sobstituidos,
A cada deformacioÁn deben de ser cambiados. evitar el cambio de possicioÁn.
Enlever les ressorts (17). Enlever les disques de freinage (18) et (19) et prendre
F F note de l'ordre du montage.
REMARQUE. ControÃler attentivement l'eÂtat des res-
sorts, ils ne doivent pas eÃtre deÂformeÂs. REMARQUE. Si les disques doivent eÃtre substitueÂs,
Toute deÂformation veut dire substitution. eÂviter d'eÂchanger leur position.
Rimuovere il pignone (4) completo di anello OR (20). Svitare ed asportare la corona (21) di regolazione del
ITA ITA gioco dischi di frenatura.
NOTA. L'anello OR deve essere sostituito ad ogni
smontaggio.
Das Kegelrad (4) samt O-Ring (20) entfernen. Den Kranz (21) zur Einstellung des Bremsscheibens-
D D piels abnehmen.
BEMERKUNG. Den O-Ring bei jedem Zerlegen aus-
wechseln.
e f
Remover el pinon (4) completo de anillo OR (20). Destornillar y sacar la corona (21) de regulacioÁn del
ESP ESP juego discos de frenadura.
NOTA. El anillo OR debe de ser sobstituido a cada
desmontaje.
Enlever le pignon (4) complet de l'anneau O'RING DeÂvisser et enlever la couronne (21) de reÂglage du jeu
F (20). F des disques de freinage.
REMARQUE. L'anneau O-Ring est aÁ remplacer aÁ
chaque deÂmontage.
008 911 71 BOMAG

19 901
16.5 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS -Axle DANA 193
MONTAJE DE LOS
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS
D1240130
F1241133 F1241134
GB a GB b
Lubricate the threaded portion of the crown wheel (21) and screw it Replace the O-ring (20) of pinion (4).
down into the arm (6) as far as it will go. Lubricate and install the pinion in the slot provided on the arm (6),
inserting the toothing into crown wheel (21).
902 BOMAG
20 008 911 71
Axle DANA 193 16.5
GB
ESP
ITA
Lubrificare la filettatura della corona (21) ed avvitarla a Sostituire l'anello OR (20) del pignone (4).
ITA fondo nel braccio (6). ITA Lubrificare il pignone e montarlo nella sede del braccio
(6) innestando la dentatura nella corona (21).
Das Gewinde des Kranzes (21) schmieren und in den O-Ring (20) des Kegelrads (4) auswechseln. Kegelrad
D Arm (6) festschrauben. D schmieren und in den Sitz des Arms (6) montieren;
dabei die ZaÈhne des Kranzes (21) einrasten.
a b
Lubrificar la rosca de la corona (21) y atornillar a Sobstituir el anillo OR (20) del pinon (4).
ESP hondo en el eje (6). ESP Lubrificar el pinon y montarlo en la sed del eje (6)
introduciendo la dentadura en la corona (21).
Lubrifier le filetage de la couronne (21), puis visser Substituer l'anneau O'RING (20) du pignon (4).
F celle-ci aÁ fond dans le bras (6). F Lubrifier le pignon, puis monter celui-ci dans le
logement du bras (6) en introduisant en meÃme temps
la denture dans la couronne (21).
008 911 71 BOMAG

21 903
MONTAJE DE LOS
F1241088 F1241089
GB a GB b
Lubricate the first friction disk (19) and install it on the axle shaft .
Lightly lubricate the first steel braking disk (18), then install it on the Complete the assembly, alternating steel disks and friction disks.
arm (6). CAUTION! Oval holes "B" of friction disks must be lined up.
A
F1241084 F1241083
GB c GB d
Position springs (17) in the appropriate slots of the arm (6). Fit the pressure plate (16).
CAUTION! Accurately check orientation: flow regulator "A" and oil
drains must be oriented towards the arm's oil drain plug.
F1241082 F1241090
GB e GB f
Lock the pressure plate into position (16) with screws (15). Lock screws (15) with a dynamometric wrench.
CAUTION! Tighten screws in sequence and a little at a time. Torque wrench setting: 20 ± 30 Nm.
904 BOMAG
22 008 911 71
Axle DANA 193 16.5
Lubrificare leggermente il primo disco di frenatura in Lubrificare il primo disco di attrito (19) e montarlo sul
ITA acciaio (18) e montarlo nel braccio (6). ITA semiasse.
Completare il montaggio alternando dischi di acciaio e
dischi di attrito.
ATTENZIONE! I dischi di attrito devono avere il foro ovale "B"
allineato.
Die erste Bremsscheibe aus Stahl (18) etwas schmie- Die erste Reibscheibe (19) schmieren und auf die
D ren und in den Arm (6) montieren. D Halbachse montieren.
Dann die Stahlscheiben abwechselnd mit den Reibs-
cheiben montieren.
a b ACHTUNG! Die LangloÈcher "B" der Reibscheiben muÈssen ge-
fluchtet sein.
Lubrificar ligermente el primer disco de frenadura en Lubrificar el primer disco de strito (19) y montarlo
ESP acero (18) y montarlo en el eje (6). ESP sobre el semi-eje.
Completar el montaje alternando discos de acero y
discos de atrito.
ATENCION! Los discos de atrito deben tener el agujero oval «B» en
linea.
Lubrifier leÂgeÁrement le premier disque de freinage en Lubrifier le premier disque de friction (19), puis monter
F acier (18), puis monter celui-ci dans le bras (6). F ce dernier sur le demi-essieu.
Achever le montage en alternant les disques en acier
et les disques de friction.
ATTENTION! Les disques de friction doivent avoir le trou ovale "B"
aligneÂ.
Posizionare nelle sedi del braccio (6) le molle (17). Montare lo spingidisco (16).
ITA ITA
ATTENZIONE! Controllare attentamente l'orientamen-
to; il frangiflusso "A" e gli scarichi olio, devono essere
orientati verso il tappo di scarico olio del braccio.
In den Sitz des Arms (6) die Federn (17) einsetzen. Die Druckplatte (16) montieren.
D D
ACHTUNG! SorgfaÈltig die Montagerichtung kontroll-
È lablaûoÈffnungen
ieren; den Stahlregler "A" und die O
muÈssen zum Ablaûstopfen des Arms gerichtet sein.
c d
Colocar en las sedes del eje (6) los muelles (17). Montar el empuja-disco (16).
ESP ESP
ATENCION! Controlar atentamente el orientamiento;
el rompe-flujo "A" y los descarga aceite, deben de ser
orientados hacia el tapon de descarga aceite del eje.
Mettre en place les ressorts (17) dans les logements Monter le plateau de pression (16).
F du bras (6). F
ATTENTION! ControÃler attentivement la direction; la
paroi brise-jet "A" et les eÂcoulements d'huile doivent
eÃtre dirigeÂs vers le bouchon de vidange d'huile du bras.
Fissare la posizione dello spingidisco (16) con le viti Bloccare le viti (15) con chiave dinamometrica.
ITA (15). ITA Coppia di serraggio: 20v30 Nm
ATTENZIONE! Serrare le viti in modo sequenziale ed
in piuÁ tempi.
Die Druckplatte (16) mit den Schrauben (15) be- Schrauben (15) mit dem Dynamometer blockieren.
D festigen. D Anzugsmoment: 20v30 Nm.
ACHTUNG! Die Schrauben der Reihe nach und
schrittweise festziehen.
e f
Fijar la posicioÁn del empuja-disco (16) con los tornillos Bloquear los tornillos (15) con llave dinamometrica.
ESP (15). ESP Par de serraje: 20v30 Nm.
ATENCION! Apretar los tornillos de manera secuen-
cial y en mas tiempos.
Fixer le plateau de pression (16) aÁ sa place avec les Bloquer les vis (15) aÁ l'aide de la cleÂ dynamomeÂtrique.
F vis (15). F Couple de serrage: 20v30 Nm.
ATTENTION! Serrer les vis en plusieurs temps en
ordre seÂquentiel.
008 911 71 BOMAG

23 905
MONTAJE DE LOS
F1241091 F1241092
GB a GB b
Fit O-rings (13) and (14) onto the piston (12). Using a plastic hammer, ram the piston (12) into the cylinder (10).
Lubricate the piston and the O-rings and install the unit into the NOTE. Lightly hammer all around the edge in an alternate
cylinder (10). sequence.
NOTE. Piston relief «C» must face downwards.
F1241079 F1241078
GB c GB d
Check the condition and the position of the O-ring (22); lubricate Position the Belleville washers (11) and engage the cylinder (10).
the O-ring and position the cylinder on the studs without fastening. NOTE. Check the sense of direction of washers (11) and relative
centring.
F1241093 F1241094
GB e GB f
Lock the cylinder (10), tightening the screws (9) with a dynamo- Check integrity and position of the arm's O-ring (23); install the
metric wrench set to a torque of 86 ± 89 Nm. complete arm (6).
NOTE. To assist axle shaft centring, slightly move the wheel hub.
906 BOMAG
24 008 911 71
Axle DANA 193 16.5
Montare sul pistone (12) gli anelli OR (13) e (14). Utilizzando un mazzuolo in materiale plastico, inserire
ITA Lubrificare il pistone e gli anelli OR e montare il ITA a fondo il pistone (12) nel cilindro (10).
gruppo nel cilindro (10). NOTA. Battere leggeri colpi distribuiti in modo
NOTA. Lo scarico "C" del pistone deve essere rivolto verso il alternato su tutta la circonferenza.
basso.
Auf den Kolben (12) die O-Ringe (13) und (14) Mit einem Gummihammer den Kolben (12) in den
D montieren. D Zylinder (10) bis zum Anschlag einschlagen.
Den Kolben und die O-Ringe schmieren und das BEMERKUNG. Den Kolben abwechselnd rund um die
Aggregat in den Zylinder (10) montieren. gesamte Kreislinie leicht schlagen.
a BEMERKUNG. Die AblaûoÈffnung "C" des Kolbens muû nach unten b
gerichtet sein.
Montar sobre el piston (12) los anillos OR (13) y (14). Utilizando un martillo de materia plastica, introducir a
ESP Lubrificar el piston y los anillos OR y montar el grupo ESP fondo el piston (12) en el cilindro (10).
en los cilindros (10). NOTA. Pegar ligeros golpes distribuidos de manera
NOTA. El escargo "C" del piston debe de ser dirijido hacia el bajo. alternada sobre toda la circonferencia.
Monter sur le piston (12), les anneaux O'RING (13) et A l'aide d'un maillet en matieÁre plastique, introduire le
F (14). F piston (12) aÁ fond dans le cylindre (10).
Lubrifier le piston et les anneaux O'RING, puis monter REMARQUE. Donner de leÂgers coups reÂguliers tout
le groupe dans le cylindre (10). autour de la circonfeÂrence.
REMARQUE. L'eÂcoulement "C" du piston doit eÃtre tourneÂ vers le
bas.
Controllare lo stato ed il posizionamento dell'anello Posizionare le molle a tazza (11) e mandare in battuta
ITA OR (22); lubrificare l'anello OR e posizionare il cilindro ITA il cilindro (10).
sui prigionieri senza mandarlo in battuta. NOTA. Controllare il senso di orientamento delle molle
a tazza (11) e la loro centratura.
Den Zustand und die Position des O-Ringes (22) Tellerfedern (11) positionieren und den Zylinder (10)
D kontrollieren; den O-Ring schmieren und den Zylinder D bis zum Anschlag einsetzen.
auf die Stiftschrauben positionieren, ohne ihn bis zum BEMERKUNG. Orientierung der Tellerfedern (11) und
Anschlag ganz einzusetzen. ihre Zentrierung kontrollieren.
c d
Controlar el estado y la colocacioÁn del anillo OR (22); Colocar los muelles a taza (11) y mandar a tope el
ESP lubrificar el anillo OR y colocar el cilindro sobre los ESP cilindro (10).
prigioneros sin llevarlo a tope. NOTA. Controlar el sentido de orientamiento de los
muelles a taza (11) y su centraje.
ControÃler l'eÂtat et la position de l'anneau O'RING (22); Positionner les ressorts belleville (11) et inseÂrer aÁ fond
F lubrifier l'anneau O'RING et positionner le cylindre sur F le cylindre (10).
les prisonniers sans l'envoyer en buteÂe. REMARQUE. ControÃler l'orientation des ressorts
belleville (11) et leur centrage.
Bloccare il cilindro (10) con le viti (9) serrate con chiave Verificare l'integritaÁ ed il posizionamento dell'anello
ITA dinamometrica ad un coppia di 86v89 Nm. ITA OR (23) del braccio; installare il braccio completo (6).
NOTA. Per agevolare la centratura del semiasse,
muovere lentamente il mozzo portaruota.
Den Zylinder (10) mit den Schrauben (9) mit einem Am Arm den Zustand und die Position des O-Ringes
D Dynamometer und einem Anzugsmoment von 86v89 Nm D (23) kontrollieren; den gesamten Arm (6) installieren.
blockieren. BEMERKUNG. Um die Halbachse leichter zentrieren
zu koÈnnen, die Radhalternabe etwas bewegen.
e f
Bloquear el cilindro (10) con los tornillos (9) apretados Averiguar la integridad y la colocacioÁn del anillo OR
ESP con llave dinamometrica a un par de 86v89 Nm. ESP (23) del eje; colocar el eje completo (6).
NOTA. Para facilitar el centraje del semi-eje, mover
lentamente el cubo porta-rueda.
Bloquer le cylindre (10) avec les vis (9), serrer aÁ l'aide VeÂrifier le bon eÂtat et le positionnement de l'anneau
F de la cleÂ dynamomeÂtrique aÁ un couple de 86v89 Nm. F O'RING (23) du bras; installer le bras complet (6).
REMARQUE. Afin de rendre plus aiseÂ le centrage du
demi-essieu, bouger lentement le moyeu porte-roue.
008 911 71 BOMAG

25 907
MONTAJE DE LOS
T2
F1241095 F1241096
GB a GB b
Temporarily lock the arm (6) with nuts (8) previously coated with Check the flatness of the arms, using tool T2; then lock the arms
Loctite 242; tighten lightly to make the unit touch the main body. into their final position, using screws (7) adequately coated with
Loctite 242.
Torque wrench setting: 182 ± 202 Nm.
NOTE. Tighten using the criss-cross method.
F1241097 F1241074
bar GB c GB d
Connect an external pump to the union piece "A" of the negative Rotate the adjustment pinion (4) anticlockwise (±) to eliminate all
brake and introduce pressure to 15 ± 30 bar. existing clearance between the braking disks.
Rotate up to a torque of 8 ± 10 Nm.
+
--
D1240132
F1241073
GB e GB f
Rotate pinion (4) clockwise (+) to determine the required clearance Install safety plate (3) and lock with screw (2).
of 1 mm. Torque wrench setting: 10 ± 11 Nm.
NOTE. A turn of the adjuster produces a clearance of 0.25 mm
(1mm = 4 turns).
908 BOMAG
26 008 911 71
Axle DANA 193 16.5
Fissare provvisoriamente il braccio (6) con i dadi (8) Controllare la planaritaÁ dei bracci con l'attrezzo T2 e
ITA spalmati con Loctite 242 e serrati leggermente per ITA fissarli definitivamente con le viti (7) spalmate con
frizionare il gruppo sul corpo centrale. Loctite 242.
Coppia di serraggio: 182v202 Nm
NOTA. Serrare con il metodo incrociato.
VoruÈbergehend den Arm (6) mit den mit Loctite 242 Die Ebenheit der Arme mit dem Werkzeug T2 kontroll-
D geschmierten Muttern (8) befestigen und Muttern D ieren und endguÈltig mit den mit Loctite 242 ge-
zuschrauben bis das Aggregat an dem ZentralkoÈrper schmierten Schrauben (7) befestigen.
anliegt. Anzugsmoment: 182v202 Nm
a b BEMERKUNG. Im Kreuz fest drehen.
Fijar provisoriamente el eje (6) con las tuercas (8) Controlar la planaridad de los ejes con la herramienta
ESP pasados con Loctite 242 y apretados ligermente para ESP T2 y fijarlos definitivamente con los tornillos (7) pasar
fricionar el grupo sobre el cuerpo central. con Loctite 242.
Par de serraje: 182v202 Nm
NOTA. Apretar de manera cruzada.
Fixer provisoirement le bras (6) avec les eÂcrous (8) ControÃler la planeÂiteÂ des bras aÁ l'aide de l'outil T2,
F enduits avec du Loctite 242, et serrer ceux-ci pour F puis fixer ceux-ci deÂfinitivement avec les vis (7)
frotter le groupe du corps central. enduites de Loctite 242.
Couple de serrage: 182v202 Nm.
REMARQUE. Serrer avec la meÂthode croiseÂe.
Collegare al raccordo "P" del freno negativo una pompa Ruotare in senso antiorario (±) il pignone di registro (4)
ITA esterna ed immettere una pressione di 15v30 bar. ITA per eliminare totalmente il gioco tra i dischi di frenatura.
Ruotare fino ad ottenere una coppia di 8v10 Nm.
An das AnschluûstuÈck "P" der Federspeicherbremse Gegen den Uhrzeigersinn (±) das Kegelrad (4),
D eine aÈuûere Pumpe schlieûen und Druck bei 15v30 bar D drehen, bis kein Spiel zwischen den Bremsscheiben
einlassen. mehr uÈbrig bleibt. Anzugsmoment: 8v10 Nm.
c d
Conectar al empalme "P" del freno negativo una Girar en sentido anti-horario (±) el pinon de registro (4)
ESP pompa externa y introducir presion de 15v30 bar. ESP para eliminar totalmente el juego entre discos de
frenadura.
Girar hasta obtener un par de 8v10 Nm.
Brancher au raccord "P" du frein neÂgatif une pompe Tourner le pignon de reÂglage (4) dans le sens contraire
F externe et envoyer une pression de 15v30 bar. F aux aiguilles d'une montre(-) le reÂgleur (4) pour faire
disparaõÃtre entieÁrement le jeu existant entre les
disques de freinage.
Tourner jusqu'aÁ obtenir un couple de 8v10 Nm.
Ruotare il pignone (4) in senso orario (+) per Montare la piastrina di sicurezza (3) e bloccarla con la
ITA determinare il gioco prescritto di 1 mm. ITA vite (2).
NOTA. Un giro del registro crea un gioco di 0,25 mm Coppia di serraggio: 10v11 Nm
(1 mm=4 giri).
Das Kegelrad (4) in den Uhrzeigersinn (+) drehen, bis Die Sicherheitsplatte (3) montieren und mit der
D das vorgeschriebene Spiel von 1 mm erreicht ist. D Schraube (2) blockieren.
BEMERKUNG. Eine Umdrehung gleicht einem Spiel Anzugsmoment: 10v11 Nm
von 0,25 mm (1 mm=4 Umdrehungen).
e f
Girar el pinon (4) en sentido horario (+) para Montar la plaqua de seguridad (3) y bloquearla con los
ESP determinar el juego prescrito de 1 mm. ESP tornillos 829.
NOTA. Un giro del registro crea un juego de 0,25 mm Par de serraje: 10v11 Nm
(1mm=4 giros).
Tourner le pignon (4) dans le sens des aiguilles d'une Monter la plaquette de seÂcuriteÂ (3), bloquer celle-ci aÁ
F montre (+) pour deÂfinir le jeu prescrit de 1 mm. F l'aide de la vis (2).
REMARQUE. Un tour de reÂgleur donne un jeu de 0,25 Couple de serrage: 10v11 Nm
mm (1mm=4 tours).
008 911 71 BOMAG

27 909
16.5 Axle-
MECHANICAL AND MANUAL RELEASE OF THE AXLE - SBLOCCAGGIO MECCANICO MANUALE DELL'ASSALE DANA 193
ACHSE MECHANISCH MANUELL ENTSICHERN - DESBLOQUEO MANUAL DE LOS AXAL -
DEBLOCAGE MECANIQUE MANUEL DE L'ESSIEU
D1240133
F1241098
GB a GB b
MANUAL EMERGENCY RELEASE Tighten screws (25) so as to fasten them onto the pressure plate
Loosen nuts (24) of screws (25) provided for the mechanical and (16).
manual release of the braking units, then move the nuts backwards
by approx. 8 mm.
F1241099 F1241100
GB c GB d
Using a wrench, tighten the screws (25) in an alternate sequence ADJUSTMENT AFTER MANUAL RELEASE
by 1/4 turn at a time so as to compress the Belleville washers (11) Remove screws (25) complete with nuts (24) and seals (26).
and disengage the braking disks. Replace seals (26), apply silicone-based Tecno Lupe /101 grease
IMPORTANT. Tighten max. by one turn. to the screws (25) and install all parts into the arm.
34 + 0,5
0
F1241101 F1241102
GB e GB f
+0.5
Adjust screws (25) to obtain a jut of 34 0 mm in relation to the arm. Lock into position with nuts (24).
CAUTION! Hold screws (25) into position while locking the nuts
(24); after locking, check the jut of screws (25) once more.
910 BOMAG
28 008 911 71
Axle DANA 193 16.5
SBLOCCAGGIO MANUALE D'EMERGENZA Avvitare le viti (25) fino a mandarle in battuta sullo
ITA Allentare i dadi (24) delle viti (25) per lo sblocco ITA spingidisco (16).
meccanico manuale dei gruppi di frenatura e far
arretrare i dadi di circa 8 mm.
MANUELLE NOT-ENTSICHERUNG Schrauben (25) bis zum Anschlag an die Druckplatte

D Die Muttern (24) der Schrauben (25) zur mechani- D (16) zudrehen.
schen manuellen Entsicherung der Bremsaggregate
lockern und die Muttern um 8 mm zuruÈck drehen.
a b
DESBLOQUEO MANUAL DE EMERGENCIA Atornillar los tornillos (25) hasta llegar al tope sobre el
ESP Aflojar las tuercas (24) de los tornillos (25) para el ESP empuja-disco (16).
desbloqueo mecanico manual de los grupos de
frenadura y hacer pasar las tuercas de 8 mm approx.
DEBLOCAGE MANUEL D'EMERGENCE Visser les vis (25) puis les envoyer en buteÂe sur le
F Desserrer les eÂcrous (24) des vis (25) pour le F plateau de pression (16).
deÂblocage meÂcanique manuel des groupes de frei-
nage en faisant reculer les eÂcrous d'environ 8 mm.
Utilizzando una chiave, avvitare le viti (25) in modo REGOLAZIONE DOPO LO SBLOCCAGGIO MANUALE
ITA alternato di 1/4 di giro alla volta, per comprimere le ITA Rimuovere le viti (25) complete dei dadi (24) e delle
molle a tazza (11) e liberare i dischi di frenatura. guarnizioni (26).
IMPORTANTE. Avvitare per max. un giro. Sostituire le guarnizioni (26), lubrificare le viti (25) con grasso al
silicone Tecno Lupe /101 e montare il tutto nel braccio.
Mit einem SchluÈssel, die Schrauben (25) abwechselnd EINSTELLUNG NACH DER MANUELLEN ENTSICHERUNG
D jeweils um 1/4 Umdrehung zudrehen, um die Tellerfe- D Die Schrauben (25) mit den Muttern (24) und den
dern (11) einzudruÈcken und die Bremsscheiben frei- Dichtungen (26) abnehmen.
zusetzen. Die Dichtungen (26) auswechseln, die Schrauben (25) mit Silikon-
c WICHTIG. Maximal um eine Umdrehung zuschrauben. d fett Tecno Lupe/101 schmieren und das ganze Teil in den Arm
montieren.
Utilizando una llave, atornillar los tornillos (25) de REGULACION DESPUES DEL DESBLOQUEO MANUAL
ESP manera alternada de 1/4 de giro a la vez, para ESP Remover los tornillos (25) completas de guarniciones
comprimir los muelles a taza (11) y librar los discos (26).
de frenadura. Sobstituir las guarniciones (26), lubrificar los tornillos (25) con
IMPORTANTE. Atornillar por max. un giro. grasa al silicone Tecno Lupe/101 y montar todo en el eje.
A l'aide d'une cleÂ, visser les vis (25) alternativement 1/ REGLAGE FAISANT SUITE AU DEBLOCAGE MANUEL
F 4 de tour aÁ la fois, pour contraindre le ressort belleville F Enlever les vis (25) compleÁtes d'eÂcrous (24) et de
(11) et deÂgager les disques de freinage. garnitures (26).
IMPORTANT. Visser pour max. un tour. Substituer les garnitures (26), lubrifier les vis (25) avec de la graisse
au silicone Tecno Lupe/101, monter le tout dans le bras.
Regolare le viti (25) fino ad avere una sporgenza Bloccare la posizione con i dadi (24).
ITA rispetto al braccio di 34+0,5
0 mm
ITA
ATTENZIONE! Mantenere la posizione delle viti (25)
quando si bloccano i dadi (24); dopo il bloccaggio,
ricontrollare la sporgenza delle viti (25).
È berstand zum Arm

Schrauben (25) einstellen, bis der U Die Position mit den Muttern (24) blockieren.
D 34+0.5
0 mm betraÈgt. D
ACHTUNG! Die Position der Schrauben (25) darf sich
beim Festziehen der Muttern (24) nicht aÈndern; nach
der Blockierung den U È berstand der Schrauben (25) nochmals
e f kontrollieren.
Regular los tornillos (25) hasta obtener una parte Bloquear la colocacioÁn con las tuercas (24).
ESP saliente respecto al eje de 34+0,5
0 mm
ESP
ATENCION! Mantener la posicion de los tornillos (25)
cuando se bloquean las tuercas (24); despues del
bloqueo, recontrolar la parte saliente de los tornillos (25).
ReÂgler les vis (25) jusqu'aÁ avoir une saillie de 34+0.5

0 mm Bloquer dans la position aÁ l'aide des eÂcrous (24).
F par rapport au bras. F
ATTENTION! Tenir les vis (25) en place quand on
bloque les eÂcrous (24); apreÁs avoir fixeÂ, controÃler la
saillie des vis (25).
008 911 71 BOMAG

29 911
16.5DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE
Axle- PLANETENGE-
DANA 193
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU
D1240131
F1241103 F1241104
GB a GB b
Remove the locking screws (1) of planetary cover (2). Using two screwdrivers or two levers inserted in the slots provided,
pry the planetary cover (2) away from the wheel hub (3).
912 BOMAG
30 008 911 71
Axle DANA 193 16.5
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
GB The axle shafts can only be removed once the 2 - Achse zuerst von der Maschine abmontieren und auf eine
extraction of the planetary cover has been performed. Werkbank legen.
Different procedures need to be followed depending on
the kind of repair work required: Nachstehende Beschreibung bezieht sich auf das Zerlegen an der
Werkbank, doch ist die Vorgehensweise in beiden FaÈllen dieselbe.
1 - Disassembly with axle connected to the machine with machine
resting on safety stands.
2 - Disassembly with the axle disconnected from the machine and
supported by the appropriate equipment (at the bench).
The explanations given herein refer to the removal operation as is La remocioÁn de los semi-ejes puede ser efectuada solo
carried out on the bench, but the stages apply to all versions. ESP despues de la remocioÁn de las tapas lleva-satelites y de
manera deversificada, en funcion del tipo de repara-
cion de efectuar:
1 - Desmontaje con axal montado sobre la maquina colocada sobre
caballetes de seguridad;
2 - Desmontaje con axial desmontado desde la maquina y susten-
tado de apositas herramientas (al banco).
Las explicaciones reportadas se refieren a la remocioÁn efectuada al
La rimozione dei semiassi puoÁ essere eseguita solo banco, ma las fases son comunes.
ITA dopo la rimozione del coperchio portasatelliti ed in
modo diversificato, in funzione del tipo di riparazione
da eseguire:
1 - Smontaggio con assale montato sulla macchina appoggiata su
cavalletti di sicurezza.
2 - Smontaggio con assale smontato dalla macchina e sostenuto da
apposita attrezzatura (al banco).
Le spiegazioni riportate si riferiscono alla rimozione eseguita al Le deÂgagement des demi-essieux ne peut se faire
banco, ma le fasi sono comuni. F qu'apreÁs avoir enleveÂ le couvercle porte-satellites
d'une facËon diversifieÂe, en fonction du type de
reÂparations aÁ effectuer:
1 - DeÂmontage essieu monteÂ sur machine deÂposeÂe sur des baÃtis de
seÂcuriteÂ.
1 - DeÂmontage essieu deÂmonteÂ de la machine et soutenu par un
outil speÂcial (sur banc).
Les explications reporteÂes se reÂfeÁrent au deÂgagement effectueÂ au
Die Halbachse kann erst abmontiert werden, wenn der banc, mais les phases sont communes.
D Deckel des Planetenradhalters abgenommen worden
ist; auûerdem wird sie je nach Reparatur unterschied-
lich abmontiert:
1 - Mit Achse abmontieren, die an der Maschine montiert und durch
SicherheitsbloÈcke gestuÈtzt ist.
Rimuovere le viti (1) di fissaggio del coperchio Utilizzando due cacciaviti o due leve inserite nelle
ITA portasatelliti (2). ITA cave predisposte, staccare il coperchio portasatelliti
(2) dal mozzo portaruota (3).
Schrauben (1) abschrauben, die den Deckel des Zwei Schraubenzieher oder zwei Hebel in die vorge-
D Planetenradhalters (2) befestigen. D sehenen Nuten stecken und den Deckel (2) des
Planetenradhalters von den Radhalternaben (3) ab-
heben.
a b
Remover los tornillos (1) de fisaje de la tapa porta- Utilizando dos destornilladores o dos palancas inser-
ESP satelites (2). ESP tadas en las ranuras predispuestas, destacar la tapa
lleva-satelites (2) del cubo lleva-rueda (3).
Enlever les vis (1) de fixation du couvercle porte- A l'aide de deux tournevis ou de deux leviers dans les
F satellites (2). F creux preÂdisposeÂs, deÂgager le couvercle porte-satel-
lites (2) du moyeu porte-roue (3).
008 911 71 BOMAG

31 913
Axle- PLANETENGE-
DANA 193
F1241105 F1241106
GB a GB b
Rotate the wheel hub (3) until one of the screw holes (1) appears at Only in case of replacement of component parts not requiring
the top. the disassembly of the crown wheel (5).
Apply a "U" piece to the screw hole; connect to a hoist and remove Countermark the position between one of the teeth of the axle shaft
the cover (2). (4) and the crown wheel (5).
F1241107 F1241108
GB c GB d
Remove the axle shaft (4). Loosen the screws (6) and remove them.
NOTE. The removal of the axle shaft allows for the substitution of
the snap ring as described in the following paragraphs.
F1241109 F1241110
GB e GB f
Remove the safety flange (7). Partially tighten five of the ten screws (6) in an alternate and
proportional manner.
Using an extractor and applying a counter pressure to the screws
(6), disengage the crown wheel (5) from the hub (3).
914 BOMAG
32 008 911 71
Axle DANA 193 16.5
Ruotare il mozzo portaruota (3) fino a portare un foro Solo se si devono sostituire dei componenti che
ITA per le viti (1) in posizione alta. ITA non richiedono lo smontaggio della corona (5).
Applicare un grillo ad "U" nel foro vite; collegare un Contrassegnare la posizione tra un dente del semias-
mezzo di sollevamento e rimuovere il coperchio (2). se (4) e la corona (5).
Nur wenn Bestandteile ausgewechselt werden

D Die Radhalternabe (3) drehen bis ein Loch fuÈr die D muÈssen, fuÈr die der Kranz (5) nicht abmontiert
Schrauben (1) in der oberen Position liegt. werden muû.
Einen U-foÈrmigen BuÈgel in das Schraubenloch stecken; ein Die Position zwischen einem Zahn der Halbachse (4) und dem
a Hebezeug anschlieûen und den Deckel (2) abnehmen. b Kranz (5) markieren.
Girar el cubo lleva-rueda (3) hasta hacer un agujero Solo si se deben de sobstituir algunos componentes
ESP para los tornillos (1) en posicioÁn alta. ESP que no comportan el desmontaje de la corona (5).
Aplicar un grillo a "U" en el agujero tornillos; conectar Senalar la colocacioÁn entre un diente del semi-eje (4) y
un medio de levantamiento y remover la tapa (2). la corona (5).
Tourner le moyeu porte-roue (3) jusqu'aÁ aÁ amener un Uniquement si on doit substituer des composants qui
F des trous pour les vis (1) en haut. F ne veulent pas le deÂmontage de la couronne (5).
Appliquer une manille en "U" dans le trou de vis; Marquer la position entre une dent du demi-essieu (4)
appliquer un moyen de relevage et enlever le couvercle (2). et la couronne (5).
Asportare il semiasse (4). Allentare le viti (6) ed asportarle.

ITA ITA
NOTA. L'asportazione del semiasse permette la
sostituzione dell'anello di tenuta come descritto di
seguito.
Die Halbachse (4) abnehmen. Schrauben (6) abschrauben.

D D
BEMERKUNG. Bei abgenommener Halbachse kann
der Dichtring, wie nachstehend beschrieben, ausge-
wechselt werden.
c d
Sacar el semi-eje (4). Aflojar los tornillos (6) y sacarlos.
ESP ESP
NOTA. Sacar el semi-eje permite la sobstitucioÁn del
anillo de tenida como descrito a seguir.
Enlever le demi-essieu (4). Desserrer les vis (6) puis les enlever.
F F
REMARQUE. Le deÂgagement du demi-essieu consent
la substitution de l'anneau d'eÂtancheÂiteÂ comme deÂcrit
par la suite.
Asportare la flangia di sicurezza (7). Avvitare parzialmente, in modo alternato ed in uguale

ITA ITA misura, cinque delle dieci viti (6).
Utilizzando un estrattore e facendo reazione sulle viti
(6) disimpegnare la corona (5) dal mozzo (3).
Sicherheitsflansch (7) abnehmen. Abwechselnd und im gleichen Maû fuÈnf von den zehn
D D Schrauben (6) zuschrauben.
Mit einem Abzieher den Kranz (5) aus der Nabe (3)
ziehen und dabei auf die Schrauben (6) wirken.
e f
Sacar la arandela de seguridad (7). Atornillar parcialmente, de manera alternada y en
ESP ESP igual mesera, cinco de las diez tornillos (6).
Utilizando un extractor y haciendo reacioÁn sobre los
tornillos (6) desempenar la corona (5) del cubo (3).
Enlever la flasque de seÂcuriteÂ (7). Visser partiellement, en alternance et de la meÃme

F F facËon cinq des dix vis (6).
A l'aide d'un extracteur, tout en faisant reÂagir les vis
(6), deÂgager la couronne (5) du moyeu (3).
008 911 71 BOMAG

33 915
Axle- PLANETENGE-
DANA 193
F1241111 F1241112
GB a GB b
Remove screws (6) and crown wheel (5). Sling the hub (3) and connect it to a hoist; partially tighten a screw
(6) and with the help of a hammer, shift the hub (3) and the external
bearing (8).
F1241113 F1241114
GB c GB d
Remove the bearing (8) and the hub (3). Extract the hub (3) complete with snap ring (9) and internal bearing
(10).
F1241115 F1241116
GB e GB f
Using an extractor, remove at the same time the snap ring (11) and Remove the safety spring rings (13) of the planetary gears (14).
the centring ring (12).
NOTE. Note down the direction of assembly of snap and centring
rings.
916 BOMAG
34 008 911 71
Axle DANA 193 16.5
Rimuovere le viti (6) e la corona (5). Imbragare il mozzo (3) e collegarlo ad un mezzo di
ITA ITA sollevamento; avvitare parzialmente una vite (6) e, con
un mazzuolo, smuovere il mozzo (3) ed il cuscinetto
esterno (8).
Schrauben (6) und Kranz (5) abnehmen. Nabe (3) anschlagen und an ein Hebezeug befestigen;
D D Schrauben (6) etwas zudrehen und mit einem Ham-
mer die Naben (3) und das aÈuûere Lager (8) bewegen.
a b
Remover los tornillos (6) y la corona (5). Atar el cubo (3) y conectarlo a un medio de
ESP ESP levantamiento; atornillar parcialmente un tornillo (6)
y, con un martillo, mover el cubo (3) y el cojinete
externo (8).
Enlever les vis (6) et la couronne (5). Elinguer le moyeu (3) puis relier celui-ci aÁ un moyen de
F F relevage; visser partiellement une vis (6), puis aÁ l'aide
d'un maillet, bouger le moyeu (3) et le palier externe
(8).
Rimuovere il cuscinetto (8) ed il mozzo (3). Asportare il mozzo (3) completo di anello di tenuta (9) e
ITA ITA cuscinetto interno (10).
Lager (8) und Nabe (3) abnehmen. Nabe (3) samt Dichtring (9) und inneres Lager (10)
D D abnehmen.
c d
Remover el cojinete (8) y el cubo (3). Sacar el cubo (3) completo de anillo de retencioÁn (9) y
ESP ESP cojinete interno (10).
Enlever le palier (8) et le moyeu (3). Enlever le moyeu (3) complet de bague d'eÂtancheÂiteÂ
F F (9) et de palier interne (10).
Utilizzando un estrattore, rimuovere contemporanea- Rimuovere gli anelli elastici (13) di ritegno satelliti (14).
ITA mente l'anello di tenuta (11) e l'anello centratore (12). ITA
NOTA. Annotare il senso di montaggio degli anelli di
tenuta e di centratura.
Mit einem Abzieher gleichzeitig den Dichtring (11) und Kolbenringe (13) und Planetenhalter (14) abnehmen.
D den Zentrierring (12) abnehmen. D
BEMERKUNG. Montagerichtung der Dicht- und Zen-
trierringe notieren.
e f
Utilizando un extractor, remover contemporaneamen- Remover los anillos elasticos (13) de retencioÁn
ESP te el anillo de retencioÁn (11) y el anillo centrador (12). ESP satelites (14).
NOTA. Anotar el sentido de montaje de los anillos de
retencioÁn y de centraje.
A l'aide d'un extracteur enlever en meÃme temps Enlever les anneaux ressorts (13) de fixation des
F l'anneau d'eÂtancheÂiteÂ (11) et l'anneau centreur (12). F satellites (14).
REMARQUE. Prendre note du sens de montage des
anneaux d'eÂtancheÂiteÂ et de centrage.
008 911 71 BOMAG

35 917
Axle- PLANETENGE-
DANA 193
F1241117 F1241118
GB a GB b
Remove the planetary gears (14). Only if necessary.
NOTE. Note down direction of assembly of planetary gears. Using an extractor, remove the shim washer (15) from the planet
carrier.
F1241119 F1241120
GB c GB d
Remove the snap ring (9) from the hub (3). Remove the internal bearing (10).
NOTE. Note down direction of assembly.
CAUTION! The snap ring may not be reused.
F1241121
GB e GB f
Remove the external thrust blocks of bearings (8) and (10), using a
pin-driver.
NOTE. Hammer in an alternate sequence to prevent crawling and
deformation of the thrust blocks.
918 BOMAG
36 008 911 71
Axle DANA 193 16.5
Asportare gli ingranaggi satelliti (14). Solo se necessario.

ITA ITA Utilizzando un estrattore, rimuovere dal portasatelliti la
NOTA. Annotare il senso di montaggio dei satelliti.
rondella di rasamento (15).
Planetengetriebe (14) abnehmen. Nur wenn notwendig.

D D Mit einem Abzieher vom Planetenradhalter die Zwi-
BEMERKUNG. Montagerichtung notieren.
schenlegscheibe (15) abnehmen.
a b
Sacar los engranajes satelites (14). Solo si necesario.
ESP ESP Utilizando un extractor, remover del lleva-satelites la
NOTA. Anotar el sentido de desmontaje de los
satelites. arandela de rasamiento (15).
Enlever les engrenages satellites (14). Uniquement si besoin.

F F A l'aide d'un extracteur, enlever du porte-satellite la
REMARQUE. Prendre note du sens de montage.
rondelle de rasage (15).
Rimuovere dal mozzo (3) l'anello di tenuta (9). Rimuovere il cuscinetto interno (10).
ITA ITA
NOTA. Annotare il senso di montaggio.
ATTENZIONE! L'anello di tenuta non puoÁ essere
riutilizzato.
Von der Nabe (3) den Dichtring (9) abnehmen. Das innere Lager (10) abnehmen.
D D
BEMERKUNG. Montagerichtung notieren.
ACHTUNG! Der Dichtring darf nicht wieder verwendet
werden.
c d
Remover del cubo (3) los anillos de retencioÁn (9). Remover el cojinete interior (10).
ESP ESP
NOTA. Anotar el sentido de montaje.
ATENCION! El anillo de retencioÁn no puede ser
reutilizado.
Oter du moyeu (3) l'anneau d'eÂtancheÂiteÂ (9). Enlever le palier interne (10).
F F
REMARQUE. Prendre note du sens de montage.
ATTENTION! L'anneau d'eÂtancheÂiteÂ ne peut pas eÃtre
reÂutiliseÂ.
Rimuovere le ralle esterne dei cuscinetti (8) e (10)

ITA utilizzando un cacciaspine. ITA
NOTA. Battere in modo alternato per evitare impunta-
menti e deformazioni delle ralle.
Die aÈuûeren Scheiben (8) und (10) mit einem DuÈbel

D abnehmen. D
BEMERKUNG. Abwechselnd schlagen, um ein Durch-
schlagen und Verformungen der Scheiben zu vermeiden.
e f
Remover las ranguas externas de los cojinetes (8) y
ESP (10) utilizando un extractor de clavijas. ESP
NOTA. Pegar de manera alternada para evitar
empuntamientos y deformacioÁnes de las ranguas.
Enlever les crapaudines externes des paliers (8) et

F (10) aÁ l'aide d'un chasse-clou. F
REMARQUE. Donner des coups alterneÂs pour eÂviter
talonnages et deÂformations des crapaudines.
008 911 71 BOMAG

37 919
16.5ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE
Axle DANA 193
- PLANETENGE-
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
T3
F1241122 F1241123
GB a GB b
Position the wheel hub (3) under a press; lubricate the seat of the Install the bearing (10).
external bearing and, using tool T3, install the thrust block of the Apply an appropriate sealant to the outer surface of the snap ring
bearing (10). (9).
Position the snap ring (9) into the hub (3).
NOTE. Check orientation of the ring.
T4 T3
F1241124 F1241125
GB c GB d
Position tool T4 and press the snap ring (9) down into its seat. Turn the hub (3) upside down, lubricate the seat of the bearing and,
using tool T3, install the thrust block of the bearing (8).
F1241126 F1241117
GB e GB f
Only if shim washer has previously been removed. Fit the planetary gear (14) onto the planetary gear cover (2).
Apply a sealant for removable seals to the outer surface of the shim CAUTION! The jointed portion of the internal ring of the bearings
washer (15) and, using a driver, fit it into the planetary gear cover must face the bottom of the pin.
(2).
920 BOMAG
38 008 911 71
Axle DANA 193 16.5
Posizionare il mozzo ruota (3) sotto una pressa; Installare il cuscinetto (10).
ITA lubrificare la sede del cuscinetto esterno e, utilizzando ITA Spalmare la superficie esterna dell'anello di tenuta (9)
l'attrezzo T3, montare la ralla del cuscinetto (10). con sigillante per guarnizioni.
Posizionare l'anello di tenuta (9) nel mozzo (3).
NOTA. Controllare l'orientamento dell'anello.
Die Radnabe (3) unter eine Presse positionieren; den Lager (10) installieren.
D Sitz des aÈuûeren Lagers schmieren und mit dem D AÈuûere FlaÈche des Dichtringes (9) mit etwas Dicht-
Werkzeug T3 die Scheibe des Lagers (10) montieren. masse schmieren.
Dichtring (9) in die Nabe (3) positionieren.
a b BEMERKUNG. Richtung des Ringes kontrollieren.
Colocar el cubo rueda (3) bajo una prensa; lubrificar la Colocar el cojinete (10).
ESP sed del cojinete externo y, utilizando la herramienta ESP Pasar la superficie externa del anillo de retencioÁn (9)
T3, montar la rangua del cojinete (10). con sigilante para guarniciones.
Colocar el anillo de retencioÁn (9) en el cubo (3).
NOTA. Controlar el orientamiento del anillo.
Positionner le moyeu roue (3) sous la presse; lubrifier Installer le palier (10).
F le logement du palier externe, puis aÁ l'aide de l'outil F Enduire la superficie externe de l'anneau d'eÂtancheÂiteÂ
T3, monter la crapaudine du palier (10). (9) avec de la colle aÁ garnitures.
Positionner l'anneau d'eÂtancheÂiteÂ (9) dans le moyeu (3).
REMARQUE. ControÃler la bonne direction de l'anneau.
Posizionare l'attrezzo T4 e pressare in sede l'anello di Capovolgere il mozzo (3), lubrificare la sede cuscinetto
ITA tenuta (9). ITA e, utilizzando l'attrezzo T3, montare la ralla del
cuscinetto (8).
Das Werkzeug T4 positionieren und den Dichtring (9) Die Nabe (3) wenden, den Lagersitz schmieren und
D in seinen Sitz druÈcken. D mit dem Werkzeug T3 die Nabe des Lagers (8)
montieren.
c d
Colocar la herramienta y apretar en sed el anillo de Volcar el cubo (3), lubrificar la sed cojinete y,
ESP retencioÁn (9). ESP utilizando la herramienta T3, montar la rangua del
cojinete (8).
Placer l'outil T4 et presser dans son logement Faire basculer le moyeu (3), lubrifier le logement du
F l'anneau d'eÂtancheÂiteÂ (9). F palier, puis aÁ l'aide de l'outil T3, monter la crapaudine
dans le palier (8).
Solo se eÁ stata rimossa. Montare sui perni del coperchio portasatelliti (2) gli
ITA Spalmare la superficie esterna della rondella di ITA ingranaggi planetari (14).
rasamento (15) con sigillante per guarnizioni removibili ATTENZIONE! La parte raccordata dell'anello interno
e, utilizzando uno spintore, montarla nel coperchio portasatelliti (2). dei cuscinetti deve essere rivolta verso il fondo del perno.
Nur wenn zuvor abgenommen. Auf die Stifte des Deckels des Planetenradhalters (2)
D AÈuûere FlaÈche der Zwischenlegscheibe (15) mit D die Planetengetriebe (14) montieren.
Dichtmasse fuÈr abnehmbare Dichtungen schmieren ACHTUNG! Das AnschluûstuÈck des inneren Lagerrin-
und mit einem StoÈûel diese Zwischenlegscheibe in den Deckel des ges muû zur unteren Seite des Stiftes gerichtet sein.
e Planetenradhalters (2) montieren. f
Solo si ha sido desplazada. Montar sobre los pernos de la tapa lleva-satelites (2)
ESP Pasar la superficie externa de la arandela de ESP los engranajes planetares (14).
rasamiento (15) con sigilante para guarnicioÁnes ATENCION! La parte empalmada del anillo interno de
removibles y, utilizando un empuje, montarla en la tapa lleva- los cojinetes debe de ser dirijida hacia el fondo de la rotula.
satelites (2).
Uniquement si elle a eÂteÂ enleveÂe. Monter sur les pivots du couvercle porte-satellites (2)
F Enduire la superficie externe de la rondelle de rasage F les engrenages planeÂtaires (14).
(15) avec de la colle pour garnitures amovibles, aÁ ATTENTION! La partie raccordeÂe de l'anneau aÁ
l'aide d'un poussoir monter celle-ci dans le couvercle porte- l'inteÂrieur du palier doit eÃtre tourneÂe vers la partie basse du pivot.
satellites (2).
008 911 71 BOMAG

39 921
Axle DANA 193
- PLANETENGE-
T5
F1241127 F1241128
GB a GB b
Lock into position the planetary gears (14) with the snap rings (13). Lubricate and fit the centring ring (12) and snap ring (11) onto tool
T5; install the rings into the arm.
CAUTION! Pay particular attention to the direction of assembly of
the rings.
F1241114 F1241113
GB c GB d
Grease the snap ring (9) and the hub of the arm. Install the external bearing (8).
Install the wheel hub (3). NOTE. Move the bearing to the limit stop by hammering lightly all
around the edge.
F1241129 F1241109
GB e GB f
Install the crown wheel (5) and, using a driver with adequate Using Tecno Lupe /101, grease the surface of the safety flange (7)
diameter, fasten it onto the hub of the arm. that touches the crown wheel.
922 BOMAG
40 008 911 71
Axle DANA 193 16.5
Fissare la posizione degli ingranaggi satelliti (14) con Lubrificare e montare sull'attrezzo T5 l'anello centra-
ITA gli anelli elastici (13). ITA tore (12) e l'anello di tenuta (11); montare gli anelli nel
braccio.
ATTENZIONE! Controllare attentamente il senso di montaggio
degli anelli.
Die Position der Planetengetriebe (14) mit den Das Werkzeug T5 schmieren und darauf den Zen-
D Kolbenringen (13) festigen. D trierring (12) und den Dichtring (11) montieren; die
Ringe in den Arm montieren.
ACHTUNG! Montagerichtung der Ringe sorgfaÈltig kontrollieren.
a b
Fijar la posicioÁn de los engranajes satelites (14) con Lubrificar y montar sobre la herramienta T5 el anillo
ESP los anillos elasticos (13). ESP central (12) y el anillo de retencioÁn (11); montar los
anillos en el eje.
ATENCION! Controlar atentamente el sentido de montaje de los
anillos.
Fixer les engrenages porte-satellites (14) aÁ leur place Lubrifier et monter sur l'outil T5 l'anneau centreur (12)
F avec les anneaux ressorts (13). F et l'anneau d'eÂtancheÂiteÂ (11); monter les anneaux
dans le bras.
ATTENTION! ControÃler attentivement le sens du montage des
anneaux.
Lubrificare con grasso l'anello di tenuta (9) ed il mozzo Montare il cuscinetto esterno (8).
ITA del braccio. ITA
NOTA. Mandare a fondo corsa il cuscinetto con
Montare il mozzo portaruota (3). leggeri colpi di mazzuolo distribuiti su tutta la
circonferenza.
Mit Fett den Dichtring (9) und die Armnabe schmieren. AÈuûeres Lager (8) montieren.
D Radhalternabe (3) montieren. D
BEMERKUNG. Das Lager bis zum Anschlag mit
leichten HammerschlaÈgen an der gesamten Kreislinie
einsetzen.
c d
Lubrificar con grasa el anillo de retencioÁn (9) y el cubo Montar el cojinete esterno (8).
ESP del eje. ESP
NOTA. Mandar a tope el cojinete con ligeros colpes de
Montar el cubo lleva-rueda (3). martillo repartidos sobre toda la circonferencia.
Lubrifier avec de la graisse l'anneau d'eÂtancheÂiteÂ (9), Monter le palier externe (8).
F le moyeu du bras. F
REMARQUE. Envoyer en buteÂe le palier avec de
Monter le moyeu porte-roue (3). leÂgers coups de maillet distribueÂs tout autour de la
circonfeÂrence.
Montare la corona (5) e, utilizzando uno spintore di Lubrificare con grasso Tecno Lupe /101 la superficie
ITA diametro adatto, mandarla in battuta sul mozzo del ITA della flangia di sicurezza (7) a contatto con la corona.
braccio.
Den Kranz (5) montieren und mit einem geeigneten Mit Fett Typ Tecno Lupe/ 101 die FlaÈche des Sicher-
D StoÈûel den Kranz bis zum Anschlag an der Armnabe D heitsflanschs (7), der am Kranz anliegt, schmieren.
einsetzen.
e f
Montar la corona (5) y, utilizando un empuje de Lubrificar con grasa Tecno Lupe/101 la superficie de
ESP diametro apto, mandarla a tope sobre el cubo del eje. ESP la brida de seguridad (7) a contacto con la corona.
Monter la couronne (5), puis aÁ l'aide d'un poussoir Lubrifier avec de la graisse Tecno Lupe/ 101 la
F d'un diameÁtre adapteÂ, envoyer celle-ci en buteÂe sur le F superficie de la flasque de seÂcuriteÂ (7) au contact de
moyeu du bras. la couronne.
008 911 71 BOMAG

41 923
Axle DANA 193
- PLANETENGE-
F1241130 F1241107
GB a GB b
Coat the screws (6) with Loctite 270 and screw them. Lubricate the snap ring (11), the toothed portions and the sealing
Tighten screws (6) in two stages, using the criss-cross method. surface of the axle shaft.
Initial torque wrench setting: 120 Nm Install the axle shaft (4), making sure that it is properly inserted into
Final torque wrench setting: 219 ± 242 Nm braking disks and differential unit.
F1241131 F1241132
GB c GB d
Fit the planetary gear cover (2) onto the wheel hub (3). Lock the planetary gear cover (2) onto the wheel hub (3) with
CAUTION! 1 - Check the condition and position of the O-ring (16). screws (1).
2 - Line up the locating release points. Screws torque wrench setting: 40 ± 0 Nm.
GB e GB f
924 BOMAG
42 008 911 71
Axle DANA 193 16.5
Spalmare le viti (6) con Loctite 270 ed avvitarle. Lubrificare l'anello di tenuta (11), le dentature e la
ITA Serrare le viti (6) in due tempi e con il metodo del ITA superficie di tenuta del semiasse.
serraggio incrociato. Montare il semiasse (4) assicurandosi che si innesti
Coppia di serraggio iniziale: 120 Nm nei dischi freni e nel differenziale.
Coppia di serraggio finale: 219v242 Nm
Die Schrauben (6) mit Loctite 270 schmieren und Dichtring (11), ZaÈhne und DichtflaÈche der Halbachse
D festschrauben. D schmieren.
Schrauben (6) im Kreuz schrittweise festziehen. Halbachse (4) montieren und darauf achten, daû sie in
Anzugsmoment zuerst: 120Nm die Bremsscheiben und in das Differential einrastet.
a Anzugsmoment am Ende: 219v242 Nm b
Pasar los tornillos (6) con Loctite 270 y atornillarlos. Lubrificar el anillo de retencioÁn (11), las dentaduras y
ESP Apretar los tornillos (6) en doss tiempos con el metodo ESP la superficie del semieje.
de torsion cruzada. Montar el semieje (4) asegurandose que se encaje en
Par de torsion inicial: 120 Nm. los discos y en el diferencial.
Par de torsion final: 219v242 Nm.
Enduire les vis (6) avec du Loctite 270 puis visser. Lubrifier l'anneau d'eÂtancheÂiteÂ (11), les dents, la
F Serrer les vis (6) en deux temps avec la meÂthode du F superficie eÂtanche des demi-essieux.
serrage croiseÂ. Monter le demi-essieu (4) en veillant aÁ ce qu'il
Couple de serrage initial: 120Nm s'enclenche bien dans les disques freins et dans le diffeÂrentiel.
Couple de serrage final: 219v242 Nm.
Montare il coperchio portasatelliti (2) sul mozzo Bloccare il coperchio portasatelliti (2) sul mozzo
ITA portaruota (3). ITA portaruota (3) con le viti (1).
ATTENZIONE! 1 - Controllare lo stato e la posizione Coppia di serraggio viti: 40v50 Nm
della guarnizione OR (16).
2 - Allineare gli scarichi di riferimento.
Den Deckel des Planetenradhalters (2) auf die Nabe Den Deckel des Planetenradhalters (2) an der Rad-
D des Radhalters (3) montieren. D halternabe (3) mit den Schrauben (1) blockieren.
ACHTUNG! 1 - Zustand und Position der O-Ringe (16) Anzugsmoment der Schrauben: 40v50 Nm
kontrollieren.
c 2 - Die Bezugsstellen bzw. AblaûoÈffnung fluchten. d
Montar la tapa lleva-satelites (2) sobre el cubo lleva- Bloquear la tapa lleva-satelietes (2) sobre el cubo
ESP rueda (3). ESP lleva-rueda (3) con los tornillos (1).
ATENCION! 1 - Controlar el estado y la posicioÁn de la Par de torsion tornillos: 40v50 Nm
guarnicioÁn OR (16).
2 - Alinear los descarges de referencia.
Monter le couvercle porte-satellite (2) sur le moyeu Bloquer le couvercle porte-satellite (2) sur le moyeu
F porte-roue (3). F porte-roue (3) aÁ l'aide des vis (1).
ATTENTION! 1 - ControÃler l'eÂtat et la position des Couple de serrage des vis: 40v50 Nm.
garnitures O'Ring (16).
2 - Aligner les points de deÂcharge de reÂfeÂrence.
ITA ITA
D D
e f
ESP ESP
F F
008 911 71 BOMAG

43 925
16.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL
T6
T7A
F1241141 F1241142
GB a GB b
REMOVAL OF THE DIFFERENTIAL UNIT Apply tool T6 - for crown wheel side centring - with relative distance
Remove the whole arms, the cylinders, and the whole reduction pieces and lock it with two nuts.
unit. Apply centring tool T7A as well.
For details, see «CHECKING WEAR AND REPLACING THE
BRAKING DISKS» and «REMOVAL OF REDUCTION GEAR».
T7B
F1241143 F1241144
GB c GB d
Remove the stud screws and remove the intermediate cover (1) on Install centring tool T7B on the opposite side of the crown wheel.
the crown wheel opposite side.
T7B
A
F1241145 F1241146
GB e GB f
Remove centring tools T6 and T7A from crown wheel side; remove Position a stop block «A» made from tender material (aluminium,
the studs and the intermediate cover (2) on the crown wheel side. etc.) between the main body (3) and the toothed portion of the
crown wheel (4).
With the crown (4) resting on block "A", remove and extract the
screws (5) and the spring washers (6).
926 BOMAG
44 008 911 71
Axle DANA 193 16.5
RIMOZIONE DIFFERENZIALE Applicare l'attrezzo T6 di centraggio dal lato corona

ITA Rimuovere i bracci completi, i cilindri freni ed il ITA con i relativi distanziali e fissarlo con due dadi.
riduttore completo. Applicare anche l'attrezzo T7A di centratura.
Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE
DISCHI FRENO» e «RIMOZIONE RIDUTTORE».
DIFFERENTIAL ABNEHMEN Das Werkzeug T6 zur Zentrierung an der Kranzseite

D Die kompletten Arme, die Bremszylinder und den D mit den entsprechenden DistanzstuÈcken anbringen
kompletten Reduzierer abnehmen. und das Werkzeug mit zwei Muttern befestigen.
Siehe «VERSCHLEISS KONTROLLIEREN UND BREMSSCHEI- Das Werkzeug T7A zur Zentrierung anbringen.
a BEN AUSWECHSELN» und «REDUZIERER ABNEHMEN». b
REMOCION DIFERENCIAL Aplicar la herramienta T6 de centraje del lado corona
ESP Remover los ejes completos, los cilindros frenos y el ESP con los relativos distanciales y fijarla con dos tuercas.
reductor completo. Aplicar tambien la herramienta T7A de centradura.
Para los detalles, vease «CONTROL DESGASTE Y SOBSTITU-
CION DISCOS FRENOS» y «REMOCION REDUCTOR».
DEGAGEMENT DU DIFFERENTIEL Appliquer l'outil T6 de centrage du coÃteÂ couronne

F Enlever les bras entieÁrement, les cylindres freins et le F avec les entretoises correspondantes et fixer l'outil
reÂducteur tout entier. avec deux eÂcrous.
Pour de plus amples deÂtails, voir "CONTROLE DE L'USURE ET Appliquer eÂgalement l'outil de centrage T7A.
SUBSTITUTION DU DISQUE FREIN" et "DEGAGEMENT DU
REDUCTEUR".
Rimuovere le viti prigioniere e rimuovere il coperchio Montare l'attrezzo T7B di centraggio sul lato opposto
ITA intermedio (1) dal lato opposto corona. ITA corona.
Die Stiftschrauben und den Zwischendeckel (1) von Das Werkzeug T7B zur Zentrierung an der dem Kranz
D der dem Kranz entgegengesetzte Seite abnehmen. D entgegengesetzte Seite montieren.
c d
Remover los tornillos prigioneros y remover la tapa Montar la herramienta T7B de centraje sobre el lado
ESP intermedia (1) del lado opuesto corona. ESP opuesto corona.
Enlever les vis prisonnieÁres et enlever le couvercle Monter l'outil de centrage T7B du coÃteÂ opposeÂ aÁ la
F intermeÂdiaire (1) du coÃteÂ opposeÂ aÁ la couronne. F couronne.
Rimuovere gli attrezzi T6 e T7A di centraggio del lato Posizionare tra il corpo centrale (3) e la dentatura della
ITA corona; asportare i prigionieri e rimuovere il coperchio ITA corona (4) un blocchetto "A" di contrasto in materiale
intermedio (2) lato corona. tenero (alluminio ecc.).
Mantenendo in appoggio la corona (4) sul blocchetto "A",
rimuovere ed asportare le viti (5) e le rondelle elastiche (6).
Die Werkzeuge T6 und T7A zur Zentrierung an der Zwischen dem ZentralkoÈrper (3) und den ZaÈhnen des
D Kranzseite entfernen; die Stiftschrauben und den D Kranzes (4) den Block "A" aus weichem Material
Zwischendeckel (2) an der Kranzseite abnehmen. (Aluminium usw.) legen.
Den Kranz (4) am Block "A" anliegen lassen und die Schrauben (5)
e f und die Federscheiben (6) abnehmen.
Remover las herramientas T6 y T7A de centraje del Colocar entre el cuerpo central 83) y la dentadura de
ESP lado corona; sacar los prigioneros y remover la tapa ESP la corona (4) un bloque "A" de contraste de material
intermedia (2) lado corona. tierno (aluminio ect.).
Manteniendo en apoyo la corona (4) sobre el bloque "A", remover y
sacar los tornillos (5) y las arandelas elasticas (6).
Enlever les outils T6 et T7A de centrage du coÃteÂ Placer entre le corps central (3) et la denture de la
F couronne; enlever les prisonniers et deÂplacer le F couronne (4) un petit bloc "A" en mateÂriel leÂger
couvercle intermeÂdiaire (2) du coÃteÂ couronne. (aluminium etc.) de contraste.
En maintenant la couronne (4) sur le petit bloc "A", deÂvisser et
enlever les vis (5), et ensuite les rondelles eÂlastiques (6).
008 911 71 BOMAG

45 927
16.5 Axle DANA
F1241147 F1241148
GB a GB b
Using a driver, push the differential unit (7) or (8) towards the Extract the whole differential unit (7) or (8).
opposite side of the crown so as to disengage it from the crown (4).
T7B
F1241223 F1241174
GB c GB d
Remove tool T7B from the crown opposite side. Extract the crown (4).
F1241149 F1241150
GB e GB f
DISASSEMBLY OF THE DIFFERENTIAL UNIT DISASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT
Using an extractor, remove bearings (9) from the differential unit. Insert stay "B" provided for holding into position the no-spin unit
(14) and screw tight the wing nut.
928 BOMAG
46 008 911 71
Axle DANA 193 16.5
Utilizzando uno spintore, spingere il differenziale (7) o Estrarre il gruppo differenziale (7) o (8) completo.
ITA (8) verso il lato opposto corona fino a disimpegnarlo ITA
dalla corona (4).
Mit einem StoÈûel das Differential (7) oder (8) in die dem Das komplette Differentialaggregat (7) oder (8) ab-
D Kranz entgegengesetzte Seite druÈcken und aus dem D ziehen.
Kranz (4) freisetzen.
a b
Utilizando un empuje, empujar el diferencial (7) o (8) Sacar el grupo diferencial (7) o (8) completo.
ESP hacia el lado opuesto corona hasta desempenarlo de ESP
la corona (4).
A l'aide d'un poussoir, pousser le diffeÂrentiel (7) ou (8) Extraire le groupe diffeÂrentiel (7) ou (8) tout entier.
F du coÃteÂ opposeÂ aÁ la couronne jusqu'aÁ le deÂgager de la F
couronne (4).
Rimuovere l'attrezzo T7B montato sul lato opposto Estrarre la corona (4).
ITA corona. ITA
Das Werkzeug T7B abnehmen, das an der dem Kranz Kranz (4) abziehen.
D entgegengesetzte Seite montiert ist. D
c d
Remover la herramienta T7B montado sobre el lado Extraer la corona (4).
ESP opuesto corona. ESP
DeÂplacer l'outil T7B monteÂ du coÃteÂ opposeÂ aÁ la Extraire la couronne (4).

F couronne. F
SMONTAGGIO DIFFERENZIALE SMONTAGGIO DIFFERENZIALE NO-SPIN

ITA Utilizzando un estrattore, asportare i cuscinetti (9) dal ITA Inserire il tirante "B" di trattenimento del gruppo no-
gruppo differenziale. spin (14) ed avvitare a fondo il dado ad alette.
DIFFERENTIAL ABMONTIEREN DAS NO-SPIN DIFFERENTIAL ABMONTIEREN

D Mit einem Abzieher die Lager (9) vom Differentialag- D Sie Spannstange "B" einsetzen, um das No-Spin
gregat abnehmen. Aggregat (14) festzuhalten und die FluÈgelmutter fest-
ziehen.
e f
DESMONTAJE DIFERENCIAL DESMONTAJE DIFERENCIAL NO-SPIN
ESP Utilizando un extractor, sacar los cojinetes (9) del ESP Introducir el tirante "B" de detencion del grupo no-spin
grupo diferencial. (14) y atornillar hasta el fondo la tuerca a aletas.
DEMONTAGE DU DIFFERENTIEL DEMONTAGE DU DIFFERENTIEL NO-SPIN

F A l'aide d'un extracteur, enlever les paliers (9) du F Introduire la tringle "B" de retenue du groupe no-spin
groupe diffeÂrentiel. (14), puis visser l'eÂcrou aÁ ailettes aÁ fond.
008 911 71 BOMAG

47 929
16.5 Axle DANA
F1241151 F1241152
GB a GB b
Remove the screws (10) and the spring washers (11) jointing the Using a plastic hammer, take the half box (12) to pieces.
differential unit half box (12). NOTE. Note down the coupling marks.
F1241153 F1241154
GB c GB d
Extract the no-spin unit (13). Unscrew the wing nut of stay "B" and take the no-spin unit to
pieces in order to remove the distance piece (14) that prevents the
axial sliding of the axle shafts.
F1241155 F1241156
GB e GB f
DISASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Remove the differential cover (18), any shims (19) and the friction
Remove the screws (16) and the spring washers (17) jointing the (20) complete with ring (21).
differential unit. CAUTION! 1 - Do not change the position of the disks forming the
friction.
2 - Check that the overall thickness of friction exceeds 17.3 mm; if
lower, substitute both friction units.
930 BOMAG
48 008 911 71
Axle DANA 193 16.5
Rimuovere le viti (10) e le rondelle elastiche (11) di Utilizzando un mazzuolo in materiale plastico scom-
ITA unione della semiscatola differenziale (12). ITA porre la semiscatola differenziale (12).
NOTA. Annotare la marcatura di accoppiamento.
Schrauben (10) und Federscheiben (11) abnehmen, Mit einem Gummihammer das halbe Differentialge-
D die das halbe DifferentialgehaÈuse (12) zusammen D haÈuse (12) zerlegen.
halten. BEMERKUNG. Die Kupplungsmarkierung notieren.
a b
Remover los tornillos (10) y las arandelas elasticas Utilizando un martillo en material plastico decomponer
ESP (11) de union de la semi-caja diferencial (12). ESP la semicaja diferencial (12).
NOTA. Anotar la marcatura de acoplamiento.
Enlever les vis (10) et les rondelles eÂlastiques (11) A l'aide d'un maillet en matieÁre plastique deÂcomposer
F d'union de la moitieÂ du boõÃtier diffeÂrentiel (12). F la moitieÂ du boõÃtier diffeÂrentiel (12).
REMARQUE. Prendre note de la marque d'accou-
plement.
Estrarre il gruppo no-spin (13). Svitare il dado ad alette del tirante "B" e scomporre il
ITA ITA gruppo no-spin per rimuovere il distanziale (14) contro
lo scorrimento assiale dei semiassi.
Das No-Spin Aggregat (13) abziehen. Die FluÈgelmutter der Spannstange "B" abschrauben
D D und das No-Spin Aggregat zerlegen, um das Differen-
tial (14) an der Achsengleitung der Halbachsen
abnehmen zu koÈnnen.
c d
Sacar el grupo no-spin (13). Destornillar la tuerca a aletas del tirante "B" y
ESP ESP decomponer el grupo no-spin para remover el distan-
cial (14) contra el deslizamiento axial de los semi-ejes.
Extraire le groupe no-spin (13). DeÂvisser l'eÂcrou aÁ ailettes de la tringle "B" et

F F deÂcomposer le groupe no-spin pour enlever le
diffeÂrentiel (14) contre le coulisseau axial des demi-
essieux.
SMONTAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Rimuovere il coperchio differenziale (18), gli eventuali
ITA Rimuovere le viti (16) e le rondelle elastiche (17) di ITA spessori (19) e la frizione (20) completa dell'anello (21).
unione del corpo differenziale. ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.
DAS ZU 45% SELBSTHEMMENDE DIFFERENTIAL ABMONTIEREN Differentialdeckel (18) und evtl. Unterlegscheiben (19)
D Schrauben (16) und Federscheiben (17), die den D und die Kupplung (20) mit dem Ring (21) abnehmen.
DifferentialkoÈrper verbinden, abnehmen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
e f 2 - Die GesamtstaÈrke der Kupplung muû mehr als 17,3 mm betragen;
sollte dies nicht der Fall sein, beide Kupplungen auswechseln.
DESMONTAJE DIFERENCIAL AUTOBLOQUEO AL 45% Remover la tapa diferencial (18), los eventuales
ESP Remover los tornillos (16) y las arandelas elasticas ESP espesores (19) y la fricion (20) completa del anillo (21).
(17) de union del cuerpo diferencial. ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3
mm; si es inferior sobstituir las dos friciones.
DEMONTAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Enlever le couvercle diffeÂrentiel (18), les eÂventuelles
F Enlever les vis (16), les rondelles eÂlastiques (17) F cales (19) et la friction (20) compleÁte d'anneau (21).
d'union du corps diffeÂrentiel. ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.
008 911 71 BOMAG

49 931
16.5 Axle DANA
F1241157 F1241158
GB a GB b
Remove the planetary gear (22). Remove the long planetary carrier journal (23) and the two short
Mark the 37 mm value on a pin-driver; using the same pin-driver, journals (24).
insert the spring pins (25) into the journals (23) and (24).
NOTE. The spring pins are centred in journals (23) and (24) when
the countermark is lined up with the edge of the body of the
differential unit (26).
F1241159 F1241160
GB c GB d
Extract the cross journal (27), the planet wheels (28) complete with Remove the 2nd friction (20) complete with ring (21). Also remove
shim washers (29) and the second planetary gear (22). any shims (19).
CAUTION! 1 - Do not change the position of the disks forming the
friction.
2 - Check that the overall thickness of friction exceeds 17.3 mm; if
lower, substitute both friction units.
F1241161 F1241162
GB e GB f
Extract the spring pins (25) from journals (23) and (24). Only if bearings are replaced.
Remove the thrust blocks of bearings (9) from the intermediate
covers (1) and (2).
932 BOMAG
50 008 911 71
Axle DANA 193 16.5
Rimuovere l'ingranaggio planetario (22). Rimuovere il perno porta satelliti lungo (23) ed i due
ITA Segnare su un cacciaspine un contrassegno a 37 mm; ITA perni corti (24).
utilizzando lo stesso cacciaspine, inserire nei perni
(23) e (24) le spine elastiche (25).
NOTA. Le spine elastiche sono centrate nei perni (23) e (24)
quando il contrassegno arriva a filo del corpo differenziale (26).
Das Planetengetriebe (20) abnehmen. An einem DuÈ- Den langen Planetenradhalterstift (23) und die beiden
D bel das Maû von 37 mm markieren; mit diesem DuÈbel D kurzen Planetenradhalterstifte (24) entfernen.
die Federstifte (25) in die Stifte (23) und (24) einsetzen.
BEMERKUNG. Die Federstifte sind in den Stiften (23) und (24)
a zentriert, wenn das markierte Maû auf der HoÈhe des Differential- b
koÈrpers (26) liegt.
Remover el engranaje planetario (22). Senalizar sobre Remover la rotula porta satelites largo (23) y las dos
ESP un extractor de clavijas un contra-segno a 37 mm; ESP rotulas cortas (24).
utilizando el mismo extractor de clavijas, introducir en
los pernos (23) y (24) las clavijas elasticas (25).
NOTA. Las clavijas elasticas son centradas en los pernos (23) y
(24) cuando el contrasegno llega al hilo del cuerpo diferencial (26).
Enlever l'engrenage planeÂtaire (22). Marquer d'une Enlever le pivot porte-satellite long (23) et les deux
F estampille le chasse-clou aÁ 37 mm; a l'aide de ce meÃme F pivots courts (24).
chasse-clou, introduire dans les pivots (23) et (24) les
goupilles eÂlastiques (25).
REMARQUE. Les goupilles eÂlastiques sont centreÂes dans les pivots
(23) et (24) quand l'estampille atteint le bord du corps diffeÂrentiel (26).
Estrarre la crociera (27), i satelliti (28) completi delle Rimuovere la 2ã frizione (20) completa dell'anello (21).
ITA rondelle di rasamento (29) ed il 2ë ingranaggio ITA Rimuovere anche gli eventuali spessori (19).
planetario (22). ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se eÁ inferiore sostituire ambedue le frizioni.
Das Kreuz (27), die Planetengetriebe (28) samt Die 2. Kupplung (20) mit Ring (21) abnehmen.
D Zwischenlegscheiben (29) und das 2. Planetengetrie- D Eventuelle Unterlegscheiben (19) auch entfernen.
be (30) abziehen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
c d 2 - Kontrollieren, ob die GesamtstaÈrke der Kupplung mehr als 17,3 mm
betraÈgt; anderenfalls beide Kupplungen auswechseln.
Sacar la cruceta (27), los satelites (28) completos de Remover la 2ë fricion (30) completa del anillo (21).
ESP las arandelas de rasamiento (29) y el 2ë engranaje ESP Remover tambien los eventuales espesores (19).
planetario (22). ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3 mm;
si es inferior sobstituir las dos friciones.
Extraire le croisillon (27), les satellites (28) complet de Enlever la 2ë friction (20) compleÁte d'anneau (21).
F rondelles de rasage (29), puis le 2ë engrenage F Enlever eÂgalement les eÂventuelles cales (19).
planeÂtaire (22). ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.
Estrarre le spine elastiche (25) dai perni (23) e (24). Solo se si sostituiscono i cuscinetti
ITA ITA Rimuovere le ralle dei cuscinetti (9) dai coperchi
intermedi (1) e (2).
Die Federstifte (25) von den Stiften (23) und (24) Nur falls die Lager ausgewechselt werden.
D abziehen. D Die Scheiben von den Lagern (9) der Zwischendeckel
(1) und (2) abnehmen.
e f
Sacar las clavijas elasticas (25) de las rotulas (23) y Solo si se sobstituiyen los cojinetes
ESP (24). ESP Remover las ranguas de los cojinetes (9) de las tapas
intermedias (1) y (2).
Extraire les goupilles eÂlastiques (25) des pivots (23) et Uniquement en cas de substitution des paliers.
F (24). F Enlever les crapaudines des paliers (9) des couvercles
intermeÂdiaires (1) et (2).
008 911 71 BOMAG

51 933
16.5 Axle DANA
GB a GB b
GB c GB d
D1240134
GB e GB f
934 BOMAG
52 008 911 71
Axle DANA 193 16.5
ITA ITA
D D
a b
ESP ESP
F F
ITA ITA
D D
c d
ESP ESP
F F
D1240135
ITA ITA
D D
e f
ESP ESP
F F
008 911 71 BOMAG

53 935
16.5 Axle DANA
REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - 193
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL
F1241154 F1241163
GB a GB b
ASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT Fit the no-spin unit into the differential unit half box (15).
Assemble the no-spin unit (13), inserting the distance piece (14) Centre the half box (12) and fasten.
and using stay "B". CAUTION! Make sure the connection marks coincide.
F1241164 F1241150
GB c GB d
Fit the spring washers (11) onto the screws (10). Remove stay "B".
Coat the screws (10) with Loctite 270 and screw tight to form the
differential box. Tighten screws using the criss-cross method and a
torque of 86 ± 89 Nm.
17,6
F1241224 F1241160
GB e GB f
ASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Insert in the body of the differential unit (26) any required shims
Using a depth gauge, check the shim of friction units complete with (19) and the friction (20) complete with ring (21).
rings (21). If thickness is lower than 17.6 mm, add more shims (19). CAUTION! Ring (21) must touch the planetary gear (22).
CAUTION! Shims must be placed right behind the body of the
differential unit (26).
936 BOMAG
54 008 911 71
Axle DANA 193 16.5
ASSEMBLAGGIO DIFFERENZIALE NO-SPIN Montare il gruppo no-spin nella semiscatola differen-

ITA Assemblare il gruppo no-spin (13) inserendo il distan- ITA ziale (15).
ziale (14) ed utilizzando il tirante "B". Centrare la semiscatola (12) e mandarla in battuta.
ATTENZIONE! Controllare che le marcature di accoppiamento
coincidano.
NO-SPIN DIFFERENTIAL ZUSAMMENBAUEN Das No-Spin Aggregat in das halbe Differentialge-

D Das No-Spin (13) Aggregat zusammenbauen; dazu D haÈuse (15) montieren.
das DistanzstuÈck (14) mit der Spannstange "B" Das halbe GehaÈuse (12) zentrieren und bis zum
einsetzen. Anschlag einsetzen.
a b ACHTUNG! Kontrollieren, ob die Kupplungsmarkierungen uÈberein-
stimmen.
MONTAJE DIFERENCIAL NO-SPIN Montar el grupo no-spin en la semi-caja diferencial

ESP Asemblaje el grupo no-spin (13) introduciendo el ESP (15).
diferencial (14) y utilizando el tirante "B". Centrar la semi-caja (12) y mandarla a tope.
ATENCION! Controlar que las marcaduras de acoplamiento
coincidan.
ASSEMBLAGE DU DIFFERENTIEL NO-SPIN Monter le groupe no-spin dans la moitieÂ du boõÃtier

F Assembler le groupe no-spin (13) en introduisant F diffeÂrentiel (15).
l'entretoise (14), puis aÁ l'aide de la tringle "B". Centrer la moitieÂ du boõÃtier (12) et l'envoyer en buteÂe.
ATTENTION! ControÃler que les estampilles d'accouplement
correspondent.
Infilare sulle viti (10) le rondelle elastiche (11). Rimuovere il tirante "B".
ITA Spalmare le viti (10) con Loctite 270 ed avvitarle a ITA
fondo per comporre la scatola differenziale.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
86v89 Nm.
Federscheiben (11) in die Schrauben (10) einsetzen. Spannstange "B" abnehmen.

D Die Schrauben (10) mit Loctite 270 schmieren und D
festziehen, um das DifferentialgehaÈuse zusammenzu-
bauen.
c Die Schrauben im Kreuz und mit einem Anzugsmoment von 86v89
Nm festziehen.
d
Insertar sobre tornillos (10) las arandelas elasticas Remover el tirante "B".
ESP (11). ESP
Pasar los tornillos (10) con Loctite 270 y atornillar
hasta el fondo para componer la caja diferencial.
Apretar los tornillos con el metodo cruzado y un par de serraje de
86v89 Nm.
Passer sur les vis (10) les rondelles eÂlastiques (11). Enlever la tringle "B".
F Enduire les vis (10) avec du Loctite 270, puis visser F
celles-ci aÁ fond pour recomposer le boõÃtier diffeÂrentiel.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
86v89 Nm.
ASSEMBLAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Inserire nella corpo differenziale (26) gli eventuali
ITA Controllare con un calibro di profonditaÁ lo spessore ITA spessori (19) e la frizione (20) completa dell'anello
delle frizioni complete degli anelli (21). Se lo spessore (21).
eÁ inferiore a 17,6 mm, aggiungere degli spessori (19). ATTENZIONE! L'anello (21) deve rimanere a contatto dell'ingra-
ATTENZIONE! Gli spessori devono essere posizionati a ridosso del naggio planetario (22).
corpo differenziale (26).
ZU 45% SELBSTHEMMENDE DIFFERENTIAL ZUSAMMENBAUEN In den DifferentialkoÈrper (26) eventuelle Unterleg-

D Mit Hilfe einer Tiefenlehre die StaÈrke der Kupplungen D scheiben (19) und die Kupplung (20) samt Ring (21)
mit den Ringen (21) messen. Sollte das Maû weniger einsetzen.
als 17,6 mm betragen, noch Unterlegscheiben (19) hinzufuÈgen. ACHTUNG! Der Ring (21) muû am Planetengetriebe (22) anliegen.
e ACHTUNG! Die Unterlegscheiben muÈssen am DifferentialkoÈrper f
(26) anliegen.
MONTAJE DIFERENCIAL AUTO-BLOQUEO AL 45% Introducir en el cuerpo diferencial (26) los eventuales
ESP Controlar con un calibro de profundidad el espesor de ESP espesores (19) y la fricion (20) completa del anillo (21).
las friciones completas de los anillos (21). Si el ATENCION! El anillo (33) debe quedar a contacto del
espesor es inferior a 17,6 mm, sumar de los espesorees (19). engranaje planetario (22).
ATENCION! Los espesores deben de ser colocados detraÁs del
cuerpo diferencial (26).
ASSEMBLAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Introduire le corps diffeÂrentiel (26), les eÂventuelles
F ControÃler aÁ l'aide d'un calibre de profondeur l'eÂpais- F cales (19) et la friction (20) compleÁte d'anneau (21.
seur des frictions compleÁtes d'anneaux (21). Si le ATTENTION! L'anneau (21) doit rester au contact de
calage est infeÂrieur aÁ 17,6 mm, ajouter des cales (19). l'engrenage planeÂtaire (22).
ATTENTION! Les cales doivent eÃtre placeÂes aÁ l'abri du corps
diffeÂrentiel (226).
008 911 71 BOMAG

55 937
16.5 Axle DANA
F1241165 F1241166
GB a GB b
Install the planetary gear (22) and three of the planet wheels (28), Install the cross journal (27), holding it into position with the long
complete with shim washers (29). journal (23).
Hold the planet wheels (28) and relative washers (29) into position Before inserting journal (23) completely, install the last planet
with pins (24). wheel (28) and the relative washer (29).
25,5
F1241167 F1241168
GB c GB d
Countermark a point at 25.5 mm on a pin-driver; using the same Install the second planetary gear (22) and the friction (20) complete
pin-driver, engage the journals (23) and (24) with the spring pins with ring (21) and any shims required (19).
(25). CAUTION! Ring (21) must be installed right behind the planetary
NOTE. When the countermark is lined up with the edge of the body gear (22) and the shims (19) right behind the differential cover (18).
of the differential unit (26), the journals are engaged by half.
F1241169 F1241170
GB e GB f
Position the differential cover (18). Fit the spring washers (17) onto the screws (16).
NOTE. Make sure that the assembly marks coincide. Coat the screws (16) with Loctite 270 and screws tight.
Tighten screws using the criss-cross method and a torque of
135 ± 138 Nm.
938 BOMAG
56 008 911 71
Axle DANA 193 16.5
Montare l'ingranaggio planetario (22) e tre degli Montare la crociera (27) e mantenerla in posizione con
ITA ingranaggi satelliti (28) completi di rondelle di rasa- ITA il perno lungo (23).
mento (29). Prima di inserire completamente il perno (23), montare
Mantenere in posizione gli ingranaggi satelliti (28) e le relative l'ultimo satellite (28) e la relativa rondella (29).
rondelle (29) con i perni (24).
Das Planetengetriebe (22) und drei der Planetenge- Das Kreuz (27) montieren und in der Position mit
D triebe (28) samt Zwischenlegscheiben (29) montieren. D einem langen Stift (23) festhalten.
Die Planetengetriebe (28) und die Zwischenlegschei- Bevor der Stift (23) ganz eingesetzt wird, das letzte
ben (29) mit den Stiften (24) in der Position festhalten. Planetengetriebe (28) und die Unterlegscheibe (29) montieren.
a b
Montar el engranaje planetario (22) y tres de los Montar la cruceta (27) y mantenerla en posicion con la
ESP engranajes satelites (28) completos de las arandelas ESP rotula larga (28).
de rasadura (29). Antes de insertar completamente la rotula (23), montar
Mantener en posicion los engranajes satelites (28) y las relativas el ultimo satelite (28) y la relativa arandela (29).
arandelas (29) con las rotulas (24).
Monter l'engrenage planeÂtaire (22) et trois des Monter le croisillon (27) et maintenir celui-ci aÁ sa place
F engrenages satellites (28) complets de rondelles de F aÁ l'aide du pivot long (23).
rasage (29). Avant d'introduire entieÁrement le pivot (23), monter le
Maintenir les engrenages satellites (28) et relatives rondelles (29) aÁ dernier satellite (28) et sa rondelle (29).
leur place avec les pivots (24).
Segnare sul cacciaspine un contrassegno a 25,5 mm; Montare il secondo ingranaggio planetario (22) e la
ITA utilizzando lo stesso cacciaspine impegnare i perni ITA frizione (20) completa dell'anello (21) e degli eventuali
(23) e (24) con le spine elastiche (25). spessori (19).
NOTA. Le spine impegnano metaÁ dei perni quando il contrassegno ATTENZIONE! L'anello (21) deve essere montato a ridosso
arriva a filo del corpo differenziale (26). dell'ingranaggio planetario (22) e gli eventuali spessori (19) a
ridosso del coperchio differenziale (18).
An dem DuÈbel das Maû von 25,5 mm markieren; mit Das zweite Planetengetriebe (22) und die Kupplung
D demselben DuÈbel die Stifte (23) und (24) mit den D (20) mit dem Ring (21) und eventuelle Unterlegschei-
Federstiften (25) einsetzen. ben (19) montieren.
BEMERKUNG. Die Stifte sind durch die Federstifte zur HaÈlfte ACHTUNG! Der Ring (21) muû nach der Montage am Planetenge-
c eingesetzt, wenn die Markierung auf halber HoÈhe des Differential- d triebe (22) und die eventuellen Unterlegscheiben (19) muÈssen am
koÈrpers (26) liegt. Differentialdeckel (18) anliegen.
Senalar sobre el extractor de clavijas un contra-segno Montar el segundo engranaje planetario (22) y la
ESP a 25,5 mm; utilizando el mismo extractor de clavijas ESP fricion (20) completa del anillo (21) y de los eventuales
empegnar las rotulas (23) y (24) con las clavijas espesores (19).
elasticas (25). ATENCION! El anillo (21) debe deser montado detras del
NOTA! Las clavijas empegnan midad de las rotulas cuando el engranaje planetario (22) y los eventuales espesores (19) detras
contra-segno llega al borde del cuerpo diferencial (26). de la tapa diferencial (18).
Marquer d'une estampille le chasse-clou aÁ 25,5 mm; Monter le second engrenage planeÂtaire (22), la friction
F a l'aide de ce meÃme chasse-clou, engager les pivots F (20) compleÁte d'anneau (21) et des eÂventuelles cales
(23) et (24) et les goupilles eÂlastiques (25). (19).
REMARQUE. Les goupilles arrivent aÁ la moitieÂ des pivots quand ATTENTION! L'anneau (21) est aÁ monter aÁ l'abri de l'engrenage
l'estampille atteint le bord du corps diffeÂrentiel (26). planeÂtaire (22) et les eÂventuelles cales (19) aÁ l'abri du couvercle
diffeÂrentiel (18).
Posizionare il coperchio differenziale (18). Infilare sulle viti (16) le rondelle elastiche (17).
ITA ITA Spalmare le viti (16) con Loctite 270 ed avvitarle a
NOTA. Controllare che le marcature di montaggio
coincidano. fondo.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
135v138 Nm.
Den Differentialdeckel (18) positionieren. Auf die Schrauben (16) die Federscheiben (17)
D D montieren.
BEMERKUNG. Kontrollieren, ob die Montagemarkie-
rungen uÈbereinstimmen. Die Schrauben (16) mit Loctite 270 schmieren und
festziehen. Die Schrauben im Kreuz mit einem Anzugsmoment von
e f 135v138 Nm festziehen.
Colocar la tapa diferencial (18). Introducir sobre los tornillos (16) las arandelas
ESP ESP elasticas (17).
NOTA. Colocar que las marcaduras de montaje
coincidan. Pasar los tornillos (16) con Loctite 270 y atornillarlos a
fondo.
Apretar los tornillos con el metodo cruzado a un par de serraje de
135v138 Nm.
Mettre le couvercle diffeÂrentiel (18) en place. Passer sur les vis (16) les rondelles eÂlastiques (17).
F F Enduire les vis (16) avec du Loctite 270 et visser
REMARQUE. ControÃler que les estampilles de mon-
tage coõÈncident. celles-ci aÁ fond.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
135v138 Nm.
008 911 71 BOMAG

57 939
16.5 Axle DANA
F1241171 F1241172
GB a GB b
INSTALLATION OF THE DIFFERENTIAL UNIT Turn the unit upside down and install the second bearing (9).
Position the differential unit (7) or (8) under a press and, using a CAUTION! Pay particular attention; position a shim with adequate
driver with an adequate diameter, install the first bearing (9). diameter in order to engage the internal ring of bearing (9) without
engaging the cage.
T8
F1241173 F1241174
GB c GB d
Only if bearings are replaced Position the crown wheel (4) in the main body (3).
Using tool T8, insert the thrust blocks of the bearings (9) into the
intermediate covers (1) and (2).
T7B
F1241175 F1241176
GB e GB f
Fit tool T7B on the crown wheel opposite side, holding it in position Install the differential unit (7) or (8), by fitting it into the hole of tool
with two studs and two nuts. T7B.
NOTE. Engage the crown (4) onto tool T7B. Install the crown (4) onto the differential unit (7) or (8), and fasten it
to the flange.
NOTE. Make sure the holes of the flange match those of the crown.
940 BOMAG
58 008 911 71
Axle DANA 193 16.5
INSTALLAZIONE DIFFERENZIALE Capovolgere il gruppo e montare il secondo cuscinetto

ITA Posizionare il differenziale (7) o (8) sotto una pressa ed ITA (9).
utilizzando uno spintore di diametro adatto montare il ATTENZIONE! Prestare molta attenzione e posiziona-
primo cuscinetto (9). re uno spessore di diametro adatto al fine di impegnare l'anello
interno del cuscinetto (9) senza impegnare la gabbia.
DIFFERENTIAL ZUSAMMENBAUEN Das Aggregat wenden und das zweite Lager montie-
D Das Differential (7) oder (8) unter eine Presse legen D ren (9).
und mit einem geeigneten Dynamometer-StoÈûel das ACHTUNG! Den Vorgang mit groûer Sorgfalt durch-
erste Lager (9) montieren. fuÈhren und einen fuÈr die StaÈrke geeigneten Dynamometer
a b verwenden, um den Ring des inneren Lagers (9) einzusetzen,
ohne den KaÈfig einzuklemmen.
INSTALACION DIFERENCIAL Volcar el grupo y montar el segundo cojinete (9).

ESP Colocar el diferencial (7) y (8) bajo una prensa y ESP
ATENCION! Tener mucho cuidado y colocar un
utilizando un empuje de diametro adapto montar el espesor de diametro apto al fin de empegnar el anillo
primer cojinete (9). interno del cojinete (9) si empegnar la jaula.
INSTALLATION DU DIFFERENTIEL Faire basculer le groupe et monter le second palier (9).

F Mettre le diffeÂrentiel (7) ou (8) en place sous la presse, F
ATTENTION! Faire treÁs attention, mettre une cale au
aÁ l'aide d'un poussoir au diameÁtre adeÂquat, monter le diameÁtre adeÂquat afin d'engager l'anneau interne du
premier palier (9). palier (9) sans y engager la cage.
Solo se si sostituiscono i cuscinetti Posizionare la corona (4) dentro il corpo centrale (3).
ITA Utilizzando l'attrezzo T8 inserire le ralle dei cuscinetti ITA
(9) nei coperchi intermedi (1) e (2).
Nur wenn die Lager ausgewechselt werden. Den Kranz (4) in den zentralen KoÈrper (3) einsetzen.
D Mit dem Werkzeug T8 die Scheiben der Lager (9) in D
die Zwischendeckel (1) und (2) einsetzen.
c d
Solo si se sobstituyen los cojinetes Colocar la corona (4) dentro del cuerpo central (3).
ESP Utilizando la herramienta T8 Introducir las ranguas de ESP
los cojinetes (9) en las tapa intermedias (1) y (2).
Uniquement en cas de substitution des paliers Mettre la couronne (4) en place dans le corps central
F A l'aide de l'outil T8, introduire la crapaudine des F (3).
paliers (9) dans les couvercles intermeÂdiaires (1) et (2).
Montare l'attrezzo T7B sul lato opposto corona, Montare il gruppo differenziale (7) o (8) impegnandolo
ITA trattenendolo con due prigionieri e due dadi. ITA nel foro dell'attrezzo T7B.
NOTA. Impegnare la corona (4) sull'attrezzo T7B. Montare la corona (4) sul differenziale (7) o (8)
mandandola in battuta sulla flangia.
NOTA. Far coincidere i fori della flangia con i fori della corona.
Das Werkzeug T7B auf der dem Kranz entgegen- Das Differentialaggregat (7) oder (8) montieren und im
D gesetzten Seite montieren und mit zwei Stiftschrauben D Loch des Werkzeuges T7B einrasten.
und zwei Muttern festhalten. Den Kranz (4) auf das Differential (7) oder (8)
BEMERKUNG. Den Kranz (4) in das Werkzeug T7B einrasten. montieren und bis zum Anschlag am Flansch einsetzen.
e f BEMERKUNG. Die FlanschloÈcher muÈssen mit den KranzloÈchern
uÈbereinstimmen.
Montar la herramienta T7B sobre el lado opuesto Montar el grupo diferencial (7) o (8) empegnandolo en
ESP corona, deteniendo con dos prigionieros y dos ESP el agujero de la herramienta T7B.
tuercas. Montar la corona (4) sobre el diferencial (7) y (8)
NOTA. Empegnar la corona (4) sobre la herramienta T7B. mandandola a tope sobre la brida.
NOTA. Hacer coincidir los agujeros de la brida con los agujeros de
la corona.
Monter l'outil T7B du coÃteÂ opposeÂ aÁ la couronne, en le Monter le groupe diffeÂrentiel (7) ou (8) en l'engageant
F tenant aÁ l'aide de deux prisonniers et de deux eÂcrous. F dans le trou de l'outil T7B.
REMARQUE. Engager la couronne (4) sur l'outil T7B. Monter la couronne (4) sur le diffeÂrentiel (7) ou (8) puis
l'envoyer en buteÂe sur la flasque.
REMARQUE. Faire correspondre les trous de la flasque avec les
trous de la couronne.
008 911 71 BOMAG

59 941
16.5 Axle DANA
F1241177 F1241145
GB a GB b
Fit spring washers (6) onto the screws (5). Check the condition and position of the O-ring (30); lubricate the
Coat screws with Loctite 270 and screw them tight into the crown. seal and install the intermediate cover (2) on crown wheel side.
Position the stop block "A"; while holding the crown resting on the
block, tighten the screws (5) to a torque of 135 ± 138 Nm.
CAUTION! Tighten screws using the criss-cross method.
T6
T7A
F1241178 F1241179
GB c GB d
Lock the intermediate cover (2) with the journals (31) tightened to a Install tool T6 on the journals (31) on the crown wheel side, placing
torque of 129 ± 143 Nm. distance pieces and locking with two nuts. Insert differential
centring and support tool T7A into tool T6.
NOTE. Make sure that the differential unit is tightly engaged in the
intermediate cover (2).
T7B
F1241180 F1241181
GB e GB f
Remove tool T7B on crown opposite side. Check state and position of O-ring (30); lubricate the seal and fit the
intermediate cover (1) on the crown opposite side.
Lock the intermediate cover (1) with journals (31) tightened to a
torque of 129 ± 143 Nm and remove tools T6 and T7A.
942 BOMAG
60 008 911 71
Axle DANA 193 16.5
Montare sulle viti (5) le rondelle elastiche (6). Controllare lo stato ed il posizionamento dell'anello
ITA Spalmare le viti con Loctite 270 ed avvitarle a fondo ITA OR (30); lubrificare la guarnizione e montare il
nella corona. Posizionare il blocchetto "A" di contra- coperchio intermedio (2) lato corona.
sto; mantenendo in appoggio la corona sul blocchetto, serrare le
viti (5) ad una coppia di 135v138 Nm.
ATTENZIONE! Serrare le viti con il metodo incrociato.
Auf die Schrauben (5) die Federscheiben (6) montieren. Den Zustand und die Position des O-Ringes (30)
D Die Schrauben mit Loctite 270 schmieren und in den D kontrollieren; die Dichtung schmieren und den Zwi-
Kranz schrauben. Den Block "A" positionieren; den schendeckel (2) an der Kranzseite montieren.
Kranz am Block anliegen lassen und die Schrauben (5) mit einem
a Anzugsmoment von 135v138 Nm festziehen. b
ACHTUNG! Die Schrauben im Kreuz festziehen.
Montar sobre los tornillos (5) las arandelas elasticas (6). Controlar el estado y la colocacion del anillo OR (30);
ESP Pasar los tornillos con Loctite 270 y atornillarlos a ESP lubrificar la guarnicion y montar la tapa intermedia (2)
fondo en la corona. Colocar el bloque "A" de contraste; lado corona.
manteniendo en apoyo la corona sobre el bloque, apretar los
tornillos (5) y un par de 135v138 Nm.
ATENCION! Apretar los tornillos con el metodo cruzado.
Monter les vis (5), les rondelles eÂlastiques (6). ControÃler l'eÂtat et le positionnement de l'anneau
F Enduire les vis avec du Loctite 270, puis visser celles- F O'Ring (30); lubrifier la garniture, puis monter le
ci aÁ fond dans la couronne. Mettre le petit bloc "A" de couvercle intermeÂdiaire (2) du coÃteÂ couronne.
contraste; en maintenant la couronne poseÂe sur le petit bloc, serrer
les vis (5) aÁ un couple de 135v138 Nm.
ATTENTION! Serrer les vis avec la meÂthode croiseÂe.
Bloccare il coperchio intermedio (2) con i prigionieri Montare l'attrezzo T6 sui prigionieri (31) lato corona,
ITA (31) serrati ad una coppia di 129v143 Nm. ITA interponendo i relativi distanziali e bloccandolo con
due dadi. Inserire nell'attrezzo T6 l'attrezzo T7A di
centratura e sostegno del differenziale.
NOTA. Assicurarsi che il differenziale sia impegnato a fondo nel
coperchio intermedio (2).
Den Zwischendeckel (2) mit den Stiftschrauben (31) Das Werkzeug T6 an den Stiftschrauben (31) an der
D blockieren und mit einem Anzugsmoment von D Kranzseite montieren und dabei DistanzstuÈcke einsetzen
129v143 Nm festziehen. und mit zwei Muttern befestigen. In das Werkzeug T6 das Werkzeug
T7A zur Zentrierung und Halterung des Differentials einsetzen.
c d BEMERKUNG. Sicherstellen, daû das Differential fest im Zwischen-
deckel (2) sitzt.
Bloquear la tapa intermedia(2) con los prigioneros (31) Montar la herramienta T6 sobre los prigioneros (31)
ESP apretados a un par de 129v143 Nm. ESP lado corona, interponiendo de los distanciales y
bloqueando con dos tuercas. Introducir en la herramienta T6 la
herramienta T7A de centradura y sosten del diferencial.
NOTA. Asegurarse que el diferencial sea empegnado a fondo en la
tapa intermedia (2).
Bloquer le couvercle intermeÂdiaire (2) aÁ l'aide des Monter l'outil T6 sur les prisonniers (31) coÃteÂ cou-
F prisonniers (31) serreÂs aÁ un couple de 129v143 Nm. F ronne, en y intercalant des entretoises, puis bloquer
celui-ci avec deux eÂcrous. Introduire dans l'outil T6,
l'outil T7A de centrage et de support du diffeÂrentiel.
REMARQUE. S'assurer que le diffeÂrentiel soit engageÂ aÁ fond dans
le couvercle intermeÂdiaire (2).
Rimuovere l'attrezzo T7B del lato opposto corona. Controllare lo stato ed il posizionamento dell'anello
ITA ITA OR (30); lubrificare la guarnizione e montare il
coperchio intermedio (1) lato opposto corona.
Fissare il coperchio intermedio (1) con i prigionieri (31) serrati ad
una coppia di 129v143 Nm e rimuovere gli attrezzi T6 e T7A.
Werkzeug T7B an der dem Kranz entgegengesetzten Den Zustand und die Position des O-Ringes (30)
D Seite abnehmen. D kontrollieren; die Dichtung schmieren und den Zwi-
schendeckel (1) an der dem Kranz entgegengesetzten
Seite montieren. Den Zwischendeckel (1) mit den Stiftschrauben
e f (31) und einem Anzugsmoment von 129v143 Nm befestigen und
die Werkzeuge T6 und T7A entfernen.
Remover la herramienta T7B del lado opuesto corona. Controlar el estado y la colocacion del anillo OR (30);
ESP ESP lubrificar la guarnicion y montar la tapa intermedia (1)
lado opuesto corona.
Fijar la tapa intermedia (1) con los prigioneros (31) apretados a un
par de 129v143 Nm y remover las herramientas T6 y T7A.
Enlever l'outil T7B du coÃteÂ opposeÂ aÁ la couronne. ControÃler l'eÂtat et le positionnement de l'anneau
F F O'Ring (30); lubrifier la garniture, puis monter le
couvercle intermeÂdiaire (1) du coÃteÂ opposeÂ aÁ la
couronne.
Fixer le couvercle intermeÂdiaire (1) aÁ l'aide des prisonniers (31)
serreÂs aÁ un couple de 129v143 Nm, enlever les outils T6 et T7A.
008 911 71 BOMAG

61 943
16.5 Axle DANA
T9
F1241182 F1241183
GB a GB b
Remove the screws (33) and remove the safety tabs (34). Using wrench T9, extract the adjustment ring nuts (32) and remove
any residue of thread locking substances.
Screw ring nuts again after applying Loctite 242.
F1241184 F1241185
GB c GB d
Remove the spring ring (35) and extract the cap (36) to allow Coat the surface of the main body (3) with Loctite 510 and install
checking of the clearance between pinion and crown to take place. the reduction gear (37) complete with pinion.
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.
T9
F1241186 F1241183
GB e GB f
Coat screws (38) with Loctite 242 and screw tight. Tighten screws Screw ring nut (32) on crown wheel side until clearance between
(38), using the criss-cross method and a tightening torque of pinion and crown equals zero, then unscrew by 1/4 turn approx.
129 ± 143 Nm.
944 BOMAG
62 008 911 71
Axle DANA 193 16.5
Asportare le viti (33) e rimuovere le linguette di Utilizzando la chiave T9 rimuovere le ghiere (32) di
ITA sicurezza (34). ITA registrazione ed asportare ogni traccia di frenafiletti.
Riavvitare le ghiere dopo averle spalmate con
Loctite 242.
Die Schraube (33) abschrauben und den Sicherheits- Mit einem SchluÈssel T9, die Nutmuttern (32) zur
D keil (34) abnehmen. D Einstellung entfernen und jede alle uÈberschuÈssigen
Reste der SchraubensicherungsloÈsung sorgfaÈltig ent-
fernen.
a b Nutmuttern mit Loctite 242 schmieren und wieder festschrauben.
Sacar los tornillos (33) y remover les lengues de Utilizando la llave T9, remover las virolas (32) de
ESP seguridad (34). ESP registracion y sacar cada senal de frenaroscas.
Restornillas las virolas despues de haberias pasadas
con Loctite 242.
Enlever le vis (33), puis deÂplacer le languettes de A l'aide de la cleÂ T9, enlever les eÂcrous annulaires (32)
F seÂcuriteÂ (34). F de reÂglage et toute trace de l'agent d'arreÃt de vis.
Enduire les eÂcrous annulaires avec Loctite 242 et
visser.
Asportare l'anello elastico (35) e rimuovere il tappo Spalmare la superficie del corpo centrale (3) con
ITA (36) per poter controllare il gioco tra pignone e corona. ITA Loctite 510 ed installare il riduttore (37) completo di
pignone.
NOTA. Assicurarsi che il sigillante crei un velo continuo attorno ai
fori di fissaggio.
Den Kolbenring (35) abnehmen und den Stopfen (363) Die FlaÈche des ZentralkoÈrpers (3) mit Loctite 510
D entfernen, um das Spiel zwischen Kegelrad und Kranz D schmieren und den Reduzierer (37) samt Kegelrad
kontrollieren zu koÈnnen. installieren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
c d maÈûigen Film um die BefestigungsloÈcher herum bildet.
Sacar el anillo elastico (35) y remover la tapa (36) para Pasar la superficie del cuerpo central (3) con Loctite
ESP poder controlar el juego entre pignon y corona. ESP 510 y instalar el reductor (37) completo de pignon.
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor a los agujeros de fisaje.
Enlever l'anneau eÂlastique (35), enlever le bouchon Enduire la superficie du corps central (3) avec du
F (36) pour controÃler le jeu existant entre pignon et F Loctite 510, installer le reÂducteur (37) complet de
couronne. pignon.
REMARQUE. S'assurer que la couche de colle entoure bien les
trous de fixation.
Spalmare le viti (38) con Loctite 242 e avvitarle a fondo. Avvitare la ghiera (32) lato corona fino ad azzerare i
ITA Serrare le viti (38) con il metodo incrociato ad una ITA giochi tra pignone e corona e poi svitare per circa 1/4
coppia di serraggio di 129v143 Nm. di giro.
Die Schrauben (38) mit Loctite 242 schmieren und Nutmuttern (32) an der Kranzseite zuschrauben bis
D festziehen. Die Schrauben (38) im Kreuz mit einem D zwischen Rad und Kranz kein Spiel mehr uÈbrig bleibt;
Anzugsmoment von 129v143 Nm festziehen. danach um 1/4 Umdrehung aufschrauben.
e f
Pasar los tornillos (38) con Loctite 242 y atornillas a Atornillar las virolas (32) lado corona hasta acerar los
ESP fondo. ESP juegos entre el pinion y corona y despues destornillar
Apretar los tornillos (38) con el metodo cruzado y un por cerca 1/4 de giro.
par de torsion de 129v143 Nm.
Enduire les vis (38) avec du Loctite 242, puis visser Visser l'eÂcrou annulaire (32) du coÃteÂ couronne jusqu'aÁ
F celles-ci aÁ fond. F annuler le jeux entre pignon et couronne, puis
Serrer les vis (38) avec la meÂthode croiseÂe aÁ un couple deÂvisser 1/4 de tour.
de serrage de 129v143 Nm.
008 911 71 BOMAG

63 945
16.5 Axle DANA
T3
F1241187 F1241188
GB a GB b
Allow pinion to turn a few times in both directions to allow bearings Introduce a comparator with rotary key "C" through the rear cap
to set. Pre-load the bearings through the ring nut on crown opposite hole (43).
side to increase pinion torque up to a value of 140 ± 210 Ncm Position comparator on the centre of one of the crown teeth (4), pre-
checked by means of a torque meter. set it to 1 mm and reset it to zero.
CAUTION! If bearings are old, check static torque. If new, check Manually move the crown (4) in both directions to check the
continuous torque. existing clearance between pinion and crown.
RATIO - RAPPORTO CLEARANCE - GIOCO - SPIEL

VERHAÈ LTNIS JUEGO - JEU
RAPORTE - RAPPORT MIN. MAX.
T9
6v43 0,18 0,23
Difference between MIN and MAX clearance for whole circumference
should not exceed 0.09 mm.
La differenza tra gioco MIN e MAX rilevata sull'intera circonferenza
non deve superare il valore di 0,09 mm.
Der Unterschied zwischen dem MIN e MAX Spiel der gesamten
Kreislinie darf den Wert von 0,09 mm nicht uÈberschreiten.
La diferencia entre el juego Min y Max determinada sobre la entera
circonferencia no debe de superar el valor de 0,09 mm.
La diffeÂrence de jeu entre MIN et MAX releveÂe sur toute la
circonfeÂrence ne doit pas aller au-delaÁ de la valeur de 0,09 mm.
F1241183
GB c GB d
Mark the position of the ring nuts (32) in relation to the intermediate
covers.
Using wrench T9, adjust clearance between pinion and crown by
loosening one ring nut (32) and tightening the opposite proportion-
ally.
Normal clearance: see table.
F1241189 F1241190
GB e GB f
Install safety tabs (41) and lock them with screws (40). Using a driver, fit the cap (36) and position it in its seat with the
Screws tightening torque: 10 ± 11 Nm. snap ring (35).
946 BOMAG
64 008 911 71
Axle DANA 193 16.5
Far compiere al pignone alcuni giri nei due sensi per Posizionare, attraverso il foro per il tappo posteriore
ITA assestare i cuscinetti. Precaricare i cuscinetti tramite la ITA (43), un comparatore a tasto orientabile "C".
ghiera lato opposto corona, per incrementare la coppia di Posizionarlo sul centro di un dente della corona (4),
rotazione pignone fino a 140v210 Ncm controllati con un torsiometro. precaricarlo di circa 1 mm ed azzerarlo.
ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto; Muovere manualmente nei due sensi la corona (4) per controllare il
con cuscinetti nuovi, controllare la coppia di rotazione continua. gioco esistente tra pignone e corona.
Das Kegelrad um einige Umdrehungen in beide Richtungen Durch das Loch des hinteren Stopfens (43) eine
D drehen, um das Lager in die richtige Position zu bringen. Die D Meûuhr mit schwenkbarer Taste "C" einsetzen.
Lager durch die Nutmutter an der dem Kranz entgegengesetzte Seite Die Meûuhr auf die Mitte eines Zahnes des Kranzes (4)
vorbelasten, um das Gegenmoment des Kegelrads bis auf 140v210 Ncm positionieren und um 1mm vorbelasten; danach zuruÈckstellen.
a zu erhoÈhen. Den Wert mit einem Drehungsmesser kontrollieren.
ACHTUNG! Bei gebrauchten Lagern, das Anlaufdrehmoment kontrollieren; b Von Hand in beide Richtungen den Kranz (4) bewegen, um das
Spiel zwischen Kegelrad und Kranz zu kontrollieren.
bei neuen Lagern, das kontinuierliche Gegenmoment kontrollieren.
Hacer efectuar al pignon algunos giros en los dos sentidos Colocar, atraves el agujero para la tapa posterior (43),
ESP para ordenar los cojinetes. Precargar los cojinetes a ESP un comparador a tecla orientable "C".
traves de las virolas lado opuesto corona, para crecer el par de rotacion Colocarlo sobre el centro de un diente de la corona (4),
pignon hasta 140v210 Ncm controlados con un torsiometro. precargarlo de 1 mm aprox y azerarlo.
ATENCION! Con cojinetes usados, controlar el par de principio; con Mover manualmente en los dos sentidos la corona (4) para
cojinetes nuevos, controlar el par de rotacion continua. controlar el juego esistente entre pignon y corona.
Faire tourner le pignon plusieurs fois dans les deux sens Placer aÁ travers le trou servant au bouchon arrieÁre
F pour ajuster les paliers. PreÂcharger les paliers au moyen de F (43), un comparateur aÁ touche orientable "C".
l'eÂcrou annulaire, du coÃteÂ opposeÂ aÁ la couronne, pour augmenter le couple Positionner celui-ci au centre d'une des dents de la
de rotation du pignon jusqu'aÁ 140v210 Ncm controÃleÂs par un torsiomeÁtre. couronne (4), preÂcharger celui-ci d'environ 1 mm et mettre aÁ zeÂro.
ATTENTION! Avec des paliers usageÂs, controÃler le couple de pointe; avec DeÂplacer manuellement la couronne (4) dans les deux sens pour
des paliers neufs, controÃler le couple de rotation continu. controÃler le jeu existant entre pignon et couronne.
Contrassegnare la posizione delle ghiere (32) rispetto i

ITA ITA coperchi intermedi.
Con la chiave T9, regolare il gioco tra pignone e
corona allentando una ghiera (32) e serrando la ghiera opposta in
egual misura.
Gioco normale: vedere tabella.
Die Position der Nutmuttern (32) im VerhaÈltnis zu den

D D Zwischendeckeln markieren.
Mit dem SchluÈûel T9, das Spiel zwischen Rad und
Kranz einstellen, in dem eine Nutmutter (32) gelockert und die
c d entgegengesetzte festgezogen wird.
Normales Spiel: siehe Tabelle.
Contrasenalr la colocacion de las virolas (32) respecto

ESP ESP a las tapaderas intermedias.
Con la llave T9, regular el juego entre el pignon y la
corona aflojando una virola (32) y apretando la virola opuesta en la
misma mesura.
Juego normal: vease el prospecto.
Marquer la position de l'eÂcrou annulaire (32) par

F F rapport aux couvercles intermeÂdiaires.
A l'aide de la cleÂ T9, reÂgler le jeu entre pignon et
couronne en deÂvissant l'eÂcrou annulaire (32) et en vissant l'eÂcrou
annulaire opposeÂ de la meÃme mesure.
Jeu normal: voir tableau.
Montare le linguette di sicurezza (41) e fissarle con le Con uno spintore, montare il tappo (36) ed assicurarlo
ITA viti (40). ITA in sede con l'anello elastico (35).
Coppia di serraggio viti: 10v11 Nm
Den Sicherheitskeil (41) montieren und mit den Mit einem StoÈûel den Stopfen (36) montieren und in
D Schrauben (40) befestigen. D seinem Sitz mit dem Kolbenring (35) befestigen.
Anzugsmoment der Schrauben: 10v11 Nm
e f
Montar las lenguetas de seguridad (41) y fijarlas con Con un empujador, montar la tapa (36) y asegurarlo en
ESP los tornillos (40). ESP sed con el anillo elastico (36).
Par de serraje tornillos: 10v11 Nm
Monter les languettes de seÂcuriteÂ (41), fixer celles-ci aÁ A l'aide d'un poussoir, monter le bouchon (36), ajuster
F l'aide des vis (40). F celui-ci dans son logement avec l'anneau eÂlastique
Couple de serrage des vis: 10v11 Nm. (35).
008 911 71 BOMAG

65 947
16.5 Axle DANA
F1241190 F1241192
GB a GB b
Using a driver and a plastic hammer, install the driving gear (39). Apply Loctite 510 to the surface of the reduction gear body (37) and
install the cover (40).
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.
F1241193 F1241194
GB c GB d
Lock the cover (40), using the snap washers (43) and the screws Install the breath union piece (44) with the relative sealing washers
(42) and (41) adequately tightened to a torque of 82 ± 91 Nm. (45) and plugs (47) and (46); tighten to a torque of 35 ± 50 Nm.
Tighten screws (42) and (41) with a tightening torque of 82 ± 91 Nm.
GB e GB f
Complete assembly of the axle by installing, in the following order,
brake cylinders and complete arms.
For details, see «ASSEMBLING THE BRAKING UNITS».
948 BOMAG
66 008 911 71
Axle DANA 193 16.5
Utilizzando uno spintore ed un mazzuolo in materiale Spalmare la superficie del corpo riduttore (37) con
ITA plastico, montare l'ingranaggio conduttore (39). ITA Loctite 510 ed installare il coperchio (40).
NOTA. Assicurarsi che il sigillante crei un velo
continuo attorno ai fori di fissaggio.
Mit einem StoÈûel und einem Gummihammer das Die FlaÈche des KoÈrpers des Reduzierers (37) mit
D Getriebe (39) montieren. D Loctite 510 schmieren und den Deckel (40) installie-
ren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
a b maÈûigen Film um die BefestigungsloÈcher herum bildet.
Utilizando un empujador y un martillo en material Pasar la superficie del cuerpo reductor (37) con Loctite
ESP plastico, montar el engranaje conductor (39). ESP 510 y instalar la tapa (40).
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor de los agujeros de fisaje.
A l'aide d'un poussoir et d'un maillet en matieÁre Enduire la superficie du corps reÂducteur (37) avec du
F plastique, monter l'engrenage conducteur (39). F Loctite 510, installer le couvercle (40).
REMARQUE. S'assurer que la couche de colle
entoure bien les trous de fixation.
Bloccare il coperchio (40) utilizzando le rondelle Montare il raccordo di sfiato (44) con le relative rosette
ITA elastiche (43) e le viti (42) e (41) serrate con una ITA di tenuta (45) ed i tappi (47) e (46); serrarli con una
coppia di 82v91 Nm. coppia di 35v50 Nm.
Den Deckel (40) mit den Federscheiben (42) und (41) Das abgezogene VerbindungsstuÈck (44) mit den
D und den Schrauben (42) und (41) bei einem Anzu- D Dichtscheiben (45) und den Stopfen (47) und (46)
gsmoment von 82v91 Nm blockieren. montieren; Anzugsmoment 35v50 Nm.
c d
Bloquear la tapa (40) utilizando las arandelas elasti- Montar el recorde de escape (441) con las relativas
ESP cas (43) y los tornillos (42) y (41) apretadas con un par ESP rosas de tenida (45) y las tapas (47) y (46); apretarlos
de 82v91 Nm. con un par de 35v50 Nm.
Bloquer le couvercle (40) aÁ l'aide des rondelles Monter le raccord d'eÂvent (44), les relatives rosettes
F eÂlastiques (43) et des vis (42) et (41) serreÂes aÁ un F d'eÂtancheÂiteÂ (45) et les bouchons (47) et (46), serrer
couple de 82v91 Nm. ceux-ci aÁ un couple de 35v50 Nm.
Completare l'assemblaggio dell'assale installando

ITA nell'ordine i cilindri freni ed i bracci completi. ITA
Per i dettagli, vedere «ASSEMBLAGGIO GRUPPI
FRENO».
Die Achse fertig zusammenbauen und der Reihe nach

D die Bremszylinder und die kompletten Arme installie- D
ren.
Siehe «ZUSAMMENBAU DER BREMSAGGREGATE».
e f
Completar el asemblaje del axial instalando en el
ESP orden los cilindros frenos y los ejes completos. ESP
Para los detalles, vease «ASEMBLAJE GRUPOS
FRENOS».
Achever l'assemblage de l'essieu en y installant dans

F l'ordre les cylindres freins et les bras complets. F
Pour de plus amples deÂtails voir "ASSEMBLAGE DU
GROUPE FREIN".
008 911 71 BOMAG

67 949
16.5DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER
Axle DANA 193
UND KEGELRAD
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE
F1241141 F1241195
GB a GB b
Remove the whole arms and the differential unit. Loosen and remove screws (1) and (2) and the washers (3) locking
For details, see «CHECKING WEAR AND REPLACING THE the cover (4), the plugs (5) and (6) for oil fill and oil drain, and the
BRAKING DISKS» and «REMOVAL OF DIFFERENTIAL UNIT». bleed union piece (7).
NOTE. Leave two screws (2) in position for safety.
F1241196 F1241197
GB c GB d
Using a plastic hammer, remove the cover (4) and move it away. Place a block of tender material (aluminium, etc.) between the
NOTE. If operations on the differential unit need to be performed, reduction body (11) and the gear (12) of the pinion.
remove the complete reduction gear unit (screws (9) and (10)). Loosen and remove the pinion locking nut (13).
F1241198 F1241199
GB e GB f
Remove the gear of the pinion (12) and the driving gear (14) Take the driving gear to pieces (14), extracting the bearing (15).
complete with bearing (15). NOTE. If necessary, use an extractor.
NOTE. To remove the gear (14), use a lever.
950 BOMAG
68 008 911 71
Axle DANA 193 16.5
Rimuovere i bracci completi ed il differenziale. Allentare ed asportare le viti (1) e (2) e le rondelle (3) di
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA ritegno coperchio (4), i tappi (5) e (6) di carico e scarico
SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE olio ed il raccordo di sfiato (7).
GRUPPO DIFFERENZIALE». NOTA. Lasciare in posizione per sicurezza due viti (2) contrappo-
ste.
Die kompletten Arme und das Differential abnehmen. Schrauben (1) und (2) abschrauben und die Unter-
D Siehe «VERSCHLEISS KONTROLLIEREN UND D legscheiben (3) zur Halterung des Deckels (4), die
BREMSSCHEIBEN AUSWECHSELN» und «DIFFE- OÈ leinfuÈll- und Ablaûstopfen (5) und (6) sowie das
RENTIALAGGREGAT ABNEHMEN». EndluÈftungsstuÈck (7) abnehmen.
a b BEMERKUNG. Die entgegengesetzten Schrauben (2) zur Sicher-
heit zuruÈck lassen.
Remover los ejes completos y el duferencial. Aflojar y sacar los tornillos (1) y (2) y las arandelas (3)
ESP Para los detalles, vease «CONTROL DESGASTE Y ESP de retencion tapa (4), los tapones (5) y (6) de carga y
SOBSTITUCION DISCOS FRENOS» y «REMOCION descarga aceite y el recorde de escape (7).
GRUPO DIFERENCIAL». NOTA. Dejar en posicion de seguridad dos tornillos (2) contra-
puestas.
Enlever les bras complets et le diffeÂrentiel. Desserrer et enlever les vis (1) et (2), les rondelles (3)
F Pour de plus amples deÂtails, voir "CONTROLE F de fixation du couvercle (4), les bouchons (5) et (6) de
USURE ET SUBSTITUTION DES DISQUES FREIN" remplissage et vidange d'huile et le raccord d'eÂvent (7).
et "DEPOSE DU GROUPE DIFFERENTIEL". REMARQUE. Pour plus de suÃreteÂ, garder deux vis (2) super-
poseÂes.
Utilizzando un mazzuolo in materiale plastico, rimuo- Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)
ITA vere il coperchio (4) ed asportarlo. ITA del pignone un blocchetto "A" di materiale tenero
NOTA. Se si deve intervenire sul gruppo differenziale, (alluminio, ecc.).
rimuovere il gruppo riduttore completo (viti (9) e (10)). Allentare ed asportare il dado (13) di ritegno pignone.
Mit einem Gummihammer den Deckel (4) ausrasten Zwischen dem ReduziererkoÈrper (11) und dem Getrie-
D und abnehmen. D be (12) des Kegelrads einen Block aus weichen
BEMERKUNG. Soll am Differentialaggregat gearbeitet Material einsetzen (Aluminium usw.)
werden, das komplette Reduzieraggregat abnehmen (Schrauben Mutter (13) zur Halterung des Kegelrads abschrauben.
c (9) und (10)). d
Utilizando un martillo en material plastico, remover la Colocar entre el cuerpo reductor (11) y el engranaje
ESP tapa (4) y sacarla. ESP (12) del pinon un bloquete "A" de material tierno
NOTA. Si se debe intervenir sobre el grupo diferen- (aluminio, ect.).
cial, remover el grupo reductor completo (tornillos (9) y (10)). Aflojar y sacar la tuerca (13) de retencion pinon.
A l'aide d'un maillet en matieÁre plastique, deÂplacer le Ajuster, entre le corps reÂducteur (11) et l'engrenage
F couvercle (4) et puis l'enlever. F (12) du pignon, un petit bloc "A" en mateÂriel leÂger
REMARQUE. S'il faut intervenir sur le groupe diffeÂ- (aluminium etc.).
rentiel, enlever le groupe reÂducteur complet (vis (9) et (10)). Desserrer et enlever l'eÂcrou (13) de fixation pignon.
Rimuovere l'ingranaggio del pignone (12) e l'ingra- Scomporre l'ingranaggio conduttore (14) estraendo il
ITA naggio conduttore (14) completo di cuscinetto (15). ITA cuscinetto (15).
NOTA. Per rimuovere l'ingranaggio (14), utilizzare una NOTA. Se necessario, usare un estrattore.
leva.
Das Getriebe (12) des Kegelrads und das Getriebe Das Getriebe (14) zerlegen; dazu das Lager (15)
D (14) samt Lager (15) entfernen. D abziehen.
BEMERKUNG. Um das Getriebe (14) abnehmen zu BEMERKUNG. Wenn noÈtig, einen Abzieher verwen-
koÈnnen, einen Hebel verwenden. den.
e f
Remover el engranaje del pinon (12) y el engranaje Descomponer el engranaje conductor (14) sacando el
ESP conductor (14) completo de cojinete (15). ESP cojinete (15).
NOTA. Para remover el engranaje (14), utilizar una NOTA. Si necesario, usar un extractor.
palanca.
DeÂplacer l'engrenage du pignon (12) et l'engrenage DeÂcomposer l'engrenage conducteur (14) en deÂga-
F conducteur (14) complet de palier (15). F geant le palier (15).
REMARQUE. Pour deÂplacer l'engrenage (14), utiliser REMARQUE. Si besoin, utiliser un extracteur.
un levier.
008 911 71 BOMAG

69 951
Axle DANA 193
UND KEGELRAD
F1241200 F1241201
GB a GB b
Loosen all screws (9) and (10) and remove the upper check screws Connect the whole reduction gear body (11) to a hoist and remove
(9) of the reduction gear body. the screws (10) previously left in place for safety.
NOTE. Leave the two lower screws (10) in position for safety. Using a plastic hammer, pull away the whole reduction gear body
(11).
F1241202 F1241203
GB c GB d
Position the reduction gear body (11) under a press and, using a Remove distance piece (20) and shims (19) from the pinion(16).
driver, extract the pinion (16) complete with internal bearing (17), Position the pinion under a press and remove the internal bearing
shims (19) and distance piece (20). (17).
F1241204
GB e GB f
With the help of an extractor, remove the thrust blocks (17) and (21)
of the bearings, and the snap ring (22).
NOTE. Note down direction of assembly of snap ring (22).
952 BOMAG
70 008 911 71
Axle DANA 193 16.5
Allentare tutte le viti (9) e (10) ed asportare le viti (9) Collegare il corpo riduttore completo (11) ad un mezzo
ITA superiori di ritegno del corpo riduttore. ITA di sollevamento ed asportare le viti (10) lasciate in
NOTA. Lasciare in sede le due viti (10) inferiori per sede per sicurezza.
sicurezza. Utilizzando un mazzuolo in materiale plastico, rimuovere il corpo
riduttore (11) completo.
Alle Schrauben (9) und (10) lockern und die oberen Den kompletten ReduziererkoÈrper (11) an ein Hebe-
D Schrauben (9) zur Halterung des ReduziererkoÈrpers D zeug befestigen und die zuvor zur Sicherheit zuruÈck-
abnehmen. gelassenen Schrauben (10) abschrauben.
BEMERKUNG. Die beiden unteren Schrauben (10) zur Sicherheit Mit einem Gummihammer, den kompletten ReduziererkoÈrper (11)
a zuruÈck lassen. b abnehmen.
Aflojar todos los tornillos (9) y (10) y sacar los tornillos Conectar el cuerpo reductor completo (11) a un medio
ESP (9) superiores de retencion del cuerpo reductor. ESP de elevacion y sacar los tornillos (10) dejadas en su
NOTA. Dejar en su lugar los dos tornillos (10) lugar para seguridad.
inferiores para seguridad. Utilizando un martillo en material plastico, remover el cuerpo
reductor (11) completo.
Desserrer toutes les vis (9) et (10), enlever les vis Brancher le corps reÂducteur complet (11) aÁ un moyen
F supeÂrieures (9) de fixation du corps reÂducteur. F de relevage, puis enlever les vis laisseÂe (10) dans leur
REMARQUE. Garder les deux vis infeÂrieures (10) dans sieÁge pour plus de seÂcuriteÂ.
leur sieÁge pour plus de seÂcuriteÂ. A l'aide d'un maillet en matieÁre plastique, enlever le corps
reÂducteur (11) complet.
Posizionare il corpo riduttore (11) sotto una pressa e, Rimuovere dal pignone (16) il distanziale (20) e gli
ITA utilizzando uno spintore, estrarre il pignone (16) ITA spessori (19).
completo di cuscinetto interno (17), spessori (19) ed Posizionare il pignone sotto una pressa e rimuovere il
il distanziale (20). cuscinetto interno (17).
Den ReduziererkoÈrper (11) unter eine Presse legen Vom Kegelrad (16) das DistanzstuÈck (20) und die
D und mit einem StoÈûel das Kegelrad (16) samt dem D Unterlegscheiben (19) abnehmen.
inneren Lager (17), den Unterlegscheiben (19) und Das Kegelrad unter eine Presse legen und das innere
dem DistanzstuÈck (20) abziehen. Lager (17) abnehmen.
c d
Colocar el cuerpo reductor (11) debajo de una prensa Remover del pinon (16) el distancial (20) y los
ESP y, utilizando un empujador (16) completo de cojinete ESP espesores (19).
interno (17), espesores (19) y el distancial (20). Colocar el pinon bajo una prensa y remover el cojinete
interno (17).
Placer le corps reÂducteur (11) sous une presse, aÁ Enlever du pignon (16) l'entretoise (20) et les cales
F l'aide d'un poussoir extraire le pignon (16) complet de F (19).
palier interne (17), cales (19) et entretoise (20). Placer le pignon sous une presse et enlever le palier
interne (17).
Con un estrattore, rimuovere dal corpo riduttore (11) le

ITA ralle dei cuscinetti (17) e (21) e l'anello di tenuta (22). ITA
NOTA. Annotare il senso di montaggio dell'anello di
tenuta (22).
Mit einem Abzieher vom ReduziererkoÈrper (11) die

D Scheiben der Lager (17) und (21) und den Dichtring D
(22) entfernen.
BEMERKUNG. Montagerichtung des Dichtringes (22) notieren.
e f
Con un extractor, remover del cuerpo reductor (11) las
ESP ranguas de los cojinetes (17) y (21) y el anillo de ESP
retencion (22).
NOTA. Anotar el sentido de desmontaje del anillo de retencion
(22).
A l'aide d'un extracteur, enlever le corps reÂducteur

F (11), les crapaudines des paliers (17) et (21) et F
l'anneau d'eÂtancheÂiteÂ (22).
REMARQUE. Prendre note du sens de montage de l'anneau
d'eÂtancheÂiteÂ (22).
008 911 71 BOMAG

71 953
Axle DANA 193
UND KEGELRAD
GB a GB b
GB c GB d
D1240136
GB e GB f
954 BOMAG
72 008 911 71
Axle DANA 193 16.5
CAUTION! 1 - If disassembly has only been carried ATENCION! 1 - Si el desmontaje ha sido efectuado
GB out to replace the snap ring (22), position the new ring ESP solo para la sobstitucion del anillo de retencion (22),
and reassemble the unit, respecting the tightening proceder al alojamiento del nuevo anillo y remontar el
torques specified in the following section and using the specified grupo respectando los pares de serraje indicadas en el paragrafo
locking and sealing products. siguiente y utilizando los productos de bloqueo y tenida prescritos.
2 - If disassembly is performed to replace either crown wheel and 2 - Si el desmontaje viene efectuado para la sobstitucion del par
pinion, bearings, or planetary gears, take the unit to pieces and find conico, de los cojinetes o de los engranajes satelites, proceder a la
shims and clearances as specified in the sections relative to the descomposicion y a la busqueda de los espesores y de los juegos
removal, disassembly, assembly and installation of the differential como indicados en los paragrafos concernientes la remocion, el
unit and bevel pinion. desmontaje, el asemblaje y la instalacion del diferencial y del pinon
conico.
ATTENZIONE! 1 - Se lo smontaggio eÁ stato eseguito ATTENTION! 1 - Si le deÂmontage n'est effectueÂ que

ITA solo per la sostituzione dell'anello di tenuta (22), F pour substituer l'anneau d'eÂtancheÂiteÂ (22), positionner
procedere al posizionamento del nuovo anello e le nouvel anneau et remonter le groupe en respectant
rimontare il gruppo rispettando le coppie di serraggio indicate nel les couples de serrage indiqueÂs dans le paragraphe suivant aÁ l'aide
paragrafo seguente ed utilizzando i prodotti di bloccaggio e tenuta des produits de blocage et d'eÂtancheÂiteÂ prescrits.
prescritti. 2 - Si le montage est effectueÂ pour substituer le couple conique des
2 - Se lo smontaggio viene eseguito per la sostituzione della coppia paliers et des engrenages satellites, passer aÁ la deÂcomposition et aÁ
conica, dei cuscinetti o degli ingranaggi satelliti, procedere alla la recherche des cales et des jeux comme indiqueÂ dans les
scomposizione ed alla ricerca degli spessori e dei giochi come paragraphes concernant la deÂpose, le deÂmontage, l'assemblage et
indicato nei paragrafi riguardanti la rimozione, lo smontaggio, l'installation du diffeÂrentiel et du pignon conique.
l'assemblaggio e l'installazione del differenziale e del pignone
conico.
ACHTUNG! 1 - Falls das Teil zum Auswechseln des

D Dichtringes (22) zerlegt wurde, den neuen Ring
einsetzen und das Aggregat wieder montieren; dabei
die Anzugsmomente einhalten, die im nachstehenden Kapitel
angegeben sind und die vorgeschriebenen Materialien zur Blok-
kierung und Abdichtung verwenden.
2 - Falls das Zerlegen zum Auswechseln des Kegelradpaars, der
Lager oder der Planetengetriebe vorgenommen wird, den An-
weisungen der Paragraphen zum Zerlegen, Abmontieren und
Zusammenbauen sowie zur Installation des Differentials und des
Kegelrads folgen und die StaÈrken und Spiele einhalten.
008 911 71 BOMAG

73 955
16.5 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION
Axle DANA 193
UND
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE
MEASURE (42.35)
MISURA (42,35)
MAß (42,35) St
MESURA (42,35)
MESURE (42,35) B
MARK
CONTRASSEGNO
C C
B KENNZEICHEN
CONTRASENALACION
MARQUAGE
F1241205 F1241206
GB a GB b
Mark the thrust block and the internal bearing (17) on a faceplate, Lay two 20 mm gauged blocks "C" on the face of the reduction gear
allow the bearing to set by rotating them in both directions and by body (11). With depth gauge "B" (set to zero at the previous point),
applying a vertical thrust. With a centesimal, digital depth gauge measure space between the "C" blocks and the striking surface of
"B", check overall thickness of bearing (e.g.: 42.35 mm) and set the internal bearing (17). The size obtained (e.g.: 0.81 mm) is the
gauge to zero again. theoretical shim "St" (18) to be inserted under the thrust block of
bearing (17).
DIFFERENTIAL AXIS
ASSE DIFFERENZIALE
DIFFERENTIALACHSE
EJE DEFERENCIAL S
ESSIEU DIFFERENTIEL
Y
X
+ --
DEVIATION "X"
SCOSTAMENTI "X"
ABWEICHUNG "X" S = St + (± X)
DESPLAZAMIENTOS "X"
ECARTS "X"
D1240137
F1241225
GB c GB d
On the bar-hold of pinion (16), check the value "X" (in brackets) To calculate final thickness "S", add the negative value of "X" to
relative to the deviation from the theoretical centre distance. "St" or, alternatively, subtract the positive value of "X".
NOTE. "Y" is the number of pinion/crown coupling. For ex.: Deviation X=(±0.13 mm): S=St+X=0.81+0.13=0.94 mm
Deviation X=(+0.12 mm): S=St ± X=0.81 ± 0.12=0.69 mm
CAUTION! Round off to as close to 0.05 mm as possible.
T10
F1241227 F1241207
GB e GB f
Using a driver, mount the sealing ring (22) in the reduction unit (11). Place the reduction gear body (11) under a press and, using tool
NOTES. 1 - Carefully check the direction of assembly. T10, insert the thrust block of external bearing (21).
2 - Lubricate the outer surface of the sealing ring. CAUTION! Insert the thrust block of the bearing that is not
countermarked.
956 BOMAG
74 008 911 71
Axle DANA 193 16.5
Contrassegnare la ralla ed il cuscinetto (17) interno su Appoggiare sul piano di appoggio del corpo riduttore
ITA un piano di riscontro, assestare il cuscinetto con delle ITA (11) due blocchetti calibrati da 20 mm "C". Con il
rotazioni parziali nei due sensi ed esercitando una calibro di profonditaÁ "B" (azzerato nella fase precedente), rilevare la
spinta verticale. Con un calibro di profonditaÁ digitale centesimale misura tra i blocchetti "C" ed il piano di battuta del cuscinetto
"B", rilevare lo spessore totale del cuscinetto (es 42,35 mm) ed interno (17). La misura risultante (es. 0,81 mm) eÁ lo spessore "St"
azzerare il calibro. (18) teorico da inserire sotto la ralla del cuscinetto (17).
Die Scheibe und das innere Lager (17) an einer Auf eine AuflageflaÈche des ReduziererkoÈrpers (11) zwei
D BezugsflaÈche markieren, das Lager durch hin und her D kalibrierte BloÈcke zu 20 mm "C" legen. Mit einer Tiefen-
Drehen und einem senkrechten Druck richtig ein- lehre "B" (zuvor zuruÈckgestellt) das Maû zwischen den BloÈcken "C" und
setzen. Mit einer digitalen hundertteiligen Tiefenlehre "B" die der AnschlagflaÈche des inneren Lagers (17) messen. Das ermittelte Maû
a GesamtstaÈrke des Lagers messen (z.B. 42,35 mm) und die Lehre
zuruÈckstellen.
b (z.B. 0,81 mm) entspricht der theoretischen Unterlegscheibe "St" (18),
die unter die Scheibe des Lagers (17) gelegt werden muû.
Senalar la rangua t el cojinete (17) interno sobre una Colocar sobre la superficie de apoyo del cuerpo reductor
ESP superficie de rescontre, ordenar el cojinete con unas ESP (11) dos bloques calibrados de 20 mm "C". Con el calibre
rotaciones parciales en los dos sentidos y ejercitando de profundidad "B" (azerando en la fase precediente),
un empuje vertical. Con un calibre de profundidad digital centesimal relevar la mesura entre los bloquetes "C" y la superficie del tope del
"B", relevar el espesor total del cojinete (es.:42,35 mm) y azerar el cojinete interno (17). La mesura resultante (es.: 0,81 mm) es el
calibre. espesor "St" (18) teorico de introducir bajo la rangua del cojinete (17).
Estampiller la crapaudine et le palier (17) interne sur DeÂposer sur un plan d'appui du corps reÂducteur (11),
F un marbre de controÃle, ajuster les paliers par des F deux petits blocs calibreÂs aÁ 20 mm "C". A l'aide du
rotations partielles dans les deux sens tout en calibre de profondeur "B" (mis aÁ zeÂro preÂceÂdemment),
poussant verticalement. A l'aide d'un calibre de profondeur relever la mesure existante entre les petits blocs "C" et le plan de
numeÂrique centeÂsimal "B", relever le calage total des paliers (ex. buteÂe du palier interne (17). La mesure reÂsultante (ex. 0,81 mm) est
42,35 mm), mettre le calibre aÁ zeÂro. le calage "St" (18) aÁ introduire sous la crapaudine du palier (17).
Controllare sul codolo del pignone (16) il valore "X" Per calcolare lo spessore "S" definitivo, aggiungere a
ITA (racchiuso tra parentesi) dello scostamento rispetto ITA "St", il valore "X" negativo oppure sottrarre il valore
l'interasse teorico. "X" positivo.
NOTA. Il numero "Y" eÁ il numero di accoppiamento pignone- Es.: Scostamento X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
corona. Scostamento X=(+0,12 mm): S=St ± X=0,81 ± 0,12=0,69 mm
ATTENZIONE! Arrotondare al valore piuÁ prossimo dei 0,05 mm.
Den Wert "X" der Gleitung am Kegelradschaft (16) (in Um die endguÈltige StaÈrke "S" auszurechnen, "St" und
D Klammern angegeben) im VerhaÈltnis zum theoreti- D "X" addieren, wenn "X" neÂgatif ist oder "X" von "St"
schen Achsenabstand kontrollieren. abziehen, falls "X" postif ist.
BEMERKUNG. Die Zahl "Y" entspricht dem Kegelrad-Kranz- Beispiel: Abweichung X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
c Kopplungsgrad. d Abweichung X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm
ACHTUNG! Auf einen Wert abrunden, der 0,05 mm am naÈchsten liegt.
Controlar sobre al espigon del pinon (16) el valor "X" Para calcolar el espesor "S" definitivo, adicionar a
ESP (serrado entre parantesis) del desplazamiento respec- ESP "St", el valor "X" negativo o detraer el valor "X"
to al intereje teorico. positivo.
NOTA. El numero "Y" y el numero de acoplamiento pinon-corona. Es.: Desplazamiento X=(± 0,13mm): S=St+X=0,81+0,13=0,94 mm
Desplazamiento X=(0,12mm): S=St ± X=0,81 ± 0,12=0.69 mm
ATENCION! Acercar al valor mas cerca de 0,05 mm.
ControÃler sur la queue du pignon (16) la valeur "X" Pour calculer l'eÂpaisseur "S" deÂfinitif, additionner aÁ
F (entre parentheÁses) de l'eÂcart par rapport aÁ l'entraxe F "St" la valeur "X" neÂgative ou soustraire la valeur "X"
theÂorique. positive.
REMARQUE. Le numeÂro "Y" est le numeÂro de l'accouplement Ex. Ecart X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
pignon-couronne. Ecart X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm
ATTENTION! Arrondir aÁ la valeur plus proche aÁ 0,05 mm.
Utilizzando uno spintore, montare nel corpo riduttore Sistemare il corpo riduttore (11) sotto una pressa e,
ITA (11) l'anello di tenuta (22). ITA utilizzando l'attrezzo T10 inserire la ralla del cusci-
NOTE. 1 - Controllare attentamente il senso di netto esterno (21).
montaggio. ATTENZIONE! Inserire la ralla del cuscinetto non contrassegnato.
2 - Lubrificare la superficie esterna dell'anello di tenuta.
Mit einem StoÈûel den Dichtring (22) in den Reduzierer- Den ReduziererkoÈrper (11) unter eine Presse legen
D koÈrper (11). D und mit dem Werkzeug T10 die Scheibe des aÈuûeren
BEMERKUNG. 1 - SorgfaÈltig die Montagerichtung des Lagers (21) einsetzen.
Dichtrings kontrollieren. ACHTUNG! Die Scheibe des nicht gekennzeichneten Lagers
e È
2 - Auûere FlaÈche des Dichtrings schmieren. f einsetzen.
Utilizando un espesor, montar en el cuerpo reductor Colocar el cuerpo reductor (11) debajo de una prenso
ESP (11) el anillo de retencion (22). ESP y, utilizando la herramienta T10 insertar la rangua del
NOTA. 1 - Controlar atentamente el sentido de cojinete esterno (21).
montaje. ATENCION! Introducir la rangua del cojinete no segnalado.
2 - Lubrificar la superficie exterior del anillo de retencion.
A l'aide d'un poussoir, monter dans le corps reÂducteur Ajuster le corps reÂducteur (11) sous la presse, aÁ l'aide
F (11) l'anneau d'eÂtancheÂiteÂ (22). F de l'outil T10 introduire la crapaudine du palier
NOTE. 1 - ControÃ ler attentivement le sens de externe (21).
montage. ATTENTION! Introduire la crapaudine du palier non estampilleÂe.
2 - Lubrifier la surface externe de l'anneau d'eÂtancheÂiteÂ.
008 911 71 BOMAG

75 957
Axle DANA 193
UND
T11
F1241208 F1241209
GB a GB b
Turn the reduction gear body (11) upside down and insert shim "S"; Fit tool T12 onto tool T11. Then, install bearings (17) and (21) so
then, with tool T10, insert the thrust block of the internal bearing that they are opposed to each other and spaced by the distance
(17). piece (20).
CAUTION! Insert the thrust block of the countermarked bearing. Position the depth comparator in one of the four radial holes; pre-
set the comparator to 3 ± 4 mm, then set it to zero.
T11
T11
F1241210 F1241211
GB c GB d
Remove the bearings from tool T11 and fit them in the thrust blocks Install tool T11 and tighten it manually to obtain a safe rolling
of the reduction gear body. torque.
CAUTION! Check that the countermarked bearing is fitted in the NOTE. During tightening, perform a few rotations to set the
centring hub of the body of the reduction gear and in the bearings.
countermarked thrust block too.
H + 0,13 ÷ 0,15 = S1
S
F1241212 F1241221
GB e GB f
Introduce the previously reset comparator, in one of the four radial The deviation found is to be added to a fixed value of 0.13(0.15
holes and measure. The deviation from zero indicates the nominal mm. in order to: obtain shim "S1" (to be inserted between internal
value "H" relative to the shims that are to be inserted. bearing (17) and distance piece (20)) and, hence, produce the
specified pre-load of bearings.
CAUTION! Perform accurate measurements - a variation of 0.001 mm
causes a variation in the torque by 20 ± 40 Nm
958 BOMAG
76 008 911 71
Axle DANA 193 16.5
Capovolgere il corpo riduttore (11) ed inserire lo Montare sull'attrezzo T11 l'attrezzo T12. Quindi mon-
ITA spessore "S" e con l'attrezzo T10 la ralla del ITA tare i cuscinetti (17) e (21) contrapposti ed intervallati
cuscinetto interno (17). con il distanziale (20).
ATTENZIONE! Inserire la ralla del cuscinetto contrassegnato. Posizionare un comparatore di profonditaÁ in uno dei quattro fori
radiali; precaricare il comparatore di 3v4 mm ed azzerarlo.
Den RedurziererkoÈrper (11) wenden und die Unter- Auf das Werkzeug T11 das Werkzeug T12 montieren.
D legscheibe "S" einsetzen; mit dem Werkzeug T10 die D Dann die entgegengesetzten Lager (17) und (21)
Scheibe des inneren Lagers (17) einsetzen. montieren und dazwischen das DistanzstuÈck (20)
ACHTUNG! Die Scheibe des gekennzeichneten Lagers einsetzen. legen.
a b Eine Meûuhr in eines der vier RadialloÈcher positionieren; die
Meûuhr auf 3v4 mm vorbelasten und dann zuruÈckstellen.
Volcar el cuerpo reductor (11) y introducir el espesor Montar sobre la herramienta T11 la herramienta T12.
ESP "S" y con la herramienta T10 la rangua del cojinete ESP Entonces colocar los cojinetes (17) y (12) contra-
interno (17). puestos y intervalados con el distancial (20).
ATENCION! Introducir la rangua del cojinete segnalado. Colocar un comparador de profundidad en uno de los cuatro
agujeros radiales, precargar el comparador de 3-4 mm y acerarlo.
Faire basculer le corps reÂducteur (11), introduire la Monter sur l'outil T11, l'outil T12. Ensuite monter les
F cale "S", et aÁ l'aide de l'outil T10 la crapaudine du F paliers (17) et (21) en les superposant et intercalant
palier interne (17). avec l'entretoise (20).
ATTENTION! Introduire la crapaudine du palier estampilleÂ. Placer un comparateur de profondeur dans l'un des quatre trous
radiaux; preÂcharger le comparateur aÁ 3v4 mm, puis le mettre aÁ
zeÂro.
Rimuovere i cuscinetti dall'attrezzo T11 e montarli Montare l'attrezzo T11 e serrarlo manualmente fino ad
ITA nelle ralle del corpo riduttore. ITA avere una sicura coppia di rotolamento.
ATTENZIONE! Controllare che il cuscinetto contras- NOTA. Durante il serraggio, eseguire alcune rotazioni
segnato sia montato nel mozzo di centratura del corpo riduttore e per assestare i cuscinetti.
quindi nella ralla contrassegnata.
Die Lager vom Werkzeug T11 abnehmen und in den Das Werkzeug T11 montieren und von Hand fest-
D Scheiben des ReduziererkoÈrpers montieren. D ziehen bis ein sicheres Gegenmoment erreicht ist.
ACHTUNG! Kontrollieren, ob das markierte Lager in BEMERKUNG. Beim Festziehen einige Umdrehungen
den Zentriernaben des ReduziererkoÈrpers und folglich in der vornehmen, um die Lager richtig in ihren Sitz zu bringen.
c markierten Scheibe montiert ist. d
Remover los cojinetes de la herramienta T11 y Montar la herramienta T11 y apretarla manualmente
ESP montarlos en las ranguas del cuerpo reductor. ESP hasta obtener una segura pareja de rotacion.
ATENCION! Controlar que el cojinete segnalado sea NOTA. Durante la torsion, efectuar algunas rotaciones
colocado en el cubo central del cuerpo reductor y por lo tanto en la para ordenar los cojinetes.
rangua segnalada.
Oter les paliers de l'outil T11, puis monter ces Monter l'outil T11 et serrer celui-ci aÁ la main jusqu'aÁ
F derniers dans les crapaudines du corps reÂducteur. F obtenir un couple de roulement assureÂ.
ATTENTION! ControÃler que le palier estampilleÂ soit REMARQUE. En serrant, effectuer quelques tours de
monteÂ dans le moyeu de centrage du corps reÂducteur, donc, dans rotation pour ajuster les paliers.
la crapaudine estampilleÂe.
Introdurre in uno dei fori radiali il comparatore Lo scostamento rilevato eÁ da sommare ad una misura
ITA azzerato precedentemente ed eseguire la lettura. ITA fissa di 0,13v0,15 mm, per ottenere lo spessore "S1"
Lo scostamento rispetto lo zero, indica il valore (19) da inserire tra cuscinetto interno (17) e distanziale (20) e
nominale "H" degli spessori da inserire. quindi, determinare il precarico stabilito per i cuscinetti.
ATTENZIONE! Curare le misurazioni in quanto la variazione di
0,01 mm fa variare la coppia di rotazione di 20v40 Ncm.
In eines der RadialloÈcher die zuvor zuruÈckgestellte Die ermittelte Abweichung muû mit einem Festmaû von 0,3 (0,15
D Meûuhr einsetzen und das Maû ablesen. D mm zusammengerechnet werden, um die Unterlegscheibe "S1"
Die Abweichung im VerhaÈltnis zur Null, gibt den (19) zu ermitteln, die zwischen dem inneren Lager (17) und das DistanzstuÈck (20)
Nennwert "H" der einzulegenden Unterlegscheiben an. gelegt werden muû und um die Vorbelastung der Lager festlegen zu koÈnnen.
e f ACHTUNG! Die Messungen sehr sorgfaÈltig vornehmen, da ein Unter-
schied von 0,01 mm das Gegenmoment um 20v40 Ncm veraÈndert.
Introducir en uno de los agujeros radiales el compa- El desplazamiento relevado es de sumarse a una
ESP rador acerado precedentemente y efectuar la lectura. ESP mesura fija de 0,13-0,15 mm, para obtener el espesor
El desplazamiento respecto a lo cero, indica el valor "S1" (19) de introducir entre cojinete interno (17) y distancial (20) y
nominal "H" de los espesores de introducir. entonces, determinar el precario establecido para los cojinetes.
ATENCION! Poner atencion a las mesuraciones porque la variacion
de 0,01 mm hace cambiar de ratacion de 20v40Ncm.
Introduire dans l'un des trous radiaux le comparateur L'eÂcart releveÂ est aÁ additionner aÁ la mesure fixe 0,13v0,15 mm
F mis aÁ zeÂro preÂceÂdemment et en faire la lecture. F pour obtenir la cale "S1" (19) aÁ introduire entre le palier interne
L'eÂcart par rapport au zeÂro, indique la valeur nominale (17) et l'entretoise (20) et deÂfinir la preÂcharge eÂtablie pour les paliers.
"H" des cales aÁ introduire. ATTENTION! Effectuer soigneusement les mesurages parce qu'une diffeÂ-
rence de 0,01 mm ameÁne une variation du couple de rotation de 20v40 Ncm.
008 911 71 BOMAG

77 959
Axle DANA 193
UND
F1241213 F1241214
GB a GB b
With the help of the press, install the internal, countermarked Fit the pinion (16), the shims (19), the distance piece (20) and the
bearing (17) onto the pinion (16). external bearing (21) into the body of the reduction gear (11) and
CAUTION! Lubricate pinion with oil. assemble the unit with a press.
CAUTION! Lubricate pinion with oil.
F1241215 F1241216
GB c GB d
Fit the reduction gear (11) into the main body (23) without Fit the gear (12) of the pinion; coat the nut (13) with Loctite 242 and
differential unit; lock temporarily with the two lower screws (9). hand-screw it.
Fit the bearing (15) of the motion in gear and lock it.
F1241217
GB e GB f
Between the body of the reduction gear (11) and the gear (12) of the
pinion, place block "A" used for disassembling, and tighten the nut
(13) to a minimum required tightening torque of 500 Nm, using a
box wrench and a dynamometric wrench.
960 BOMAG
78 008 911 71
Axle DANA 193 16.5
Con la pressa, montare il cuscinetto interno e Montare nel corpo riduttore (11) il pignone (16), gli
ITA contrassegnato (17) sul pignone (16). ITA spessori (19), il distanziale (20) ed il cuscinetto esterno
ATTENZIONE! Lubrificare il pignone con olio. (21) ed assemblare il gruppo con la pressa.
ATTENZIONE! Lubrificare il pignone con olio.
Mit einer Presse, das innere und markierte Lager (17) In den ReduziererkoÈrper (11) das Kegelrad (16), die
D auf das Kegelrad (16) montieren. D Unterlegscheiben (19), das DistanzstuÈck (20) und das
ACHTUNG! Rad mit O È l schmieren. aÈuûere Lager (21) montieren und das Aggregat mit der
Presse zusammenbauen.
a b ACHTUNG! Rad mit O È l schmieren.
Con la prensa, montar el cojinete interno y segnalado Montar en el cuerpo reductor (11) el pinon (16) los
ESP (17) sobre el pinon (16). ESP espesores (19), el distancial (20) y el cojinete esterno
ATENCION! Lubrificar el pinon con aceite. (21) y asemblar el grupo con la prensa.
ATENCION! Lubrificar el pinon con aceite.
A l'aide de la presse, monter le palier interne Monter dans le corps reÂducteur (11), le pignon (16), les
F estampilleÂ (17) sur le pignon (16). F cales (19), l'entretoise (20) et le palier externe (21),
ATTENTION! Lubrifier le pignon avec de l'huile. assembler le groupe aÁ l'aide de la presse.
ATTENTION! Lubrifier le pignon avec de l'huile.
Montare il corpo riduttore (11) sul corpo centrale (23) Montare l'ingranaggio (12) del pignone; spalmare il
ITA privo di differenziale e fissarlo provvisoriamente con le ITA dado (13) con Loctite 242 ed avvitarlo manualmente.
due viti inferiori (9).
Montare il cuscinetto (15) dell'ingranaggio di entrata del moto e
mandarlo in battuta.
Den ReduziererkoÈrper (11) auf den zentralen KoÈrper Das Getriebe (12) des Kegelrads montieren; Mutter
D (23) ohne Differential montieren und voruÈbergehend D (13) mit Loctite 242 schmieren und von Hand
mit den zwei unteren Schrauben (9) befestigen. zuschrauben.
Das Lager (15) des Einganggetriebes montieren und bis zum
c Anschlag einsetzen. d
Montar el cuerpo reductor (11) sobre el cuerpo central Asemblar el engranaje (12) del pinon, pasar la tuerca
ESP (23) sin el diferencial y fijarlo provisoriamente con los ESP (13) con Loctite 242 y atornillarla manualmente.
dos tornillos inferiores (9).
Asemblar el cojinete (15) del engranaje de entrada del movimiento
y mandarlo a tope.
Monter le corps reÂducteur (11) sur le corps central (23) Monter l'engrenage (12) du pignon; enduire l'eÂcrou
F sans diffeÂrentiel et fixer provisoirement ce dernier F (13) avec du Loctite 242 et visser celui-ci aÁ la main.
avec les deux vis infeÂrieures (9).
Monter le palier (15) de l'engrenage d'acceÁs au mouvement, puis
l'envoyer en buteÂe.
Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)

ITA del pignone il blocchetto "A" usato per lo smontaggio ITA
e serrare il dado (13) alla coppia minima di 500 Nm,
utilizzando una chiave a bussola ed una chiave dinamometrica.
Zwischen dem ReduziererkoÈrper (11) und dem Getrie-

D be (12) des Kegelrads den Block «A» legen, der zum D
Abmontieren verwendet wurde, und Mutter (13) mit
einem Anzugsmoment von mindestens 500 Nm mit einem
e InbuûschluÈssel und einem Dynamometer festziehen. f
Colocar entre el cuerpo reductor (11) y el engranaje
ESP (12) del pinon el bloquete "A" usado para el ESP
desmontaje y apretar la tierca (13) al valor minimo
de 500 Nm, utilizando una llave a manguito y una llave
dinamometrica.
Placer, entre le corps reÂducteur (11) et l'engrenage

F (12) du pignon, le petit bloc "A" utiliseÂ au deÂmontage, F
serrer l'eÂcrou (13) au couple minimum de 500 Nm aÁ
l'aide d'une cleÂ aÁ pipe et d'une cleÂ dynamomeÂtrique.
008 911 71 BOMAG

79 961
Axle DANA 193
UND
T13
F1241217
GB a
Allow the pinion to rotate a few times in both directions to enable
bearings to set.
Apply bar-hold T13 onto pinion (16) and, with a torque meter, check
the torque of the pinion.
Torque: 140 ± 150 Ncm.
CAUTION! If torque exceeds the maximum value, then the shim
"S1" (19) placed between bearing (17) and distance piece (20)
needs to be increased.
If torque does not reach the set value, increase the tightening
torque setting of nut (13), in different stages, until the maximum
admitted value of 700 Nm is obtained.
CAUTION! If torque does not reach the minimum value, then the
shim "S1" (19) needs to be reduced.
CAUTION! In order to be able to calculate the increase or reduction
of shim "S1", it is necessary to bear in mind that a 0.01 mm
variation in the size of shim (19) results in the torque of the pinion
(16) varying by 20 ± 40 Ncm.
F1241226
GB b
Remove the whole reduction gear body (11) and continue with the
assembly of the differential unit and arms.
For details, see «ASSEMBLY AND INSTALLATION OF THE
DIFFERENTIAL UNIT - ASSEMBLING THE BRAKING UNIT».
962 BOMAG
80 008 911 71
Axle DANA 193 16.5
Far compiere al pignone alcuni giri nei due sensi per Das Kegelrad um einige Umdrehungen in beide
ITA assestare i cuscinetti. D Richtungen drehen, um die Lager richtig einzusetzen.
Applicare sul pignone (16) il codolo T13 e con un Am Kegelrad (16) den Schaft T13 anbringen und mit
torsiometro, controllare la coppia di rotazione del pignone. einem Drehungsmesser das Gegenmoment des Ke-
Coppia di rotazione: 140v150 Ncm gelrads kontrollieren.
ATTENZIONE! Se la coppia supera il valore massimo bisogna Gegenmoment: 140v150 Ncm.
aumentare lo spessore "S1" (19) tra cuscinetto (17) e distanziale ACHTUNG! Falls der Wert den Maximalwert uÈberschreitet, braucht
(20). es eine groÈûere Unterlegscheibe "S1" (19) zwischen Lager (17) und
Se la coppia di rotazione non raggiunge il valore stabilito, DistanzstuÈck (20).
aumentare la coppia di serraggio del dado (13) in piuÁ tempi fino a Falls das Gegenmoment den festgelegten Wert nicht erreicht, das
raggiungere il valore massimo ammesso di 700 Nm. Anzugsmoment der Mutter (13) schrittweise erhoÈhen, bis der
ATTENZIONE! Se la coppia di rotazione non raggiunge il valore maximal zulaÈssige Wert von 700 Nm erreicht worden ist.
minimo, eÁ necessario diminuire lo spessore "S1" (19). ACHTUNG! Falls das Gegenmoment den Mindestwert nicht
ATTENZIONE! Al fine di poter calcolare gli incrementi o la erreicht, muû die Unterlegscheibe "S1" (19) kleiner sein.
diminuzione dello spessore "S1", eÁ necessario considerare che la ACHTUNG! Um das hoÈhere oder niedrigere Maû der Unter-
variazione dello spessore (19) di 0,01 mm, fa variare la coppia di legscheibe "S1" ausrechnen zu koÈnnen, darauf achten, daû ein
rotazione del pignone (16) di 20v40 Ncm. Unterschied von 0,01 mm der Unterlegscheibe (19) das Gegen-
moment des Kegelrads (16) um 20v40 Ncm aÈndert.
a
Hacer efectuar al pinon algunos giros en los dos Faire faire quelques tours au pignon dans les deux
ESP sentidos para ordenar los cojinetes. F sens de manieÁre aÁ ajuster les paliers.
Aplicar sobre el pinon (16) el codolo T13 y con un Appliquer sur le pignon (16), la queue T13, puis aÁ
torsiometro, controlar el par de rotacion del pinon. l'aide d'un torsiomeÁtre, controÃler le couple de rotation du pignon.
Par de rotacion: 140v150 Ncm. Couple de rotation: 140v150 Ncm.
ATENCION! Si el par supera el valor maximo hay que augmentar el ATTENTION! Si le couple de rotation deÂpasse la valeur maximum,
espesor "S1" (19) entre cojinete (17) y distancial (20). augmenter la cale "S1" (19) entre le palier (17) et l'entretoise (20).
Si el par de rotacion no llega al valor establecido, augmentar el par Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le
de torsion de la tuerca (13) en mas tiempos hasta llegar al valor couple de serrage de l'eÂcrou (13), en plusieurs temps, jusqu'aÁ
maximo admitido de 700 Nm. atteindre la valeur maximum admise de 700 Nm.
ATENCION! Si el par de rotacion no llega al valor minimo, es ATTENTION! Si le couple de rotation n'atteint pas la valeur
necesario disminuir el espesor "S1" (19). minimum, diminuer la cale "S1" (19).
ATENCION! Al fin de poder calcular los encrementos o la ATTENTION! Pour pouvoir calculer les augmentations et les
disminuciones del espesor "S1", es necesario considerar que la diminutions de la cale "S1", tenir compte que la diffeÂrence de
variacion del espesor (19) de 0,01 mm, hacer cambiar el par de 0,01 de la cale (19) fait varier le couple de rotation du pignon (16) de
rotacion del pinon (16) de 20v40 Ncm. 20v40 Ncm.
Rimuovere il corpo riduttore completo (11) e procedere

ITA con il montaggio del differenziale e dei bracci.
Per i dettagli, vedere «ASSEMBLAGGIO ED INSTAL-
LAZIONE GRUPPO DIFFERENZIALE - ASSEMBLAGGIO GRUP-
PO FRENO».
Den kompletten ReduziererkoÈrper (11) abnehmen und

D das Differential und die Arme montieren.
Siehe «ZUSAMMENBAU UND INSTALLATION DES
DIFFERENTIALAGGREGATS - ZUSAMMENBAU DES BREMSAG-
b GREGATS».
Remover el cuerpo reductor completo (11) y proceder

ESP con el montaje del diferencial y de los ejes.
Para los detalles, vease «ASEMBLAJE Y INSTALA-
CION GRUPO DIFERENCIAL - ASEMBLAJE GRUPO FRENO».
Enlever le corps reÂducteur complet (11) et aller de

F l'avant avec le montage du diffeÂrentiel et des bras.
Pour de plus amples deÂtails, voir "ASSEMBLAGE ET
INSTALLATION DU GROUPE DIFFERENTIEL - ASSEMBLAGE
DU GROUPE FREIN".
008 911 71 BOMAG

81 963
16.5 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle DANA 193
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
4.3 T1 T2
45°
20
25
1
=
32
32
200
=
90
= =
50
160
110
120± 0.1
120± 0.1
32
32
25
1
840
45°
10 4.5 930
2313 D1240046 2305 D1240043
T3 Ø40
T4
Ø40
32
3 x45°
3 x45°
150
150
190
195
0
R1
10
0
R1
8
17 13
40
25
32
45
32
32
3 x45°
32
Ø153
32
125
Ø154
20°
Ø178 Ø178
Ø189
Ø184
Ø200
1502 D1240120 1742 D1240121
T5
295
136 10 150
65 3 x45°
27.5
20
3 x15°
-- 0.05
-- 0.4
-- 0.6
-- 0.3
-- 0.4
-- 0.1
Ø80
Ø61
Ø35
Ø25
Ø45
Ø63
Ø46
R1
32 32
0
32
32
107.5 ---- 0.2

0.3
1501 D1240122
964 BOMAG
82 008 911 71
Axle DANA 193 16.5
75 Ø290
T6
5 Ø271
12
Ø20
Ø16
A Sez. B - B
1° 30'
° 2
32 17
°
17
32
7°
° 30' 17° 30' 1
3x15°
B
Ø150 H 7
Ø150 Hn 67
Ø318
B
43.60
° 17
82.13
113.48
17
134.91
°
17
°
Ø22
Ø16
17
21° 30'
Ø26
Ø22
Ø15
53.14
32
32
12 A
90.26
68 12
119.50
80 82
139.29
Sez. A - A n°2 pezzi
1545 D1240124
119.50 T7
190
53.14
Ø20
Ø16
9
Ø25
32 32
20
0 0 2 x30°
R1 R1 32 1° 30'
° 2
17
°
134.91
17
T7B
82.13
7°
17° 30' 7° 30' 1
Ø161.5 ±0.1
Ø264 ---- 0.15

0.25
Ø185 ---- 0.08
0.12
Ø262 ---- 0.15

0.25
Ø250
Ø172
Ø320
43.60
17°
113.49
32
°
17
17°
R5
'
21° 30
15°
15°
Ø16
5 x15° 90.26
16 20 138.29
110
32
Ø290 ±0.15
143
153
70
T7A 30 30
3 x15° 32
PROFILO HURT 45.5 x 40.5
A
Ø24
R5
Ø150 ---- 0.08
0.12
2
Ø140
Ø30
Ø38
0
R1 0
R1
Ø25 Hg 67
Ø24
Ø23,9
40 74
1.2 h 11
200 200
Particolare A 400
1769 D1240125
008 911 71 BOMAG

83 965
16.5 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle DANA 193
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
T8 T9
5 - +0
.5
-0
Ø9
Ø25
13 ± 0..2
Ø102 +-- 0.2
Ø120
0
3 x45°
160
192
Sez. A-A
0
R1
22 10
0.8 600
Ø40
0.8
Es Ch 22
␣✽
15 20
30
Ø✽
Ø129
Ø16
] Bearing ref. 32017 DIN720 Acciaio Fe 42
] Ref. cuscinetto 32017 DIN720
] Lager Ref. 32017 DIN720
] Ref. cojinete 32017 DIN720
] ReÂf. palier 32017 DIN720
Acciaio Fe 42
0355 D1240123
Ø85.5
T10
490
Ø40
Ø25
R1
30
0
3 x45°
78
R2
48
40
10
22
150
A A
188
135
Acciaio 18 Ni Cr Mo 5
Cementazione 0.6÷0.8
Temprato HRC 60÷63
0
R1
35.5
32
1.5
40
8
32
30
3
4.5
32
32
20°
Ø23.9 ±-- 00.05
Ø104
H7
Ø25 g7
Ø109
Ø30
32
-- 0.1
Ø40.5-- 0.15
Ø80
Ø92
1487/B D1240126 1495 D1240128
966 BOMAG
84 008 911 71
Axle DANA 193 16.5
T11 Ø49.8
T12
Ø41.5
4 x45°
15
93
M14 x1
40 300
Ø110 2323 D1240127
Ø65
T13
M14 x1
Ch
22
Ø20
20
M14 x1
61 –– 0.01
0.02
R5
3/4"
4"
41
1/
30
25 25
50
Ø20
Ø9
Ø41.2 +-- 0.03
0 14
195
95
25
45
35
Ø11
60
10
Ø80
10
50
Ø6.5 25
Ø35
2312 D1240075 0870 D1240129
008 911 71 BOMAG

85 967
16.5 Axle DANA 193
968 BOMAG 008 911 71

17 Circuit diagrams
008 911 71 BOMAG 969

Circuit diagrams
●
The circuit diagrams valid at the date of printing are
part of these repair instructions.
● The circuit diagrams valid for the machine serial
number can be found in the spare parts catalogue
for the machine.
970 BOMAG 008 911 71

17.1 Wiring diagram
008 911 71 BOMAG 971

17.1 Wiring diagram
Wiring diagram 582 702 07 from serial number
101 582 121 001 Variocontrol

101 582 511 081 BW 213 DH-4
101 582 521 013 BW 213 PDH-4
101 582 531 083 BW 213 DH-4 BVC
101 582 541 035 BW 213 DH-4 BVC /P
101 582 581 041 BW 214 DH-4
101 582 591 001 BW 214 PDH-4
101 582 641 001 BW 216 DH-4
101 582 651 001 BW 216 PDH-4
101 582 771 001 BW 219 DH-4
101 582 821 022 BW 226 DH-4 BVC
101 582 851 003 BW 226 DH-4 BVC
101 582 861 001 BW 226 DH-4 BVC
101 582 881 001 BW 226 DH-4
101 583 061 001 BW 213 DH-4 BVC /P
101 583 141 001 BW 213 DH-4
101 583 151 001 BW 213 PDH-4
101 583 161 001 BW 213 DH-4 BVC
101 583 191 001 BW 214 DH-4
972 BOMAG 008 911 71

Inhaltsverzeichnis: BW 177..226 DH−4
008 911 71
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
Wiring diagram
001 582 702 07 Stromlaufplan Circuit Diagram

002 582 702 07 Versorgung, Starten, Hupe supply, starting unit, signal horn
003 582 702 07 Motor Deutz EMR II engine Deutz EMR II
004 582 702 07 Motor Deutz EMR III engine Deutz EMR III
005 582 702 07 Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch
006 582 702 07 Datensammler, LC−Display data−collector, LC−display
007 582 702 07 Lenkung, Vibration steering, vibration
008 582 702 07 Fahrhebel, Vibrationsplatten joystick, vibration−plates
009 582 702 07 Variocontrol, Messtechnik Variocontrol, measurement equipm.
010 582 702 07 Bomag Compaction Management BCM Bomag Compaction Management BCM
011 582 702 07 Diebstahlschutz System anti − theft system
012 582 702 07 Beleuchtung und StvZO illumination and StvZO
013 582 702 07 Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph
014 582 702 07 Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater
101 582 702 07 Bauteilliste component listing
BOMAG
19.10.2005
Vogt 001 001 582 702 07
Stromlaufplan
19.10.2005
17.1
973
circuit diagram 001
Seis
974
30
17.1
K11
2:12
87
K30 13:1
30 4:1 K11:87 6:1
X1:15E X1:16E X1:27E X1:28E X1:30E
X1:9
F13 1 F05 1 F95 1 F23 1 F39 1
X1:10
30A 10A 10A 15A 15A
2 2 2 2 2
X1:15A X1:16A X1:27A X1:28A
X1:30A
X37:A X1:151
7:17
5:9
30 21 11 31 41 51 61
X36:B
X36:A
nur bei EMR III S00 S01 X3:3
only EMR III
22 12 32 42 52 62
Startschalter NOT−Aus
K32:86
starting swwitch 15 54 58 19 17 50a Emerg.−Stop 13:1
2 x 10qmm
X1:152 X1:155
X1:79
S01:22 3:1
X37:B
F05:2
V01 X1:3 X1:4 6:8
K05 30
2 1 8:3
5
125mA
5 87 87a
X34:P
K14 86 1 30
nicht bei EMR III, bei BW177DH−4 Option

not at EMR III, at BW177DH−4 option
K14.2 K61 K61
Sicherung Heizflansch/Glühstiftkerzen
heating−flange/glow plugs
Hauptsicherung
main fuse
13 23
4:20 3:19 3 R10 2:7 S03
3 2 2 82 OHM
F48 F00
125A 125A 85 2 87 87a X1:7 X1:8 Taster Hupe
push button, horn 14 24
BOMAG
1 1 D+ 6:2
B+ 2:13 2:8 B+
D+ MESX 9:2
G03 G01 X38:A X1:97 X1:98
+ +
− −
X1:1 X1:101 X1:102
1 1 1
X1:109
nur bei Klimaanlage

only acc.to air conditioning
Anzugsw.:50A / Haltew.:10A
30 50
R81
R83
R85
167A
2 2 2 1 B+ D+ 86 86 B11 B11
1 1 1 1 K09 K11 1 2 2 1
G02 M01 V02 XS +
R19 S30 M
12V
R86
R82
R84
2 2 2 2 2 1 V03 1 2 −
Option
option
85 85 −
2
31 EMR 3:3 B− W
X1:110 X1:168 X1:123 X1:103 X1:104
31 31 3:1
Glühstiftkerzen Trennschalter Batter 2:10 14:7 2:16 Starter Signalhörer Steckdose

glow plugs break switch battery starter warning horns socket
Batterie Batterie Generator Nur bei Geländer/ROPS/SD

battery battery generator only at hand−rail/ROPS/sun−roof
Heizflansch
heating−flange
19.10.2005
1 1
008 911 71
Wiring diagram
Vogt Versorgung, Starten, Hupe 582 702 07

19.10.2005
Seis supply, starting unit, signal horn 002
2:17 S01:22 S01:22 4:1
X1:95
1
K14
008 911 71
Relais Heizflansch
relay heating−flange 2
X1:96
Wiring diagram
X1:179
X1:185
Steckerschnittstelle Deutz
connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8
EPC−Stecker
max 7A
A48
Motorsteuerung EMR2
engine−controller EMR2
X30:14
X31:21
X31:22
X31:13
X31:11
X31:14
X31:15
X31:24
X31:25
X31:4
X31:9
X31:5
X31:6
X31:3
X31:2
X31:7
X30:10
X30:11
X30:12
X30:13
X30:1
X30:2
X31:20
X31:12
X31:10
X31:17
X31:18
X31:19
X31:16
X31:23
X31:8
X31:1
L
K
+5V
+5V
STG−
STG+
AGND
AGND
AGND
AGND
AGND
Signal
Signal
Signal
Signal
Ubat −
CAN low
CAN high
Signal Druck
Signal Temperatur
BOMAG
X1:180
X1:181
CAN2− 4:15
CAN2+ 4:15
X57:20
X57:21
X57:22
X57:12
X57:13
X57:10
X57:11
X57:14
X57:15
X57:17
X57:18
X57:19
X57:16
X57:23
X57:24
X57:25
X57:4
X57:9
X57:8
X57:1
X57:6
X1:183
X1:184
ESX Fahrst.
RF−
RF REF
3 2 1 1 2 1 2 7 2 6 1 1 4 3 2 1 2
RF MESS
EMR Stellglied
EMR commander
B88 B114 B130 Y137 5 B115 B113
X32:L
X32:K
X32:B
X32:H
X32:G
X32:A
X1:186
X34:N
X1:182
Diagnosestecker EMR
diagnosis interface EMR
2:6 4:18
31 31 EMR 31 EMR
2:20 31 4:1
2:4
Motordrehzahlsensor
sender engine rpm 2
Motordrehzahlsensor EMR Kühlmitteltemperatur
sender engine rpm 1 EMR coolant temperature
EMR Motoröldruck Ladeluftdruck + Temp
EMR engine oil pressure charging air pressure + temperature
19.10.2005
1 1 582 702 07
Vogt Motor Deutz EMR II
19.10.2005
17.1
975
Seis engine Deutz EMR II 003
976
2:15 30 30 5:1
3:20 S01:22 S01:22 7:1
Diagnosestecker EMR 3:4 CAN2+ CAN2+ 5:11
X1:14E Wasserabscheider
17.1
water−seperator diagnosis interface EMR 3:4 CAN2− CAN2− 5:11

1
F93
25A
2
X32:A
X32:K
X32:M
X32:F
X32:H
X32:G
X32:B
X1:14A
B124
86
K41 K41 30
4:2
Nur bei EMRIII

only EMRIII
X1:107 X1:108
87 87a
85
X1:179
X1:191
X1:193
X1:192
X1:194
X1:184
X1:185 X1:183 X1:198 X1:199 max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 3.5m
2.5 qmm in der hier dargestellten Installation (Querschnitt 2,5qmm)
max 7A
K−Line
CAN 1 High
CAN 1 Low
CAN 2 High
CAN 2 Low
max. Kabellänge von Batterie zum Steuergerät (Versorgungsleitung) max. 10m
bei einer Kabelbaumumgebungstemperatur von 85 Grad C. (Querschnitt 4x2,5qmm)
A48
Motorsteuerung EMR3 (EDC 16)
engine−controller EMR3 (EDC16)
X30:1
X30:5
X30:3
X30:61
X30:63
X30:60
X30:72
X30:25
X30:62
X30:28
X30:82
X30:64
X31:47
X31:46
X31:33
X31:31
X31:48
X31:32
X31:50
X31:12
X31:19
X31:40
X31:14
X31:53
X31:43
X31:8
X31:58
X31:56
X31:13
X31:13
X31:40
X31:24
X31:34
X31:16
X31:1
X31:10
X31:20
X31:27
X31:7
X31:49
X31:23
X31:26
X31:41
X31:51
X31:23
X30:2
X30:4
X30:6
Sign.
Sign.
AGND
AGND
AGND
GND
GND
GND
Signal
AGND
AGND
AGND
AGND
AGND
Signal
Signal
Signal
Signal Druck
Signal Druck
BOMAG
Signal Temperatur
X57:34
X57:35
X57:39
X57:36
X57:40
X57:42
X57:37
X57:41
X57:14
X57:13
X57:9
X57:21
X57:15
X57:1
X57:19
X57:20
X57:28
X57:23
X57:22
X57:29
X57:32
X57:25
X57:31
X57:30
X57:24
X57:27
X57:26
X57:33
X57:28
X57:23
X57:29
X1:180
X1:181
X1:182
X1:186
X66:3
X66:2
1 1 1
Y147 Y148 Y149
Y15.1 Y15.5 Y15.3 85
2 2 2 K14.2
1 2 3 2 1 3 1 4 3 2 3 2 1 1 2 3 2 1 1 2 3 4
1 1 1 1 86
Y166 Y170 Y169 Y137
Y15.6 Y15.2 Y15.4 Y19
2
2 2 2 B114 B130 B93 B113 B88 B145
B40.1 B40.2 B48 B49 B43 B6 B51
X1:90
X1:91
X1:92
3x2.5
3:5
31 31 EMR
3:20 31 5:1
4:3 2:2
EMR Stellglied EMR Kühlmitteltemperatur
EMR commander EMR coolant temperature
Injektor A1 Injektor A2 Injektor A3 Motordrehzahlsensor Ladeluftdruck + Temp EMR Motoröldruck
jet pump A1 jet pump A2 jet pump A3 sender engine rpm 1 charging air pressure + temperature EMR engine oil pressure
Injektor A4 Injektor A5 Injektor A6 Motordrehzahlsensor EMR Kraftstoffdruck EMR Niederdruck Kraftstoff
jet pump A4 jet pump A5 jet pump A6 sender engine rpm 2 rail pressure sensor EMR fuel low pressure sensor
19.10.2005
1 1
008 911 71
Wiring diagram
Vogt Motor Deutz EMR III 582 702 07

19.10.2005
Seis engine Deutz EMR III 004
4:20 30 30 6:1
F24:2 6:3 X1:2 4:20 CAN2+ CAN2+ 8:6
EMR Deutz Fahrhebel
4:20 CAN2− CAN2− 8:6
X1:145
CAN1+ 6:8
31 LC−Display, OPUS 21
CAN1− 6:8
X1:119 X1:120
008 911 71
S01
2:16
120 OHM 120 OHM
X1:146 32 1 2 1 2
X52:1
X52:2
R22 R20
Wiring diagram
rt sw X1:17E X1:34E
Diagnosestecker Fahrzeug
F67 1 F84 1 X34:G X34:H X34:C X34:D X34:A X34:B diagnosis interface equipment
B112
15A 10A
2 2
Drucksensor Fahrpumpe X1:17A X1:34A
pressure sensor drive pump
X1:34A
X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
9:2
120 OHM 120 OHM
1 2 1 2
R23 R21
Drucksensor
Leistung
Elektronik
TxD
RxD
CAN2+
CAN2−
CAN1+
CAN1−
Pot. 15
A34
Fahr−Steuerung
X35:5
driving controller
X35:4
X35:31
X35:56
X35:57
X35:59
X35:60
X35:53
X35:33
X35:58
X35:27
X35:26
X35:28
X35:54
X35:38
X35:12
X35:37
X35:34
X35:30
X35:15
X35:24
X35:49
X35:64
X35:46
X35:47
X35:55
X35:65
X35:66
X35:67
X35:68
speed
speed
BOMAG
Neigung
Richtung
Richtung
Gehäuse
housing
Achsmotor
Sitzkontakt
X1:45 X1:44
Bandagenmotor
Fahrpumpe vorw.
Fahrpumpe rückw.
Rückfahrwarnsum.
FM3 7:5 +45_G=4,5V X1:158 X1:114 X1:121 X1:122 X1:143 X1:141
+ −45_G=0,5V
B57 1V
X1:171
X1:173
X1:175
X1:177
X1:176
bl
br
ws
br
ws
bl
+ +
dir. dir.
0,46A
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
B60 B59 2,5V X14:B X9:1
speed
9:2 speed
DIR MESX S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
Y17 Y16
13:6 4V H14 Y30 Y31
sw
sw
SPEED TAC − b a
− 2 2 2 2
X1:174 9:2 X1:178 − S X1:46 X14:A X9:2 X16:2 X15:2
SPEED MESX
X1:82
X1:124
X1:142
X1:142
X1:143
X1:143
X1:55 7:4 9:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:124

31 PITCH MESX
4:20 31 6:1
Sensor Achse Sensor Bandage Neigungssensor Sitzkontaktschalter Prop.−Pumpe Vorw. Prop.−Ventil Bandagenmotor
sender axle sender drum slope sensor switch, seat contact prop.−pump forwards prop.−Valve drum motor
Rückfahrwarnsummer Prop.−Pumpe Rückw. Prop.−Ventil Achsmotor

back up alarm buzzer prop−pump backwards prop.−Valve axle motor
19.10.2005
1 1 582 702 07
Vogt Fahrantrieb, Neigungssensor, Sitzkontakt
19.10.2005
17.1
977
Seis driving system, slope sensor, seat contakt switch 1 005
978
30
5:20 30 9:1
2:20 K11:87 K11:87 8:14
5:3 F24:2 F24:2 7:15
17.1
X1:29E 2:17 F05:2

1 5:17 CAN1+ CAN1+ 8:14
F24 ESX Fahrsteuerung DIOS Platten
10A 5:17 CAN1− CAN1− 8:14
2
X1:29A
X1:87 X1:88 X1:80 X1:86
X1:41
X1:39
X1:40
11:1
X34:R
VCC
CAN1 high
CAN1 low
CAN1 high
CAN1 low
Ub "30"
Ub "15"
not connected
not connected
Ub out
X27:8
Steckerfarbe: X26−grau; X27−schwarz
A80 connector−colour: X26−grey; X27−black
A81
Datensammler LC−Display
X28:6
X29:8
data−collector LC−display
X28:1
X27:6
X27:7
X29:7
X28:3
X28:5
X28:4
X26:3
X26:5
X26:8
X26:10
X27:2
X27:4
X27:9
X26:9
X26:1
X26:2
X26:6
X26:4
X26:11
X27:10
X27:11
X27:12
X27:1
X27:3
X29:2
X29:1
X29:3
X29:4
X29:5
X29:6
X27:5
X26:12
X28:2
GND
GND
GND
UIN1
DIN1
DIN1
AIN1
UIN3
UIN2
DIN3
DIN5
DIN9
DIN6
DIN3
DIN5
DIN6
DIN8
DIN2
DIN2
AIN2
DIN4
DIN4
DIN11
DIN10
Sepa1
Sepa2
GND/UIN3
BOMAG
X1:106 X1:111 X1:112 X1:105 X1:107 X1:108
BL 12:17 ECO
Low High
BR 12:17 23 13
BEL S127
12:4
24 14
Hydraulikölfilter
hydraulic oil filter
Luftfilter
air cleaner
Kühlmittelvorrat
coolant stock level
Füllstand Diesel
fuel−level
Wasserabscheider
water−seperator
X21:1 X10:2 X8:1
B21 1 B03 1 B55 B124
D+ R03
2:8 P P Q
Schalter Motordrehzahl
2 2 switch engine−rpm mode
X21:2 X10:3 X8:2
0 .. 67 OHM
Nur bei EMRII
only EMRII
X1:117 X1:94 X1:94 X1:117 X1:164 X1:149 X1:82
31
5:20 31 7:1
19.10.2005
1 1
008 911 71
Wiring diagram
Vogt Datensammler, LC−Display 582 702 07

19.10.2005
Seis data−collector, LC−display 006
4:20 S01:22 S01:22
6:20 F24:2
X1:148 Lenkwinkelsensor
X23:1 steering angle sensor
8:1
X1:41
X1:201
X51:1 Lenkeinheit X1:187
008 911 71
B65 + A45 steering unit br
Aufnehmer Vibrationsmotor
S 5:4 FM3 X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC X39:2 bl
S1 B − X22:2
−
X1:160 X41:3 X40:1 VCC X40:2 bei BW177 sw / bei BW213 bl
B B16
Wiring diagram
bei BW177 bl / bei BW213 sw

X1:159 X41:4 X40:4 S2 X40:3
X1:203
B132 2 2 2 2 0V A ws X22:3
VIB
X1:162 X41:2 X39:4 0V X39:3 X22:4 13:6
S1 A gg sw
X1:55 X1:202
Lenkwink.
1 1 1 1
−
BTS BREMSE 8:2
X41:5
X41:7
X41:8
X41:6
Sig.
AGND
X34:J
X1:60 FM5 X1:61
X1:56 FM1 X1:57
X1:62 FM3 X1:63

X1:58 FM2 X1:59
X1:189
X1:188
armrest−switch
X1:55
Schalter Armlehne
Vib.− Richtung
Vib.− Frequenz
BTS Bremse
5:6
X1:205
X1:207
X1:206
X1:208
8,5V
X1:42
nur BVC
A34
only BVC
Fahr−Steuerung
X35:1
driving controller
X35:19
X35:17
X35:18
X35:41
X35:35
X35:29
X35:23
X35:40
X43:2 X43:1
X35:16
X35:20
X35:21
X35:43
X35:22
X35:2
X35:48
X35:3
X35:61
30
Bremse
Armlehne
Prop. out
30 K48 8:2
Warnsummer
BOMAG
X51:3
X51:2
X1:89 87 87a
Umsch. Amplitude
K43 7:12
Pumpe Vib.−Platten
X1:154 X1:196 X1:195 87 87a
Schnellverschl.−Platten
KA MESX
9:2 X1:147
X1:38
X35:22 GA MESX 11
8:13 9:2
X1:37 S01
X35:43
8:13 X1:116 X1:115 2:16
12
X1:150
400 ... 1.200mA

400 ... 1.200mA
150mA
X6:1 X7:1 9:2

400 ... 1.200mA
1 1 K43 86 Y08 1 Y07 1 H07

X1:113 BRAKE MESX
+ Y04 1
Y93 Y92
b d
2 2 85 2 2 − a1 2
X6:2 X7:2
max.1.8A
X1:149 X1:197 X1:197 X1:82 X1:117 X1:190

X1:118
6:20 8:1
31
31 Anbau 177DH: h.r. a Anbau 177DH: h.l. b
7:14 Anbau 213DH: unten Anbau 213DH: oben
Prop.−Ventil Vibration klein Magnetventil Bremse

prop. valve vibration small solenoid valve brake
Prop. Ventil lenken links Prop−Ventil Vibration groß

prop. valve steering left prop. valve vibration big
Prop. Ventil lenken rechts Warnsummer Störung

prop. valve steering right warning buzzer, failure
19.10.2005
1 1 582 702 07
Vogt Lenkung, Vibration
19.10.2005
17.1
979
Seis steering, vibration 007
980
7:2 X23:1 5:17 CAN2+ 6:14 CAN1+ CAN1+ 9:16
ESX Fahrst. LC−Display BTM
5:17 CAN2− 6:14 CAN1− CAN1− 9:16
K11:87
17.1
6:20 K11:87 9:1

Taster 1 = Platten rechts
push button 1 = plates right X1:31E
Taster 2 = Platten heben
push button 2 = lift plates 1 F145
Taster 3 = Vibration EIN/AUS Näherungssch. Platten oben
push button 3 = vibration ON/OFF 20A
Taster 4 = Platten links
sensor plates up 2
push button 4 = plates left
Taster 5 = platten senken Näherungssch. Platten Mitte X1:31A
push button 5 = lower plates
sensor plates centered
Taster 7 = Infotaste 1 X1:209
push button 7 = info button 1
X1:213
X1:214
Taster 8 = Infotaste 2
X1:156
push button 8 = Info button 2
X1:157
BTS BREMSE
7:18
br
br
3 2 + +
X63:1
X63:1
7
B135 B134
1 Fahrstufenschalter
4 − −
5 8 speed range selector
bl bl
S S
X63:2
X63:2
sw
ws
S42
quick connecting clutch

+ − S
X35:43 X1:215
Ub in CAN− 7:11
X25:2
X25:4
X25:3
Bremse zu = 0V 1 7
Schnellverschluss − Kupplung
Bremse auf = Ub BTS Bremse CAN+
3 S55 6 X35:22
BTS zus. Fahrhebel +5V out
7:11
X1:153 4 5
travel lever
0V in 0V (Ref PIN5) X62:12
2 8 A54
Add1 AK Ext1 Platten Steuerung
X62:1
X62:3
X62:9
X62:2
9 11
X62:4
X62:10
Add2 AK Ext2
plate−controller
10 12
Stecker X23
BOMAG
Stecker X24
1 2 3 4 5 6 7 8
X62:5
X62:6
X62:7
X62:8
X62:11
X62:13
X62:15
X62:14
Ub out
OV out
DK Ext1
DK Ext3
DK Ext5
DK Ext6
DK Ext2
DK Ext4
X50:2
X50:3
X50:1
S − + Y123 1 Y143 1 Y144.2 1

X1:210
S35 K0G S09 13 S64 13 S36 13 S139
13 23 2 2 2
400 .. 1.200 mA
86 86 1 Y122 1 Y142 1 Y144.1 1 Y145 1

K48 K05 Y98
14 14 14 14
24
2 2 2 2 2
85 85
X1:149 X1:211 X1:212

7:20 31
9:1
7:17 2:13 31
nicht bei BVC Nur bei BVC Schalter Schwimmstellung Platten MV Platten heben MV Platten rechts
not at BVC Only at BVC sw. swimming pos. plates plates up plates right
Frequenzverstellung Platten
freq. adjust plates MV Platten senken MV Platten Schwimmst
Schalter Amplitude Schalter Vibration Ein/Aus Schalter Betriebsart Platten Prop−Pumpe Platten plates down plates float−pos.
switch amplitudes switch vibration on/off modesw. plates prop.−valve plates MV Platten links MV Platten Priorität
plates left plates priority
19.10.2005
1 1
008 911 71
Wiring diagram
Vogt Fahrhebel, Vibrationsplatten 582 702 07

19.10.2005
Seis joystick, vibration−plates 008
Beschleunigungssensoren Beschleunigungssensoren Aufnehmer Verstellmotor Drucker Bedieneinheit BEM Display Messtechnik BOP
acc. sensor front acc. sensor rear sens. adjust. motor printer control−unit BEM display measurem. BOP
X1:34A
5:9
6:20 30 30 12:1
Pot 30
8:20 K11:87 K11:87 12:1
Pot 15
008 911 71
X2:47 X2:48 X2:49
+ −
X2:66
X2:70 X42:1 X42:2 X42:3
X46:B X46:A X46:E

Wiring diagram
X1:32E X1:35E
X2:77 P16 F1 F2
1 1 1
F148 F146
nur bei BEM

only at BEM
10A 15A
X2:56 X2:53 X2:60 X2:57 FM4 X2:71
2 2 2
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33
CAN+
F148:2 B62 B62 X2:67 X2:68 CAN−
10:15
X4:C
X4:E
X4:D
+/sw
+/sw
−/gg −/gg X47:A X47:B
X46:D X46:F
nur bei BTM+/BTM prof
only at BTM+/BTM prof
X42:4 X42:5
15g/bl 15g/bl
−/sw
X74:3
X74:5
X74:4
8:20
X2:57 B61 P11 CAN1−
20g/br
20g/br
+/rt 8:20
DIOS Platten
X48:3 X48:4 X49:3 X49:4 S/ws

CAN1+
nur bei BTM prof

X74:1 X74:2
only at BTM prof

X2:54 X2:55 X2:58 X2:59 X47:C
X4:A X4:B
X2:50 X2:51
R24
X2:69 X2:64 X2:65 1 2
Pot. 15
Leistung
Elektronik
8.5V
AGND MESX
Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
Erregerpos.
RxD TxD CAN1+ 60 OHM CAN1−
BOMAG
X44:1
X44:7
X44:9
X44:5
X44:27
X44:26
X44:4
X44:31
X44:56
X44:57
X44:59
X44:60
X44:30
X44:58
X44:29
X44:23
X44:28
X44:54
A83
Messtechnik−Rechner
measurement calc. unit
X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:53
X44:33
X44:3
X44:55
X44:65
X44:66
X44:67
X44:68
CAN3+ CAN3−
7:15 KA MESX
EVIB
GA MESX
Prop.
Prop.
GND
0..6VDC
7:15
SPEED MESX X1:85 10:15
5:3 CAN3−
400 .. 1.200mA
400 .. 1.200mA
DIR MESX X2:75 X2:73 X2:52 +

5:3
PITCH MESX Y140 1 Y141 1 P07 E 10:15
5:8 VIB CAN3+
BRAKE MESX
v.l.
v.r.
7:17 −
D+ MESX BEL MESX 2 2
2:8 12:4 X2:49 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 10:1
8:20
Prop−Ventil Erreger auf EVIB−Meter

solenoid−valve exciter up EVIB−meter
Prop−Ventil Erreger ab nur bei BEM
solenoid valve exciter down only at BEM
19.10.2005
1 1 582 702 07
Vogt Variocontrol, Messtechnik
19.10.2005
17.1
981
Seis Variocontrol, measurement equipm. 009
982
17.1
F148:2
9:4
CAN3−
9:18
9:18 CAN3+
CAN3+ CAN3−
1 R25 2
60 OHM
X2:61 X2:62
X4:N X4:M
X75:7 X75:2
A87
USB−CAN Schnittst.
USB−CAN Interface BCM
BOMAG
X2:70
X76:1 X4:G
P15 X76:2
X4:F
X2:63
BCM 05
BCM 05
nur bei BCM
only at BCM
9:20 31 31 11:1
19.10.2005
1 1
008 911 71
Wiring diagram
Vogt Bomag Compaction Management BCM 582 702 07

19.10.2005
Seis Bomag Compaction Management BCM 010
9:3 K11:87 K11:87
9:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
F11 F18 F07 F08
15A 10A 15A 15A
008 911 71
30
X1:18A K06 X1:19A X1:25A
X1:26A
12:4 X1:305
X1:83
X1:301
Schalter StvZO 87 87a
switch, StvZO
Wiring diagram
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:306
X1:307
X3:4 X3:5 with cabin 30 49L 49R

STV1
X1:302
13:17 A02
STV2
13:17
X1:23E X1:24E
K16 30 31 82 L R
12:9 F09 F10
10A 10A
87 87a X1:23A X1:24A
BEL 6:9 BL
6:9
13 BR
6:9
S16 14
switch, working head lights
BOMAG
X1:304
13 23
Schalter Arbeitsbele
01
X1:311
X1:310
X1:319
X1:313
X1:312
X1:321
X1:314
X1:309
X1:303
X1:320
X1:322
S14
lights without StvZO
Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
X1:84
Warnblinkschalter 14 24
BEL MESX
X61:1
X61:3
X60:1
X59:5
X60:3
X59:3
X58:5
X58:3
X59:2
X58:2
switch, hazard light
Arbeitsscheinwerfer hinten links

working head lights, rear lh.
Arbeitsscheinwerfer hinten rechts
working head lights, rear rh.
Arbeitsscheinwerfer vorne links
working head lights, front lh.
Arbeitsscheinwerfer vorne rechts
working head lights, front rh.
9:7
X1:43
0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 E08 1 E09 1 E10 1 E11 1
0,125A
2 2 86 2 2 2 2 86 2 2 2 2 + 2 2 2 2
K06 K16
4,6A
4,6A
4,6A
4,6A
H06
85 85 −
4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
X3:1
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
X1:323 X60:4
X1:323 X60:2
X1:324 X61:2
X1:324 X61:4
11:12 13:1
31 12:10 Schlußleuchte links 12:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
Scheinwerfer rechts
Parkleuchte rechts Blinkleuchte HL
head light RH parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH
19.10.2005
1 1 582 702 07
Vogt Beleuchtung und StvZO
19.10.2005
17.1
983
Seis illumination and StvZO 012
984
X3:6
2:15 K30 K32:87 14:2
X3:7
17.1
K32 30 STV2
X3:8 12:13
13:1 12:13 STV1
87 87a
G H A B C E F
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3 6
5
F42 14:8
F130 13:9 F130 F130 14:7
13:14
A12
15
1,75A
0,83A
K141 30 1 B51 + + 30 01W 7 2 01W 7 2 1 S163 5 1 S38 5
+ + B51
01 01 E72
K32:86 13:16 E29 E70
− − − − 1
87 87a 2 2 2 1
2:19 31 S21 5 4 S20 5 4
Radio
radio
1 Tachographenmodul
E71 1 module, tachograph
R80 A2+A3
X3:17
4,6A
4,6A
4,6A
4,6A
2 4 6 A1
Nachtleuchte
5:3 P09 +
indicator
X55:1
X56:1
X55:3
X56:3
2 1 XS
X55:4
X56:4
night illumination
SPEED TAC A16 1 B3 E27 1 E28 1 E23 1 E25
12V
Kontrolleuchte
Innenleuchte
inside light, cabin
−
socket
Steckdose
+ 7,8,9 2 B4 2 2 2 2
max. 13A
A01 VIB X3:18 5 3 C3
7:18
A5+A6
BOMAG
S45 TK −
Heizung Heckscheibe
heating rear screen
3,8A
3,8A
Schalter Innenleuche
switches interior lights
3
5A
86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 − M06 4 −
85
2,9A
3 min
ZA
4,7A
X55:2 X56:2 option

Abfallverzögert
14:18
KABINE 31
Relais Kabine Türkontaktschalter Tachograph Schalter Nachtleuchte
relais cabin door switch tachograph switch, night illumination
X3:1
X3:2
Schalterbel.
switch illum.
12:20 31 31 14:1
3:6 Wascher hinten Wascher vorn 13:2 Arbeitsscheinwerfer vorn

washer rear washer front working head lights, front
Wischer hinten Wischer vorne Arbeitsscheinwerfer hinten Rundumkennleuchte

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon
19.10.2005
1 1
008 911 71
Wiring diagram
Vogt Kabinenausrüstung, Beleuchtung, Radio, Tachograph 582 702 07

19.10.2005
Seis cabin−equipment, headlights, radio, tachograph 013
13:19 K32:87
Potential 15 aus Kabine
13:17 F130
F42 Potential 15 aus Kabine
13:9
D Potential 30 aus Kabine H A
F31 F40 F15
20A 20A 5A
4 8 1
008 911 71
Wiring diagram
Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C control−unit cab−heater /air conditioning X54:4 X54:3 X54:2
0123 4 3 2
S44 A72
Steuergerät 5
control unit
6 11 12 1 Regel aus = 0,4A 0123
Schalter Kabinenlüfter
E30 Kleine Stufe = 0,67A S28
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater große Stufe = 1.9A
X3:13 Power Stufe = 2,8A
6 2 1 3
Anlaufstrom beim Start = 8,3A
K09 30
X3:14
switch, cab add.−heater
X53:L
X53:H
X53:M
2:10
Schalter Kabinenzusatzheizung
87 87a X1:167 10 9 5 6 8 7 4 15
X1:169 X18:1
X3:9
X3:11
X3:10
X3:12
X19:1
B131
B103 1 1
_t _t
2 2
BOMAG
X19:2
X20:1 X18:2
X17:1 X1:163
Thermofühler Klimaan
temperature sensor air conditioning
X17:3 X1:166
X17:2 X1:165
Thermofühler Heizung
temperature sensor heating unit
B104 4
P
HP
1A
LP 3
ge rt or ge rt or
Y138 1 1
X1:170 13:19
X20:4
X20:3
V06 Y14 KABINE 31
monitoring coolant pressure

M09 M M09 M
2 2 2
Überwachung Kühlmitt
Stromaufnahme Lüfter / current blower br br
Stufe 1: 3.0A pro Lüfter
X20:2 V04
Stufe 2: 4.5A pro Lüfter 1
Y15 1
X17:4 X1:168
2
3,5A
X1:164
X1:190
13:20 31 31
Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Kabinenlüfter
cab ventilator
19.10.2005
1 1 582 702 07
Vogt Kabinenheizung, Klimaanlage, Zusatzheizung
19.10.2005
17.1
985
Seis cabin−heater, air conditioning, add. heater 014
17.1 Wiring diagram
Name Bl. Pf. Benennung title TYP
004 12
A02 012 17 Blinkrelais indicator relay

A12 013 5 Radio Radio
A16 013 6 Elektronik Tachograph Electronic system, tachograph
A34 005 6 Prozessorplatine Prozessing circuit board
A45 007 9 Lenkrad Steering wheel
A48 003 3 Elektronische Motorsteuerung Electronic engine management
A54 008 17 Modul Pumpenansteuerung Modul pump control
A66 011 9 Elektronik Steuereinheit Electronic control unit
A67 011 15 Eingabeeinheit Keyboard
A72 014 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
Seis
19.10.2005
Vogt
19.10.2005
A80 006 3 Modul Datensammler modul data−collector

A81 006 18 Anzeigeeinheit Display−Unit
A83 009 6 Elektronik Messtechnik electronic measurement−equipment
A87 010 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
B03 006 3 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B11 002 16 Signalhorn Warning horn
B16 007 16 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 006 2 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B51 013 4 Lautsprecher Radio Speaker radio
B55 006 4 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 005 6 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 005 4 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 005 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 009 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 009 8 Beschleunigungsaufnehmer Acceleration sensor
B65 007 4 Sensor, Lenkwinkel vorn Sensor, angularity steering, front
B88 003 6 Druckgeber Motoroel Sender, engine oil pressure
B93 004 13 Leistungskraftstoffdruck Sensor RPS Rail pressure sensor
B103 014 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 014 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B112 005 3 Druckgeber Fahrpumpe pressure sender, driving pump
B113 003 13 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 003 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
component listing

B115 003 11 Geber Ladeluftdruck Sender, charging air pressure
Bauteilliste
B124 004 5 Geber Wasserstandsabscheider Diesel Sender, water separator fuel

B126 003 14 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B131 014 10 Temperaturschalter Heizung Temperature switch, heating
B132 007 2 Inititator Armlehne links proximity switch left arm rest
B134 008 17 Näherungsschalter Platten oben proximity switch, plate up
B135 008 16 Näherungsschalter Platten mitte proximity switch, plate middle
B145 004 17 Sensor Niederdruck Kraftstoff fuel low pressure sensor
E08 012 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 012 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 012 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 012 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 012 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 012 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 012 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 012 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 012 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 012 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 012 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 013 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 012 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 013 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 012 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 013 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 012 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 013 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 013 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 014 13 Heizgeraet Heating unit
E32 013 19 Kennleuchte Warning light 5A
E70 013 15 Nachtleuchte Night lamp 0,83A
E71 013 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 013 16 Beleuchtung Bedienschalter illum. Switches
F00 002 6 Hauptsicherung Batterie Fuse, main, battery 125A

1
F05 002 14 Sicherung Steckdose Fuse, socket 10A

F07 012 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 012 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 012 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 012 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
11
F11 012 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 11 Sicherung Startschalter Fuse, starter switch 30A
F15 014 18 Sicherung Heizgeraet Fuse, heating unit 5A
F18 012 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
582 702 07
F19 012 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 15A
F22 012 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 15A
F23 002 18 Sicherung Signalhorn Fuse, warning horn 15A
F24 006 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A
F31 014 3 Sicherung Kabinenluefter Fuse, cabin ventilator 20A
101
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A

F40 014 13 Sicherung Kabinenheizung Fuse, heating unit cab 20A
F41 013 19 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A
986 BOMAG 008 911 71

Wiring diagram 17.1
F42 013 3 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F43 013 10 Sicherung Wischermotor hinten Fuse, wipermotor rear 15A
F44 013 13 Sicherung Wischermotor vorn Fuse, wipermotor front 15A
F48 002 5 Sicherung Gluehanlage Fuse, glow plug system 125A
F67 005 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 15A
F68 002 8 Sicherung Potential 30 Fuse, potential 30 5A
F84 005 9 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F93 004 3 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F95 002 16 Sicherung Motormanagement intern Fuse, engine controller (internal) 10A
FM1 007 6 Platinensicherung Multifuse MULTIFUSE
Seis
19.10.2005
Vogt
19.10.2005
F130 013 15 Sicherung Nachtleuchte Fuse, night lamp 10A

F143 013 2 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A
F144 013 20 Sicherung Kabinensteckdose Fuse cabin−socket 15A
F145 008 18 Sicherung Anhängeplatten fuse vibration plates 20A
F146 009 5 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30) 15A
G01 002 6 Batterie Battery 103A

G02 002 7 Generator Generator
H06 012 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 007 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 005 11 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX O,46A
K05 008 3 Relais Startstrom Relay, starting current BOSCHW

K06 012 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 10 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 12 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K14 003 19 Relais Vorgluehen Relay, glow plug system TYCOX
K16 012 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K32 013 1 Relais Kabine Relay, cabin BOSCHW
K41 004 2 Trennrelais Relay, separation BOSCHW
K43 007 12 Relais Vibration Relay, vibration BOSCHW
K48 008 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K61 002 7 Relais Ladekontrolle Relay, charge control BOSCHW
K14.2 004 20 TYCOX
K141 013 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
component listing
M01 002 13 Starter Starter 2.3 KW

M04 013 12 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
Bauteilliste
M05 013 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A

M06 013 13 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 013 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 014 3 Kabinenluefter Cabin ventilator
P07 009 15 Omegameter Omegameter

P09 013 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 009 14 Drucker Printer
P15 010 16 BCM 03 Bildschirm BCM 03 terminal
P16 009 16 Diagnose, Variomatic Diagnostics, varimatic
P33 009 18 Opus 21 Opus 21
R03 006 5 Geber Tankanzeige Sender, level gauge 0 .. 67 OHM

R10 002 8 Parallelwiderstand Parallel resistor 82 OHM
R19 002 4 Heizflansch heater flange 167A
R20 005 15 Widerstand Resistor 120 OHM
R80 013 2 Heizung Heckscheibe heating rear screen MAX. 13A
R81 002 1 Gluehstiftkerze 1 glow plug 1
S00 002 11 Startschalter Starter switch

S01 002 16 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 002 18 Taster Signalhorn Push button, warning horn
S06 005 10 Sitzkontaktschalter links Switch, seat contact, lh.
S09 008 8 Vibrationsschalter vorne Switch, vibration, front
S14 012 15 Warnblinkschalter Switch, hazard light
S15 012 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
2
S16 012 4 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 013 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 013 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 014 18 Schalter Kabinenheizung Switch, cabin heating
S30 002 5 Batterietrennschalter Switch, battery disconnect
11
S35 008 7 Vibrationsschalter klein/gross Switch, vibration low/high

S36 008 11 Vibrationsschalter Switch, vibration
S37 012 18 Schalter Blinker Switch, indicator
S38 013 19 Schalter Kennleuchte Switch, warning light
582 702 07
S42 008 11 Stufenumschalter schnell−langsam Speed range selector, fast−slow

S44 014 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 013 3 Schalter Kabineninnenleuchte Switch, cabin inside light
S55 008 6 Schalter Fahrhebel Switch, travel control lever
S64 008 10 Schalter Schwimmstellung Switch, float position
102
S86 013 3 Schalter Tuer, links Switch door, lh.

S127 006 17 Schalter Motordrehzahl Switch, engine rpm
S139 008 13 Schalter Frequenzverstellung Switch, frequency control
008 911 71 BOMAG 987

17.1 Wiring diagram
S158 013 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 013 16 Schalter Heckscheibenheizung switch rear screen heating unit
V01 002 9 Diode Diode FE5B

V06 014 9 Diode Diode
X1:1 002 7 WAGO ZENTRALELEKTRIK WAGO E−BOX

Seis
19.10.2005
Vogt
19.10.2005

component listing

Bauteilliste

3

11

582 702 07

103

988 BOMAG 008 911 71

Wiring diagram 17.1
Seis
19.10.2005
Vogt
19.10.2005

X1:14A 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:14E 004 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

Bauteilliste

4

11

582 702 07

104

008 911 71 BOMAG 989

17.1 Wiring diagram
Seis
19.10.2005
Vogt
19.10.2005

component listing

Bauteilliste

X2:47 009 18 WAGO−MESSTECHNIK Wago−measurement equip.
5

11

582 702 07

105

X3:1 012 11 STECKER ROPS/SD conn. ROPS/SR
990 BOMAG 008 911 71

Wiring diagram 17.1
X3:1 013 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 002 19 SETCKER KABINE/ROPS Con cabin/ROPS
Seis
19.10.2005
Vogt
19.10.2005

X4:A 009 14 KABINENST. MESST. con. measurem.equipm.
X4:B 009 14 KABINENST. MESST. con. measurem.equipm.
X4:C 009 14 KABINENST. MESST. con. measurem.equipm.
X4:D 009 14 KABINENST. MESST. con. measurem.equipm.
X4:E 009 15 KABINENST. MESST. con. measurem.equipm.
X4:F 010 18 KABINENST. MESST. con. measurem.equipm.
X4:G 010 18 KABINENST. MESST. con. measurem.equipm.
X4:M 010 16 KABINENST. MESST. con. measurem.equipm.
X4:N 010 15 KABINENST. MESST. con. measurem.equipm.
X6:1 007 13 STECKER VIBRATION GRO conn. vibration big
X7:1 007 15 STECKER VIBRATION KLE conn. vibration small
X8:1 006 6 STECKER WASSERABSCHEI connector water separator
X9:1 005 11 STECKER RÜCKFAHRALARM conn. backupalarm
XS 002 19 Steckdose Socket
X10:2 006 5 STECKER TAUCHROHRGEBE connector fuel level sensor
X14:A 005 10 STECKER SITZKONTAKT connector seat contact switch
X14:B 005 10 STECKER SITZKONTAKT connector seat contact switch
X15:1 005 13 STECKER FAHRPUMPE RÜC connectoe driving pump back
X16:1 005 12 STECKER FAHRPUMPE VOR connector driving pump front
component listing
X17:1 014 3 STECKER LÜFTER HKL conn. blower

Bauteilliste

X18:1 014 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 014 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 006 4 STECKER KÜHLMITTEL connector coolant sensor
X22:1 007 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X25:2 008 10 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X26:1 006 8 STECKER DATENSAMMLER connector data collector
6

11
X28:1 006 16 STECKER LC−DISPLAY 1 connector LC−display 1

582 702 07

106

008 911 71 BOMAG 991

17.1 Wiring diagram
X30:1 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
Seis
19.10.2005
Vogt
19.10.2005

X31:1 003 16 EMR−Stecker Motor EMR−connector engine
component listing

Bauteilliste

7

11

582 702 07
X32:A 003 2 EMR − Diagnose EMR−diagnosis

X32:B 003 3 EMR − Diagnose EMR−diagnosis
X32:F 004 13 EMR − Diagnose EMR−diagnosis
107
X32:G 003 3 EMR − Diagnose EMR−diagnosis

X32:H 003 3 EMR − Diagnose EMR−diagnosis
992 BOMAG 008 911 71

Wiring diagram 17.1
X32:K 003 2 EMR − Diagnose EMR−diagnosis
X32:L 003 2 EMR − Diagnose EMR−diagnosis
X32:M 004 13 EMR − Diagnose EMR−diagnosis
X33:1 003 19 Trennstelle EMR II conector EMR II
X34:A 005 14 DIAGNOSESTECKER ESX connector diagnosis ESX
Seis
19.10.2005
Vogt
19.10.2005
X34:B 005 16 DIAGNOSESTECKER ESX connector diagnosis ESX

X34:C 005 12 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:D 005 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:G 005 10 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:H 005 11 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:J 007 3 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:N 003 4 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:P 002 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:R 006 2 DIAGNOSESTECKER ESX connector diagnosis ESX
X35:1 007 4 ESX STECKER esx connector
component listing

Bauteilliste

X36:A 002 5 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 6 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X37:B 002 13 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 13 STECKER STARTER E−KAS connector starter, e−Box
X39:1 007 9 STECKER 1 LENKRAD connector 1 steering unit
8

X41:1 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
11

582 702 07

X42:1 009 18 STECKER ADAPTER BOP conector adapter BOP
108

X43:1 007 2 STECKER SCHALTER ARML connector switch arm rest
008 911 71 BOMAG 993

17.1 Wiring diagram
X44:1 009 13 MESX STECKER MESX Stecker
Seis
19.10.2005
Vogt
19.10.2005

X46:A 009 19 STECKER BOP Connector BOP
X46:B 009 18 STECKER BOP Connector BOP
X46:D 009 18 STECKER BOP Connector BOP
X46:E 009 19 STECKER BOP Connector BOP
X46:F 009 18 STECKER BOP Connector BOP
X47:A 009 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 009 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
component listing
X47:C 009 12 STECKER AUFN. PLEIGER conn. sender PLEIGER

X48:1 009 8 STECKER AUFN. VORNE conn. sender front
Bauteilliste

X49:1 009 10 STECKER AUFN. HINTEN conn. sender rear
X50:1 008 13 ST. PLATTENFREQ. conn. plate−freq.
X51:1 007 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X52:1 005 3 STECKER DRUCKSENSOR connector pressure sensor
X53:B 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 014 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 014 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 014 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 014 11 STECKER HEIZSTEUERUNG conn. heating controller
X55:1 013 11 STECKER WISCHER HINTE connector wiper rear
X56:1 013 14 STECKER WISCHER VORNE conn. wiper front
X57:1 003 15 Stecker Motor connector engine
9

11

582 702 07

109

994 BOMAG 008 911 71

Wiring diagram 17.1
Seis
19.10.2005
Vogt
19.10.2005

X58:2 012 17 STECKER STVZO VL Con. STVZO FL
X59:2 012 19 STECKER STVZO VR Con. STVZO FR
component listing

Bauteilliste

X60:1 012 18 STECKER STVZO HL Con. STVZO BL
X61:1 012 19 STECKER STVZO HR Con. STVZO BR
X62:1 008 19 STECKER DIOS PLATTEN con. DIOS−plates
X63:1 008 13 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X65:1 011 5 KEYBOARD Keyboard
10

X66:2 004 19 ANSCHLUß EMR3 VORGLÜH connector EMR3 preglow
11

X74:1 009 14 STECKER DRUCKER con. printer
582 702 07

X75:2 010 16 SUB−D STECKER BCM INT con. SUB−D BCM
X75:7 010 15 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 010 17 STECKER VERS. BCM con. Power−sup. BCM
110
Y04 007 17 Magnetventil Bremse Solenoid valve, brake MAX. 1.8A
008 911 71 BOMAG 995

17.1 Wiring diagram
Y07 007 15 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high 0.4 .. 1.2A
Y08 007 13 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low 0.4 .. 1.2A
Y14 014 14 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 014 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 005 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 0.4 .. 1.2A
Y17 005 12 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 0.4 .. 1.2A
Y30 005 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 0.4 .. 1.2A
Y31 005 16 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 0.4 .. 1.2A
Y92 007 6 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. 0.4 .. 1.2A
Y93 007 5 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. 0.4 .. 1.2A
Y98 008 14 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear 0.4 .. 1.2A
Y122 008 16 Magnetventil Platten heben Solenoid valve, lift plates MAX. 1.8A
Y123 008 17 Magnetventil Platten senken Solenoid valve, let down plates MAX. 1.8A
Y137 003 10 EMR Verstellung EMR adjustment
Seis
19.10.2005
Vogt
19.10.2005

Y138 014 10 Magnetveentil Heizung Solenoid valve, heating unit 1A
Y140 009 10 Magnetventil Erreger auf solenoid valve exciter up 0.4 .. 1.2A
Y141 009 11 Magnetventil Erreger ab solenoid valve exciter down 0.4 .. 1.2A
Y142 008 17 Magnetventil Plattenverschieben Links solenoid valve, plate displace left MAX. 1.8A
Y143 008 18 Magnetventil Plattenverschieben rechts solenoid−valve, plate displace right MAX. 1.8A
Y144.1 008 19 MAX. 1.8A
Y144.2 008 19 MAX. 1.8A
Y145 008 20 Magnetventil Platten (Priorität) solenoid−valve, plate (priority) MAX. 1.8A
Y147 004 1 Injektor A1 jet pump A1
component listing
Bauteilliste
11
11
582 702 07
111
996 BOMAG 008 911 71

X38
X36 X37
008 911 71
A80
Wiring diagram
Nur bei StvzO

only acc. To StvZO illumination
BOMAG
A02 R10 K05
K11 K16 K06
Nur bei Klimaanlage

K09 K43
only acc. to aircond.
K48
K61
B57
K41
X32:1-12 X34:1-19
Gez.: 19.10.2005 Seite: 1 von: 2

Name: Vogt Übersicht Schaltkasten BW 177...226 DH/BVC-4 page: 1 from: 2
582 702 07
17.1
997
Gepr.: 19.10.2005 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box BW 177...226 DH/BVC-4 Replaces: Sheet No.: 201
Nur bei VM8
998
only acc. To VM8
F1 F2
CAN 1
17.1
LCD+
CAN 1
Datensammler
A34
Fahrsteuerung
CAN 2 EMR + Fahrhebel
BOMAG
CAN 1 OPUS 21
A83
Messtechnik Steuerung
CAN 3 BCM
008 911 71
Wiring diagram
Gez.: 19.10.2005 Seite: 2 von: 2

Name: Vogt
Übersicht Schaltkasten-Tür BW 177...226 DH-4 page: 2 from: 2
582 702 07
Name: Seis
overview e-box door BW 177...226 DH-4 Replaces: Sheet No.: 201
Wiring diagram 17.1
WAGO smart DESIGNER 4.1
1 057 564 17
2 280-315
3 2 x 057 564 25 "L" + 793-501
5 2 x 057 564 25 "L" + 057 564 20 + 793-501
7 057 564 22
8 4 x 057 564 23 "L" + 057 564 19 + 793-501
12 18 x 057 564 36 "R" + 057 564 19 12 F93 Flachsicherung DIN 72581-C25 / 057
+ 793-501 511 09 (Nur bei EMR III)
13 F13 Flachsicherung DIN 72581-C30 / 057

510 99

510 97

510 98

510 98 (Nur bei E2 StvZO Beleuchtung)


511 73 (Nur bei Diebstahlschutz)

510 98

510 98




510 97

510 97

510 98

510 97

510 98

511 00 (Nur bei AG28 Plattenanbau)
Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : DH-4 Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Ort :
Optional4 :
Tragschiene : Absicherung DH-4 komplett Lieferadresse :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Größe der Bohrung : 5.20 x 25.00 [mm]
Copyright WAGO. Technische Änderungen vorbehalten.

30.11.2005 08:36:29 Seite 1
008 911 71 BOMAG 999

17.1 Wiring diagram
30 3 x 057 564 36 "R" + 793-501 30 F148 Flachsicherung DIN 72581-C10 / 057

510 97 (Nur bei VM8-11 Messtechnik)


33 057 564 35
34 2 x 057 564 17
36 057 564 21
37 2 x 057 564 25 "L" + 793-501
39 3 x 057 564 25 "L" + 057 564 20 + 793-501
42 5 x 057 564 25 "L" + 793-501
47 8 x 057 564 25 "L" + 057 564 20 + 793-501
55 057 564 25 "L" + 793-501
56 4 x 057 564 38 "L" + 793-501 56 Nur bei BVC
57 Nur bei BVC
60 057 564 17

Artikelnummer :
Ort :
Optional4 :

30.11.2005 08:36:29 Seite 2
1000 BOMAG 008 911 71

Wiring diagram 17.1

Artikelnummer :
Ort :
Optional4 :

30.11.2005 08:36:59 Seite 3
008 911 71 BOMAG 1001

17.1 Wiring diagram

Artikelnummer :
Ort :
Optional4 :

30.11.2005 08:36:59 Seite 4
1002 BOMAG 008 911 71

Wiring diagram 17.1
1 05756417
2 3 x 05756540 "R" + 793-501
5 05756535 "R" + 793-501
6 05756537
7 3 x 05756540 "R" + 793-501
10 05756537
11 05756540 "R" + 793-501
12 05756535 "R" + 793-501
13 05756537
14 2 x 05756538 "R" + 793-501
16 2 x 05756539 "R" + 793-501
18 05756537
19 4 x 05756540 "R" + 793-501
23 05756537
24 4 x 05756540 "R" + 793-501
28 2 x 05756539 "R" + 793-501
30 05756537
31 05756540 "R" + 793-501
32 05756539 "R" + 793-501
33 05756537
34 4 x 05756540 "R" + 793-501
38 05756535 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
44 05756537
45 05756540 "R" + 793-501
46 05756535 "R" + 793-501
47 05756537
48 05756540 "R" + 793-501
49 05756535 "R" + 793-501
50 05756537

Artikelnummer :
Ort :
Optional4 :
Tragschiene : Kabelbäume DH-4 komplett Lieferadresse :

08.11.2005 11:25:37 Seite 1
008 911 71 BOMAG 1003

17.1 Wiring diagram
51 05756538 "R" + 793-501
52 2 x 05756540 "R" + 793-501
54 05756538 "R" + 793-501
55 05756537
56 3 x 05756540 "R" + 793-501
59 05756538 "R" + 793-501
60 05756537
61 3 x 05756540 "R" + 793-501
64 05756535 "R" + 793-501
65 05756537
66 2 x 05756540 "R" + 793-501 66 Bei DH-4 TierIII und BVC
67 Bei DH-4 TierIII und BVC
68 05756535 "R" + 793-501
69 05756537 69 Bei DH-4 TierIII und BVC

70 3 x 05756540 "R" + 793-501 70 Nur bei Variocontrol
71 Nur bei Variocontrol
72 Nur bei Variocontrol
73 05756535 "R" + 793-501 73 Nur bei Variocontrol
74 05756537 74 Nur bei Variocontrol

75 2 x 05756540 "R" + 793-501 75 Nur bei AG28 Anbau-Vibrationsplatten
76 Nur bei AG28 Anbau-Vibrationsplatten
77 2 x 05756535 "R" + 793-501 77 Nur bei AG28 Anbau-Vibrationsplatten
78 Nur bei AG28 Anbau-Vibrationsplatten
79 05756537 79 Nur bei AG28 Anbau-Vibrationsplatten

80 05756417

Artikelnummer :
Ort :
Optional4 :

08.11.2005 11:25:37 Seite 2
1004 BOMAG 008 911 71

Wiring diagram 17.1

Artikelnummer :
Ort :
Optional4 :

08.11.2005 11:26:35 Seite 3
008 911 71 BOMAG 1005

17.1 Wiring diagram

Artikelnummer :
Ort :
Optional4 :

08.11.2005 11:26:35 Seite 4
1006 BOMAG 008 911 71

Wiring diagram 17.1
1 05756417
2 2 x 05756540 "R" + 793-501
4 05756539 "R" + 793-501
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
9 05756538 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
13 05756539 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501
17 05756540 "R" + 793-501
18 05756537

Artikelnummer :
Optional2 : Projekt : Messtechnik / BVC* Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : Klemmenleiste X2 Lieferadresse :

08.11.2005 12:45:24 Seite 1
008 911 71 BOMAG 1007

17.1 Wiring diagram
19 05756540 "R" + 793-501 19 Nur bei BVC
20 05756539 "R" + 793-501 20 Nur bei BVC
21 05756537 21 Nur bei BVC

22 2 x 05756438 "R" + 793-501 22 Nur bei BVC
23 Nur bei BVC
24 05756421 24 Nur bei BVC

25 05756417

Artikelnummer :
Ort :
Optional4 :

08.11.2005 12:45:24 Seite 2
1008 BOMAG 008 911 71

Wiring diagram 17.1

Artikelnummer :
Ort :
Optional4 :

08.11.2005 12:45:47 Seite 3
008 911 71 BOMAG 1009

17.1 Wiring diagram

Artikelnummer :
Ort :
Optional4 :

08.11.2005 12:45:47 Seite 4
1010 BOMAG 008 911 71

Wiring diagram 17.1
1 05756417 1 Nur bei ZA E2 StvZO Beleuchtung
2 4 x 05756540 "R" + 793-501 2 Nur bei ZA E2 StvZO Beleuchtung
3 Nur bei ZA E2 StvZO Beleuchtung



Artikelnummer :
Optional2 : Projekt : E2 Beleuchtung Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : Option E2 StvZO Beleuchtung Lieferadresse :

08.11.2005 14:30:09 Seite 1
008 911 71 BOMAG 1011

17.1 Wiring diagram

Artikelnummer :
Ort :
Optional4 :

08.11.2005 14:30:27 Seite 2
1012 BOMAG 008 911 71

X74 X75
X55
X56 X76 X53 X54
008 911 71
X29
Wiring diagram
X28 X21
X39 X23 X24 X50
X59 X40 X25 X41
X13
X58 X42 X51 X43 X57
X20
X46 X14
X18 X30 X77

X17 X33 X6 X7
X52
X47 X22 X19 X31 X4 X3 X15 X16
X8
X48 X49 X48 X49 X10
(BVC) (BVC) X36 X26 X60
X37 X1 X27 X61 X62
X38 X2
X9
X44
X35
X32 X34
BOMAG
X61
X77 X9
X21
X74 X75
X59 X62
X76
X42 X23 X24 X50 X8
X57
X10
X46 X25 X41 X51
X56
X53
X20
X29 X18
X17 X14
X28 X19 X55 X6 X7
X54 X15 X16
X39
X43
X40
X30
X58 X52 X33
X31 X4 X3
X36 X35 X1 X26
X37 X44 X2 X27
X38 X32 X34 X60
X47
X48 X49
(BVC) (BVC) X48 X49
X22
Gez.: 19.10.2005 Seite: 1 von: 1

Name: Vogt
Übersicht Schaltkasten-Tür BW 177...226 DH-4 page: 1 from: 1
582 702 07
17.1
1013
Name: Seis overview e-box door BW 177...226 DH-4 Replaces: Sheet No.: 301
17.1 Wiring diagram
1014 BOMAG 008 911 71

17.2 Wiring diagram
008 911 71 BOMAG 1015

17.2 Wiring diagram
Wiring diagram 582 702 32 from serial number
101 582 121 002 Variocontrol

101 582 641 060 BW 216 DH-4
101 582 651 005 BW 216 PDH-4
101 582 771 171 BW 219 DH-4
101 582 861 026 BW 226 DH-4 BVC
101 582 881 003 BW 226 DH-4
101 583 061 014 BW 213 DH-4 BVC /P
101 583 141 076 BW 213 DH-4
101 583 151 006 BW 213 PDH-4
101 583 161 027 BW 213 DH-4 BVC
101 583 191 005 BW 214 DH-4
101 583 201 001 BW 214 PDH-4
1016 BOMAG 008 911 71

008 911 71
table of contents: BW 177..226 DH−4
Wiring diagram

002 582 702 32 Versorgung, Starten, Kraftstoffvorwärmung, Hupe supply, starting unit, fuel pre−heater, signal horn
010 582 702 32 Bomag Compaction Management BCM, GPS Bomag Compaction Management BCM, GPS
011 582 702 32 Diebstahlschutz System DH−4 anti − theft system
BOMAG
08.03.2007
001 001
Vogt Stromlaufplan 582 702 32
08.03.2007
17.2
1017
circuit diagram 001
Seis
1018
30
17.2
K11
2:11
87
K30 13:1
30 4:1 K11:87 6:1
X1:15E X1:16E X1:27E X1:33E X1:28E X1:30E
X1:9
F13 1 F05 1 F95 1 F124 1 F23 1 F39 1
X1:10
30A 10A 10A 25A 15A 15A
2 2 2 2 2 2
X1:15A X1:16A X1:27A X1:33A X1:28A
X1:30A
X37:A X1:151
7:17
5:9
X36:B
30 21 11 31 41 51 61
X36:A
only EMR III
22 12 32 42 52 62
K32:86
15
starting swwitch 54 58 19 17 50a Emerg.−Stop 13:1
2 x 10qmm
X1:152 X1:155
X1:79
S01:22 3:1
X37:B
F05:2
V01 X1:3 X1:4 6:8
K05 30
2 1 8:3
5
125mA
5 87 87a
X34:P
K14 86 1 30

K14.2 K61 K61
Hauptsicherung
main fuse
13 23
4:20 3:19 3 R10 2:7 S03
3 2 2 82 OHM
F48 F00
125A 125A 85 2 87 87a X1:7 X1:8 Taster Hupe
push button, horn 14 24
BOMAG
1 1 D+ X1:217
6:2
B+ 2:12 2:8 B+
D+ MESX 9:2
G03 G01 X38:A X1:97 X1:98
+ +
X67:1
− −
X1:1 X1:101 X1:102
1
1 1 1 R79
X1:109
nur bei Klimaanlage

30 50
R81
R83
R85
167A
2 2 2 B+ D+ 2
1 86 86 B11 B11
1 1 1 1 K09 K11 X67:2 1 2 2 1
G02 M01 V02 XS +
R19 S30 M
12V
R86
R82
R84
2 2 2 2 2 1 V03 1 2 −
Option
option
85 85 −
2
31 EMR 3:3 B− W
Option Winterpaket
option winter package
X1:110 X1:168 X1:123 X1:218 X1:103 X1:104
31 31 3:1
Glühstiftkerzen Trennschalter Batter 2:10 14:7 2:15 Starter Signalhörer Steckdose

Batterie Batterie Generator Kraftstoffvorwärmung Nur bei Geländer/ROPS/SD

battery battery generator fuel pre−heater only at hand−rail/ROPS/sun−roof
Heizflansch
heating−flange
08.03.2007
1 1
008 911 71
Wiring diagram
Vogt Versorgung, Starten, Kraftstoffvorwärmung, Hupe 582 702 32

08.03.2007
Seis supply, starting unit, fuel pre−heater, signal horn 002
2:16 S01:22 S01:22 4:1
008 911 71
X1:95
1
Relais Heizflansch K14
relay heating−flange
X1:96 2
Wiring diagram
X1:185
X1:179 connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8
EPC−Stecker
max 7A
A48
Motorsteuerung EMR2
X30:14
X31:21
X31:22
X31:13
X31:11
X31:14
X31:15
X31:24
X31:25
X31:4
X31:9
X31:5
X31:6
X31:3
X31:2
X31:7
X30:10
X30:11
X30:12
X30:13
X30:1
X30:2
X31:20
X31:12
X31:10
X31:17
X31:18
X31:19
X31:16
X31:23
X31:8
X31:1
L
K
+5V
+5V
STG−
STG+
AGND
AGND
AGND
AGND
AGND
Signal
Signal
Signal
Signal
Ubat −
CAN low
CAN high
Signal Druck
Signal Temperatur
BOMAG
X1:180
X1:181
CAN2− 4:15
CAN2+ 4:15
X57:20
X57:21
X57:22
X57:12
X57:13
X57:10
X57:11
X57:14
X57:15
X57:17
X57:18
X57:19
X57:16
X57:23
X57:24
X57:25
X57:4
X57:9
X57:8
X57:1
X57:6
X1:183
X1:184
ESX Fahrst.
RF−
RF REF
3 2 1 1 2 1 2 7 2 6 1 1 4 3 2 1 2
RF MESS
EMR Stellglied
EMR commander
B88 B114 B130 Y137 5 B115 B113
X32:L
X32:K
X32:B
X32:H
X32:G
X32:A
X1:186
X34:N
X1:182
Diagnosestecker EMR
2:6 4:18
31 31 EMR 31 EMR
2:20 31 4:1
2:4
Motordrehzahlsensor
sender engine rpm 2

08.03.2007
1 1 582 702 32
17.2
08.03.2007
1019
30
1020
2:14 30 5:1
3:20 S01:22 S01:22 7:1
17.2

1
F93
25A
2
X32:A
X32:K
X32:M
X32:F
X32:H
X32:G
X32:B
X1:14A
B124
86
K41 K41 30
4:2
Nur bei EMRIII

only EMRIII
X1:107 X1:108
87 87a
85
X1:179
X1:191
X1:193
X1:192
X1:194
X1:184
max 7A
K−Line
CAN 1 High
CAN 1 Low
CAN 2 High
CAN 2 Low
A48
X30:1
X30:5
X30:3
X30:61
X30:63
X30:60
X30:72
X30:25
X30:62
X30:28
X30:82
X30:64
X31:47
X31:46
X31:33
X31:31
X31:48
X31:32
X31:50
X31:12
X31:19
X31:40
X31:14
X31:53
X31:43
X31:8
X31:58
X31:56
X31:13
X31:11
X31:57
X31:24
X31:34
X31:16
X31:1
X31:10
X31:20
X31:27
X31:7
X31:49
X31:23
X31:26
X31:41
X31:51
X31:54
X30:2
X30:4
X30:6
Sign.
Sign.
AGND
AGND
AGND
GND
GND
GND
Signal
AGND
AGND
AGND
AGND
AGND
Signal
Signal
Signal
Signal Druck
Signal Druck
BOMAG
Signal Temperatur
X57:34
X57:35
X57:39
X57:36
X57:40
X57:42
X57:37
X57:41
X57:14
X57:13
X57:9
X57:21
X57:15
X57:1
X57:19
X57:20
X57:28
X57:23
X57:22
X57:29
X57:32
X57:25
X57:31
X57:30
X57:24
X57:27
X57:26
X57:33
X57:28
X57:23
X57:29
X1:180
X1:181
X1:182
X1:186
X66:3
X66:2
1 1 1
Y147 Y148 Y149
Y15.1 Y15.5 Y15.3 86
2 2 2 K14.2
1 2 3 2 1 3 1 4 3 2 3 2 1 1 2 3 2 1 1 2 3 4
1 1 1 1 85
Y166 Y170 Y169 Y137
Y15.6 Y15.2 Y15.4 Y19
2
2 2 2 B114 B130 B133 B93 B113 B88 B145
B40.1 B40.2 B48 B49 B43 B6 B51
X1:90
X1:91
X1:92
3x2.5
3:5
31 31 EMR
3:20 31 5:1
4:3 2:2

08.03.2007
1 1
008 911 71
Wiring diagram

08.03.2007
4:20 30 30 6:1
F24:2 6:3 X1:2 4:20 CAN2+ CAN2+ 8:6
EMR Deutz Fahrhebel
4:20 CAN2− CAN2− 8:6
X1:145
CAN1+ 6:8
CAN1− 6:8
X1:119 X1:120
008 911 71
S01
2:15
120 OHM 120 OHM
X1:146 32 1 2 1 2
X52:1
X52:2
R22 R20
Wiring diagram
rt sw X1:17E X1:34E
F67 1 F84 1 X34:G X34:H X34:C X34:D X34:A X34:B diagnosis interface equipment
B112
15A 10A
2 2
X1:34A
X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
9:2
120 OHM 120 OHM
1 2 1 2
R23 R21
Drucksensor
Leistung
Elektronik
TxD
RxD
CAN2+
CAN2−
CAN1+
CAN1−
Pot. 15
A34
Fahr−Steuerung
X35:5
driving controller
X35:4
X35:31
X35:56
X35:57
X35:59
X35:60
X35:53
X35:33
X35:58
X35:27
X35:26
X35:28
X35:54
X35:38
X35:12
X35:37
X35:34
X35:30
X35:15
X35:24
X35:49
X35:64
X35:46
X35:47
X35:55
X35:65
X35:66
X35:67
X35:68
speed
speed
BOMAG
Neigung
Richtung
Richtung
Gehäuse
housing
Achsmotor
Sitzkontakt
X1:45 X1:44
Bandagenmotor
Fahrpumpe vorw.
Fahrpumpe rückw.
Rückfahrwarnsum.
FM3 7:5 +45_G=4,5V X1:158 X1:114 X1:121 X1:122 X1:143 X1:141
+ −45_G=0,5V
B57 1V
X1:171
X1:173
X1:175
X1:177
X1:176
bl
br
ws
br
ws
bl
+ +
dir. dir.
0,46A
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
B60 B59 2,5V X14:B X9:1
speed
9:2 speed
DIR MESX S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
Y17 Y16
13:6 4V H14 Y30 Y31
sw
sw
SPEED TAC − b a
− 2 2 2 2
X1:174 9:2 X1:178 − S X1:46 X14:A X9:2 X16:2 X15:2
SPEED MESX
X1:82
X1:124
X1:142
X1:142
X1:143
X1:143
X1:55 7:4 9:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:124

31 PITCH MESX
4:20 31 6:1

08.03.2007
1 1 582 702 32
17.2
08.03.2007
1021
30
1022
5:20 30 9:1
2:20 K11:87 K11:87 8:14
5:3 F24:2 F24:2 7:13
17.2
X1:29E 2:16 F05:2

5:17 CAN1+ CAN1+ 8:14
F24 1 ESX Fahrsteuerung DIOS Platten
5:17 CAN1− CAN1− 8:14
10A
2
X1:29A
X1:87 X1:88 X1:80 X1:86
X1:41
X1:39
X1:40
11:1
X34:R
VCC
CAN1 high
CAN1 low
CAN1 high
CAN1 low
Ub "30"
Ub "15"
not connected
not connected
Ub out
X27:8
A81
X28:6
X29:8
X28:1
X27:6
X27:7
X29:7
X28:3
X28:5
X28:4
X26:3
X26:5
X26:8
X26:10
X27:2
X27:4
X27:9
X26:9
X26:1
X26:2
X26:6
X26:4
X26:11
X27:10
X27:11
X27:12
X27:1
X27:3
X29:1
X29:2
X29:4
X29:3
X29:5
X29:6
X27:5
X26:12
X28:2
GND
GND
GND
UIN1
DIN1
DIN1
AIN1
UIN3
UIN2
DIN3
DIN5
DIN9
DIN6
DIN3
DIN5
DIN6
DIN8
DIN2
DIN2
AIN2
DIN4
DIN4
DIN11
DIN10
Sepa1
Sepa2
GND/UIN3
BOMAG
X1:106 X1:111 X1:112 X1:105 X1:107 X1:108
BL 12:17 ECO
Low High 13 23 down up
BR 12:17 13 23
S127
BEL S139
12:4
14 24 14 24
Hydraulikölfilter
Luftfilter
air cleaner
Kühlmittelvorrat
coolant stock level
Füllstand Diesel
fuel−level
Wasserabscheider
water−seperator
X21:1 X10:2 X8:1
B21 1 B03 1 B55 B124
D+ R03
2:8 P P Q
Schalter Motordrehzahl Schalter Frequenzverstellung
2 2 switch engine−rpm mode switch frequency−control
X21:2 X10:3 X8:2
0 .. 67 OHM
Nur bei EMRII
only EMRII
X1:117 X1:94 X1:94 X1:117 X1:164 X1:149 X1:82
31
5:20 31 7:1
08.03.2007
1 1
008 911 71
Wiring diagram

08.03.2007
4:20 S01:22 S01:22
6:20 F24:2
8:1
X1:41
X1:201
008 911 71
S 5:4 FM3 X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC B X39:2 X22:2 bl
S1 −
−
X1:160 X41:3 X40:1 X40:2 bei BW177 u. 213 m. Sauer Motor sw / bei BW213−226 m. Rexroth Motor bl
VCC B B16
Wiring diagram
bei BW177 u. 213 m. Sauer Motor bl / bei BW213−226 m. Rexroth Motor sw

X1:159 X41:4 X40:4 S2 X40:3
X1:203
B132 2 2 2 2 0V A ws X22:3
VIB
X1:162 X41:2 X39:4 0V A X39:3 X22:4 13:6
S1 gg sw
X1:55 X1:202
Lenkwink.
1 1 1 1
−
BTS BREMSE 8:2
X41:5
X41:7
X41:8
X41:6
Sig.
AGND
X34:J
X1:60 FM5 X1:61
X1:56 FM1 X1:57
X1:62 FM3 X1:63

X1:58 FM2 X1:59
X1:189
armrest−switch
X1:55
Schalter Armlehne
Vib.− Richtung
Vib.− Frequenz
BTS Bremse
5:6
X1:205
X1:207
X1:206
X1:208
8,5V
X1:42 X1:188
nur BVC
A34
only BVC
Fahr−Steuerung
X35:1
driving controller
X35:19
X35:17
X35:18
X35:41
X35:35
X35:29
X35:23
X35:40
X43:2 X43:1
X35:16
X35:20
X35:21
X35:43
X35:22
X35:2
X35:48
X35:3
X35:61
30
Bremse
Armlehne
Prop. out
30 K48 8:2
Warnsummer
BOMAG
X51:3
X51:2
X1:89 87 87a
Umsch. Amplitude
K43 7:12
X1:154 X1:196 X1:195 87 87a
KA MESX
9:2 X1:147
X1:38
X35:22 GA MESX 11
8:13 9:2
X1:37 S01
X35:43
8:13 X1:116 X1:115 2:15
12
X1:150
400 ... 1.200mA

400 ... 1.200mA
150mA
X6:1 X7:1 9:2

X1:113
400 ... 1.200mA
1 1 K43 86 Y08 1 Y07 1 H07 BRAKE MESX

+ Y04 1
Y93 Y92
b d
2 2 85 2 2 − a1 2
X6:2 X7:2
max.1.8A
X1:149 X1:197 X1:197 X1:82 X1:117 X1:190

X1:118
6:20 8:1
31



08.03.2007
1 1 582 702 32
17.2
08.03.2007
1023
1024
7:2 X23:1 5:17 CAN2+ 6:14 CAN1+ CAN1+ 9:16
5:17 CAN2− 6:14 CAN1− CAN1− 9:16
K11:87
17.2
6:20 K11:87 9:1

sensor plates up 2
X1:213
X1:214
X1:156
X1:157
BTS BREMSE
7:18
br
br
3 2 + +
X63:1
X63:1
7
B135 B134
4 − −
bl bl
S S
X63:2
X63:2
sw
ws
S42
+ −

S
X35:43 X1:215
Ub in CAN− 7:11
X25:2
X25:4
X25:3
Bremse zu = 0V 1 7
3 S55 6 X35:22
7:11
X1:153 4 5
travel lever
2 8 A54
X62:1
X62:3
X62:9
X62:2
9 11
X62:4
X62:10
Add2 AK Ext2
plate−controller
10 12
Stecker X23
BOMAG
Stecker X24
1 2 3 4 5 6 7 8
X62:5
X62:6
X62:7
X62:8
X62:11
X62:13
X62:15
X62:14
Ub out
OV out
DK Ext1
DK Ext3
DK Ext5
DK Ext6
DK Ext2
DK Ext4
X50:2
X50:3
X50:1
S − + Y123 1 Y143 1 Y144.2 1

X1:210
S35 K0G S09 13 S64 13 S36 13 S139
13 23 2 2 2
400 .. 1.200 mA
86 86 1 Y122 1 Y142 1 Y144.1 1 Y145 1

K48 K05 Y98
14 14 14 14
24
2 2 2 2 2
85 85
X1:149 X1:211 X1:212

7:20 31
9:1
7:17 2:12 31
08.03.2007
1 1
008 911 71
Wiring diagram

08.03.2007
X1:34A
5:9
6:20 30 30 12:1
Pot 30
8:20 K11:87 K11:87 12:1

Pot 15
008 911 71
X2:47 X2:48 X2:49
F146:1 10:2 + −
X2:66
X2:70 X42:1 X42:2 X42:3
X46:B X46:A X46:E

Wiring diagram
X1:32E X1:35E
X2:77 P16 F1 F2
1 1 1
F148 F146
nur bei BEM
only at BEM
10A 15A
X2:56 X2:53 X2:60 X2:57 FM4 X2:71
2 2 2
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33
CAN+
CAN−
F148:2 B62 B62 X2:67 X2:68

10:2
X4:C
X4:E
X4:D
+/sw
+/sw
−/gg −/gg X47:A X47:B
X46:D X46:F
X42:4 X42:5
15g/bl 15g/bl
−/sw
X74:3
X74:5
X74:4
8:20
X2:57 B61 P11 CAN1−
20g/br
20g/br
+/rt 8:20
DIOS Platten
X48:3 X48:4 X49:3 X49:4 S/ws

CAN1+
nur bei BTM prof

X74:1 X74:2
only at BTM prof

X2:54 X2:55 X2:58 X2:59 X47:C
X4:A X4:B
X2:50 X2:51
R24
X2:69 X2:64 X2:65 1 2
Pot. 15
Leistung
Elektronik
8.5V
AGND MESX
Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
Erregerpos.
BOMAG
X44:1
X44:7
X44:9
X44:5
X44:27
X44:26
X44:4
X44:31
X44:56
X44:57
X44:59
X44:60
X44:30
X44:58
X44:29
X44:23
X44:28
X44:54
A83
X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:25
X44:53
X44:33
X44:3
X44:55
X44:65
X44:66
X44:67
X44:68
CAN3+ CAN3−
7:15 KA MESX
EVIB
GPS
GA MESX
Prop.
Prop.
GND
0..6VDC
7:15
5:3 CAN3−
400 .. 1.200mA
400 .. 1.200mA
DIR MESX X2:75 X2:73 X2:52 +

5:3
PITCH MESX Y140 1 Y141 1 P07 E X2:79 10:2
5:8 VIB CAN3+
BRAKE MESX
v.l.
v.r.
7:17 − X44:25 10:2

2:8 12:4 X2:49 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 10:1
8:20

08.03.2007
1 1 582 702 32
17.2
08.03.2007
1025
1026
9:18 CAN3−
9:18 CAN3+
17.2
9:4 F148:2
9:17 X44:25
9:5 F146:1
X2 80E
1 CAN3+ R25 CAN3−
F150 1 2
5A
2 60 OHM
X2 80A
X2 X2 X2 X2 X2
43 44 70 61 62
X4 X4 X4 X4 X4
H J G N M
X75:7 X75:2
X78:1
X78:2
X78:3
X78:4
X71:12 X72:A X73:A
A93 30 A87
X71:6 X72:B X73:B USB−CAN Schnittst.
15 USB−CAN Interface BCM
X71:5
BOMAG
TxD2 X76:1
X71:8
RxD2
X71:10 X72:E X70:3
TxD1
X71:3 X72:D X70:2
RxD1
X71:7 X72:C X70:5
GND
GPS Empfänger StarFire P15
X73:C X76:2
GPS Receiver StarFire
BCM 05
nur bei BCM
only at BCM
X4:F
nur bei StarFire GPS X2:63

only at StarFire GPS
9:20 31 31 11:1
08.03.2007
1 1
008 911 71
Wiring diagram
Vogt Bomag Compaction Management BCM, GPS 582 702 32

08.03.2007
Seis Bomag Compaction Management BCM, GPS 010
A67 1 2 3
Keyboard
008 911 71
keyboard
4 5 6
7 8 9
Wiring diagram
ANN 0 VAL
A66
Steuereinheit
control unit
X68:1 X68:2
BOMAG
+
H80
−
ZA
option
08.03.2007
1 1 582 702 32
Vogt Diebstahlschutz System DH−4
17.2
08.03.2007
1027
Seis anti − theft system 011
K11:87 K11:87
1028
9:3
9:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
17.2
F11 F18 F07 F08

15A 10A 15A 15A
30
X1:18A K06 X1:19A X1:25A
X1:26A
12:4 X1:305
X1:83
X1:301
switch, StvZO
13 23
S37
S15 F22 F19
32 12 24 15A 15A
X1:306
X1:307

STV1
X1:302
13:17 A02
STV2
13:17
X1:23E X1:24E
K16 30 31 82 L R
12:9 F09 F10
10A 10A
87 87a X1:23A X1:24A
BEL 6:9 BL
6:9
13 BR
6:9
S16 14
BOMAG
X1:304
13 23
01
X1:311
X1:310
X1:319
X1:313
X1:312
X1:321
X1:314
X1:309
X1:303
X1:320
X1:322
S14
werfer ohne StvZO
X1:84
BEL MESX
X61:1
X61:3
X60:1
X59:5
X60:3
X59:3
X58:5
X58:3
X59:2
X58:2

9:7
X1:43
0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 E08 1 E09 1 E10 1 E11 1
0,125A
2 2 86 2 2 2 2 86 2 2 2 2 + 2 2 2 2
K06 K16
4,6A
4,6A
4,6A
4,6A
H06
85 85 −
4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
X3:1
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
X1:323 X60:4
X1:323 X60:2
X1:324 X61:2
X1:324 X61:4
11:12 13:1
Scheinwerfer rechts
acc.to ROPS/SD
08.03.2007
1 1
008 911 71
Wiring diagram
Vogt Beleuchtung und StvZO 582 702 32

08.03.2007
F42:H 14:14 F41:5 14:14
K30 X3:6
2:14 K32:87 14:2
X3:7
K32 30 STV2
X3:8 12:13
13:1 STV1
008 911 71
12:13
87 87a
G H A B C E F
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3 6
5
Wiring diagram
F42 14:8
F130 13:9 F130 F130 14:7
13:14
A12
15
1,75A
0,83A
K141 30 1 B51 + 30 01W 7 2 01W 7 2 1 S163 5 1 S38 5
+ + + B51
01 01 E72
K32:86 13:16 E29 E70
− − − − 1
87 87a 2 2 2 1
2:19 31 S21 5 4 S20 5 4
Radio
radio
1 Tachographenmodul
R80 A2+A3
X3:17
4,6A
4,6A
4,6A
4,6A
2 4 6 A1
Nachtleuchte
5:3 P09 +
indicator
X55:1
X56:1
X55:3
X56:3
2 1 XS
X55:4
X56:4
SPEED TAC A16 night illumination E27 1 E28 1 E23 1 E25
1 B3 12V
Kontrolleuchte
Innenleuchte
inside light, cabin
−
socket
Steckdose
+ 7,8,9 2 B4 2 2 2 2
max. 13A
A01 VIB X3:18 5 3 C3
7:18
A5+A6
S45 TK −
Heizung Heckscheibe
heating rear screen
BOMAG
3,8A
3,8A
3
5A
86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 − M06 4 −
85
2,9A
3 min
ZA
4,7A
X55:2 X56:2 option

Abfallverzögert
14:11
KABINE 31
X3:1
X3:2
Schalterbel.
switch illum.
12:20 31 31 14:1


08.03.2007
1 1 582 702 32
Vogt Kabinenausrüstung, Beleuchtung, Radio, Tachograph
17.2
08.03.2007
1029
1030
13:19 K32:87
13:19 F41:5
13:17 F130 F42:H
13:4
13:9
17.2
D Potential 30 aus Kabine A B

F31 F40 BOX2 F15 BOX2
20A 20A 5A
4 1 2
2.5qmm
1 2 3 12 11 13 14 16
0123 4 3 2 5 7 11 3 10 1
S44 A72
Steuergerät
control unit
6 11 12 1 Regel aus = 0,4A
S28
E30 Kleine Stufe = 0,67A
heater timer

Schaltuhr Heizung

30 2 6 8 9 4 12
K09
X3:14
X53:L
X53:H
X53:M
2:10
87 87a X1:167 5 9 10 6 8 7 4 15
2.5qmm
X1:169 X18:1
X3:9
X3:11
X3:10
X3:12
X19:1
B131
B103 1 1 F97 1
_t 3A
BOMAG
_t 2 2
2 inline fuse
X19:2 Inline Sicherung
X20:1 X18:2
X17:1 X1:163
X17:3 X1:166
X17:2 X1:165
B104 4
P
HP X69:1 X77:1
1A
LP 3
ge rt or ge rt or +
Y138 1 1
X1:170 M17
X20:4
X20:3
V06 Y14

M09 M M09 M M
2 2 2
Stromaufnahme Lüfter / current blower br br −
X20:2 V04
X69:2 X77:2
Option
option

Y15 1
X17:4 X1:168
2 13:19
3,5A
X1:164 KABINE 31
X1:190
13:20 31 31

Kabinenlüfter
Frischluft Lüfter
cab ventilator blower fresch air
08.03.2007
1 1
008 911 71
Wiring diagram
Vogt Kabinenheizung, Klimaanlage, Zusatzheizung 582 702 32

08.03.2007
A02
Wiring diagram
A12
A16
012
013
013
17
5
6
Blinkgeber
Radio
Elektronik Tachograph
flasher
Radio
Electronic system, tachograph
17.2
Seis
08.03.2007
Vogt
08.03.2007

A93 010 7 GPS Antenne GPS antenna

component listing

Bauteilliste

B133 004 12 Sensor Ladeluftdruck / −temperatur sesnor charging air prssure / temperature

1

11
F15 014 19 Sicherung Heizgeraet Fuse, heating unit BOX2
582 702 32
101

F40 014 15 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
008 911
F41 71 013 19 Sicherung Rundumkennleuchte BOMAG
Fuse, rotary beacon 10A 1031
17.2 F42
F43
F44
013
013
013
3
10
13
Sicherung Kabineninnenleuchte
Sicherung Wischermotor hinten
Sicherung Wischermotor vorn
Fuse, inside light cab
Fuse, wipermotor rear
Fuse, wipermotor front
10A
Wiring diagram
15A
15A
F97 014 13 Sicherung Frischluftluefter fuse, blower fresh air 3A
Seis
08.03.2007
Vogt
08.03.2007

F124 002 17 Sicherung Kraftstoffvorwärmung Fuse, fuel pre−heating 25A
F150 010 14 Sicherung GPS Receiver Fuse, GPS receiver 5A

H80 011 15 Meldeleuchte Wegfahrsperre Indicator light, anti−theft device LED

K43 007 12 D*Relais Vibration E*relay, vibration BOSCHW
component listing

K14.2 004 20 TYCOX
Bauteilliste

M17 014 13 Zusatzluefter Additional blower

P33 009 18 Opus 21 Opus 21

R79 002 15 Kraftstoffvorwärmung fuel pre−heater 250W

2

11

582 702 32

102

S42 008 11 Stufenumschalter schnell−langsam Speed range selector, fast−slow
1032 S44 014 3 Schalter Kabinenluefter BOMAG
Switch, cabin ventilator 008 911 71
S45
Wiring diagram
S55
S64
013
008
008
3
6
10
Schalter Kabineninnenleuchte
Schalter Fahrhebel
Schalter Schwimmstellung
Switch, cabin inside light
Switch, travel control lever
Switch, float position
17.2

Seis
08.03.2007
Vogt
08.03.2007

component listing

Bauteilliste

3

11

582 702 32

103

008 911
X1:11971 005 2 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 1033
17.2 X1:120
X1:121
X1:122
005
005
005
4
12
13
WAGO ZENTRALELEKTRIK
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
Wiring diagram
Seis
08.03.2007
Vogt
08.03.2007

component listing

Bauteilliste

4

X1:190 011 12 WAGO,E−Kasten WAGO,E−BOX
11

582 702 32

104

1034 X1:201 007 4 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 008 911 71
X1:202
Wiring diagram
X1:203
X1:205
007
007
007
4
4
11
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
17.2
Seis
08.03.2007
Vogt
08.03.2007

component listing

Bauteilliste

5

11

582 702 32

105

008 911
X2:66 71 009 14 WAGO−MESSTECHNIK BOMAG
Wago−measurement equip. 1035
17.2 X2:66
X2:67
X2:68
009
009
009
14
11
12
WAGO−MESSTECHNIK
WAGO−MESSTECHNIK
WAGO−MESSTECHNIK
Wago−measurement equip.
Wiring diagram
Seis
08.03.2007
Vogt
08.03.2007
X2:80A 010 14 WAGO−MESSTECHNIK Wago−measurement equip.

X2:80E 010 14 WAGO−MESSTECHNIK Wago−measurement equip.
X4:H 010 14 KABINENST. MESST. con. measurem.equipm.
X4:J 010 15 KABINENST. MESST. con. measurem.equipm.
component listing

Bauteilliste

6

11

582 702 32

106

1036 X27:5 006 11 STECKER DATENSAMMLER BOMAG
connector data collector 008 911 71
X27:6
Wiring diagram
X27:7
X27:8
006
006
006
9
10
2
STECKER DATENSAMMLER
connector data collector
17.2
Seis
08.03.2007
Vogt
08.03.2007

component listing

Bauteilliste

7

11

582 702 32

107

008 911
X31:4371 004 13 EMR−Stecker Motor BOMAG
EMR−connector engine 1037
17.2 X31:46
X31:47
X31:48
004
004
004
2
1
5
EMR−Stecker Motor
EMR−Stecker Motor
EMR−Stecker Motor
EMR−connector engine
Wiring diagram
Seis
08.03.2007
Vogt
08.03.2007

component listing

Bauteilliste

8

11

582 702 32

108

1038 X39:4 007 9 STECKER 1 LENKRAD BOMAG
connector 1 steering unit 008 911 71
X40:1
Wiring diagram
X40:2
X40:3
007
007
007
9
10
10
STECKER 2 LENKRAD
STECKER 2 LENKRAD
STECKER 2 LENKRAD
connector 2 steering unit
17.2
Seis
08.03.2007
Vogt
08.03.2007

component listing

Bauteilliste

9

11

582 702 32

109

008 911
X56:3 71 013 13 STECKER WISCHER VORNE BOMAG
conn. wiper front 1039
17.2 X56:4
X57:1
X57:1
013
003
004
12
15
9
STECKER WISCHER VORNE
Stecker Motor
Stecker Motor
conn. wiper front
connector engine
connector engine
Wiring diagram
Seis
08.03.2007
Vogt
08.03.2007

component listing

Bauteilliste

10

11

582 702 32

110

1040 X65:4 011 5 KEYBOARD BOMAG
Keyboard 008 911 71
X65:5
Wiring diagram
X65:7
X65:8
011
011
011
5
5
12
KEYBOARD
KEYBOARD
KEYBOARD
Keyboard
Keyboard
Keyboard
17.2
X67:1 002 15 STECKER KRAFTSTOFFHEI connector fuel pre−heater
X68:1 011 15 STECKER LED connector led
X69:1 014 13 STECKER FRISCHLUFT LÜ connector fresh air blower
Seis
08.03.2007
Vogt
08.03.2007

X70:2 010 16 SUB−D STECKER SUB−D Connector
X71:3 010 9 STECKER GPS ANTENNE connector GPS Receiver
X72:A 010 12 STECKER ANSCHL. GPS Connector GPS
X72:B 010 12 STECKER ANSCHL. GPS Connector GPS
X72:C 010 12 STECKER ANSCHL. GPS Connector GPS
X72:D 010 12 STECKER ANSCHL. GPS Connector GPS
X72:E 010 12 STECKER ANSCHL. GPS Connector GPS
X73:A 010 13 STECKER VERS. GPS Connector Supply GPS
X73:B 010 13 STECKER VERS. GPS Connector Supply GPS
X73:C 010 13 STECKER VERS. GPS Connector Supply GPS
X75:2 010 18 SUB D STECKER BCM INT SUB D Connector BCM
X77:1 014 15 STECKER PUMPE STANDHE Conn. pump add. heater
component listing

X78:1 010 10 STECKER RTK−MODUL GPS Connector RTK−module GPS
Bauteilliste


Y07 007 15 D*Prop. Ventil Vibration groß E*prop. Valve vibration high 0.4 .. 1.2A
Y144.1 008 19 MAX. 1.8A
Y144.2 008 19 MAX. 1.8A
11
11
582 702 32
111
008 911 71 BOMAG 1041

1042
17.2
X38
X37
X36
A80
BOMAG
Nur bei StvzO
A02 R10 K05
K11 K16 K06
Nur bei Klimaanlage

K09 K43
K48
K61
B57
K41
X32:1-12 X34:1-19
008 911 71
Wiring diagram
Gez.: 08.03.2007 Seite: 1 von: 2

Name: Vogt
Übersicht Schaltkasten BW 177...226 DH/BVC-4 page: 1 from: 2
582 702 32
Name: Seis overview e-box BW 177...226 DH/BVC-4 Replaces: Sheet No.: 201
Nur bei VM8
only acc. To VM8
F1 F2 CAN 1
008 911 71
Wiring diagram
LCD+
CAN 1
Datensammler
A34
Fahrsteuerung
BOMAG
CAN 1 OPUS 21
A83
CAN 3 BCM
Gez.: 08.03.2007 Seite: 2 von: 2

Name: Vogt Übersicht Schaltkasten-Tür BW 177...226 DH-4 page: 2 from: 2
582 702 32
17.2
1043
Name: Seis
17.2 Wiring diagram
1 057 564 17
2 280-315
3 2 x 057 564 25 "L" + 793-501
5 2 x 057 564 25 "L" + 057 564 20 + 793-501
7 057 564 22
8 4 x 057 564 23 "L" + 057 564 19 + 793-501
12 18 x 057 564 36 "R" + 057 564 19

+ 793-501

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:11:33 Seite 1
1044 BOMAG 008 911 71

Wiring diagram 17.2
30 4 x 057 564 36 "R" + 793-501
34 057 564 35
35 057 564 17
36 057 564 21
37 2 x 057 564 25 "L" + 793-501
39 3 x 057 564 25 "L" + 057 564 20 + 793-501
42 5 x 057 564 25 "L" + 793-501
47 8 x 057 564 25 "L" + 057 564 20 + 793-501
55 057 564 25 "L" + 793-501
56 4 x 057 564 38 "L" + 793-501
60 057 564 17

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:11:33 Seite 2
008 911 71 BOMAG 1045

17.2 Wiring diagram

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:11:46 Seite 3
1046 BOMAG 008 911 71

Wiring diagram 17.2

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:11:46 Seite 4
008 911 71 BOMAG 1047

17.2 Wiring diagram
1 057 564 17
2 3 x 057 565 40 "R" + 793-501
5 057 565 35 "R" + 793-501
6 057 565 37
7 3 x 057 565 40 "R" + 793-501
10 057 565 37
11 057 565 40 "R" + 793-501
12 057 565 35 "R" + 793-501
13 057 565 37
14 2 x 057 565 38 "R" + 793-501
16 2 x 057 565 39 "R" + 793-501
18 057 565 37
19 4 x 057 565 40 "R" + 793-501
23 057 565 37
24 4 x 057 565 40 "R" + 793-501
28 2 x 057 565 39 "R" + 793-501
30 057 565 37
31 057 565 40 "R" + 793-501
32 057 565 39 "R" + 793-501
33 057 565 37
34 4 x 057 565 40 "R" + 793-501
38 057 565 35 "R" + 793-501
39 057 565 37
40 4 x 057 565 40 "R" + 793-501
44 057 565 37
45 057 565 40 "R" + 793-501
46 057 565 35 "R" + 793-501
47 057 565 37
48 057 565 40 "R" + 793-501
49 057 565 35 "R" + 793-501
50 057 565 37

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:15:44 Seite 1
1048 BOMAG 008 911 71

Wiring diagram 17.2
51 057 565 38 "R" + 793-501
52 2 x 057 565 40 "R" + 793-501
54 057 565 38 "R" + 793-501
55 057 565 37
56 3 x 057 565 40 "R" + 793-501
59 057 565 38 "R" + 793-501
60 057 565 37
61 3 x 057 565 40 "R" + 793-501
64 057 565 35 "R" + 793-501
65 057 565 37
66 2 x 057 565 40 "R" + 793-501
68 057 565 35 "R" + 793-501
69 057 565 37
70 3 x 057 565 40 "R" + 793-501
73 057 565 35 "R" + 793-501
74 057 565 37
75 2 x 057 565 40 "R" + 793-501
77 2 x 057 565 35 "R" + 793-501
79 057 565 37
80 057 565 40 "R" + 793-501
81 057 565 39 "R" + 793-501
82 057 565 37
83 057 564 17

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:15:44 Seite 2
008 911 71 BOMAG 1049

17.2 Wiring diagram

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:15:57 Seite 3
1050 BOMAG 008 911 71

Wiring diagram 17.2

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:15:57 Seite 4
008 911 71 BOMAG 1051

17.2 Wiring diagram
1 057 564 17
2 2 x 057 565 40 "R" + 793-501
4 057 565 37
5 2 x 057 565 40 "R" + 793-501 + 057 565 36
7 057 565 39 "R" + 793-501
8 057 565 37
9 057 565 38 "R" + 793-501
10 2 x 057 565 40 "R" + 793-501
12 057 565 38 "R" + 793-501
13 057 565 37
14 2 x 057 565 40 "R" + 793-501
16 057 565 39 "R" + 793-501
17 057 565 37
18 057 565 40 "R" + 793-501
19 057 565 38 "R" + 793-501
20 057 565 40 "R" + 793-501
21 057 565 37
22 057 565 40 "R" + 793-501
23 057 565 39 "R" + 793-501
24 057 565 37
25 057 564 21
26 2 x 057 564 38 "L" + 793-501
28 057 564 25 "L" + 793-501
29 057 564 36 "R" + 793-501
30 057 564 35
31 057 564 17

Artikelnummer :
Optional2 : Projekt : Messtechnik DH / BVC* Artikelnummer lang :
Ort :
Optional4 :

12.03.2007 12:49:55 Seite 1
1052 BOMAG 008 911 71

Wiring diagram 17.2

Artikelnummer :
Ort :
Optional4 :

12.03.2007 12:50:02 Seite 2
008 911 71 BOMAG 1053

17.2 Wiring diagram
1 057 564 17
2 4 x 057 565 40 "R" + 793-501
6 057 565 37
7 2 x 057 565 40 "R" + 793-501
9 4 x 057 565 38 "R" + 793-501
13 2 x 057 565 39 "R" + 793-501
15 057 565 37
16 057 564 17

Artikelnummer :
Zeichnung : gezeichnet: : M. Vogt TEE
Ort :
Optional4 :

03.01.2007 10:28:28 Seite 1
1054 BOMAG 008 911 71

Wiring diagram 17.2

Artikelnummer :
Ort :
Optional4 :

03.01.2007 10:28:30 Seite 2
008 911 71 BOMAG 1055

X71 X72
X70 X73
1056
X74 X75 X77
X55
X56 X76 X53 X54
17.2
X29
X28 X21
X39 X23
X11 X24
X12 X50
X59 X40 X25 X41
X13
X58 X42 X51 X43 X57
X20
X69 X46 X14
X18 X30 X77

X33 X6 X7
X17 X52
X47 X19 X31 X4 X3
X67 X8 X15 X16
X48 X49 X10
(BVC) (BVC)
X36 X26 X60
X37 X1 X27 X61 X62
X38 X2
X9
X44
X35
X32 X34
BOMAG
X71
X61
X72
X77 X9
X21
X73 X74 X70
X59 X62
X75 X76
X67 X8
X42 X23
X11 X24
X12 X50 X57
X10
X46 X25 X41
X13 X51
X56
X53
X20
X29 X18
X17 X14
X28 X19 X55 X6 X7
X54 X15 X16
X69 X39
X43
X40
X77 X30
X58 X52 X33
X31 X4 X3
X36 X35 X1 X26
X37 X44 X2 X27
X38 X32 X60
X47
X48 X49
(BVC) (BVC)
008 911 71
Wiring diagram
Gez.: 08.03.2007 Seite: 1 von: 1

582 702 32
17.3 Wiring diagram
008 911 71 BOMAG 1057

17.3 Wiring diagram
Serial number for wiring diagram 582 702 39 not yet available at the printing deadline.
1058 BOMAG 008 911 71

008 911 71
table of contents: BW 177..226 DH−4
Wiring diagram

002 582 702 39 Versorgung, Starten, Kraftstoffvorwärmung, Hupe supply, starting unit, fuel pre−heater, signal horn
010 582 702 39 Bomag Compaction Management BCM, GPS Bomag Compaction Management BCM, GPS
011 582 702 39 Diebstahlschutz System DH−4 anti − theft system
BOMAG
23.07.2007
001 001
Vogt Stromlaufplan 582 702 39
23.07.2007
17.3
1059
circuit diagram 001
Seis
1060
30
17.3
K11
2:11
87
K30 13:1
30 4:1 K11:87 6:1
X1:15E X1:16E X1:27E X1:33E X1:28E X1:30E
X1:9
F13 1 F05 1 F95 1 F124 1 F23 1 F39 1
X1:10
30A 10A 10A 25A 15A 15A
2 2 2 2 2 2
X1:15A X1:16A X1:27A X1:33A X1:28A
X1:30A
X37:A X1:151
7:17
5:9
X36:B
30 21 11 31 41 51 61
X36:A
only EMR III
22 12 32 42 52 62
K32:86
15
starting swwitch 54 58 19 17 50a Emerg.−Stop 13:1
2 x 10qmm
X1:152 X1:155
X1:79
S01:22 3:1
X37:B
F05:2
V01 X1:3 X1:4 6:8
K05 30
2 1 8:3 3
5 S03
125mA
5 87 87a
X34:P
K14 86 1 30

K14.2 K61 K61
Hauptsicherung
main fuse
4:20 3:19 3 R10 2:7 Taster Hupe
3 2 2 82 OHM push button, horn 4
F48 F00
125A 125A 85 2 87 87a X1:7 X1:8
30
BOMAG
1 1 D+ X1:217 K13
6:2
2:18
B+ 2:12 2:8 B+ 87 87a
D+ MESX 9:2
G03 G01 X38:A X1:98
+ +
X67:1
− −
X1:1 X1:101 X1:102
1
1 1 1 R79
X1:109
nur bei Klimaanlage

30 50
R81
R83
R85
167A
2 2 2 B+ D+ 2
1 86 86 B11 B11 86
1 1 1 1 K09 K11 X67:2 1 2 1 K13
G02 M01 XS +
R19 S30 M
12V
R86
R82
R84
2 2 2 2 2 V03 1 2 −
Option
option
85 85 − 85
2
31 EMR 3:3 B− W
Option Winterpaket
option winter package
X1 X1 X1 X1
X1:110 X1:168 X1:123 X1:218 103 100 104 104
31 31 3:1
Glühstiftkerzen Trennschalter Batter 2:10 14:7 2:15 Starter Signalhörer 2:16 Steckdose
Batterie Batterie Generator Kraftstoffvorwärmung Nur bei Geländer/ROPS/SD

battery battery generator fuel pre−heater only at hand−rail/ROPS/sun−roof
Heizflansch
heating−flange
23.07.2007
1 1
008 911 71
Wiring diagram
Vogt Versorgung, Starten, Kraftstoffvorwärmung, Hupe 582 702 39

23.07.2007
Seis supply, starting unit, fuel pre−heater, signal horn 002
2:16 S01:22 S01:22 4:1
008 911 71
X1:95
1
Relais Heizflansch K14
relay heating−flange
X1:96 2
Wiring diagram
X1:185
X1:179 connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8
EPC−Stecker
max 7A
A48
Motorsteuerung EMR2
X30:14
X31:21
X31:22
X31:13
X31:11
X31:14
X31:15
X31:24
X31:25
X31:4
X31:9
X31:5
X31:6
X31:3
X31:2
X31:7
X30:10
X30:11
X30:12
X30:13
X30:1
X30:2
X31:20
X31:12
X31:10
X31:17
X31:18
X31:19
X31:16
X31:23
X31:8
X31:1
L
K
+5V
+5V
STG−
STG+
AGND
AGND
AGND
AGND
AGND
Signal
Signal
Signal
Signal
Ubat −
CAN low
CAN high
Signal Druck
Signal Temperatur
BOMAG
X1:180
X1:181
CAN2− 4:15
CAN2+ 4:15
X57:20
X57:21
X57:22
X57:12
X57:13
X57:10
X57:11
X57:14
X57:15
X57:17
X57:18
X57:19
X57:16
X57:23
X57:24
X57:25
X57:4
X57:9
X57:8
X57:1
X57:6
X1:183
X1:184
ESX Fahrst.
RF−
RF REF
3 2 1 1 2 1 2 7 2 6 1 1 4 3 2 1 2
RF MESS
EMR Stellglied
EMR commander
B88 B114 B130 Y137 5 B115 B113
X32:L
X32:K
X32:B
X32:H
X32:G
X32:A
X1:186
X34:N
X1:182
Diagnosestecker EMR
2:6 4:18
31 31 EMR 31 EMR
2:20 31 4:1
2:4
Motordrehzahlsensor
sender engine rpm 2

23.07.2007
1 1 582 702 39
17.3
23.07.2007
1061
30
1062
2:14 30 5:1
3:20 S01:22 S01:22 7:1
17.3

1
F93
25A
2
X32:A
X32:K
X32:H
X32:G
X32:M
X32:F
X32:B
X1:14A
B124
86
K41 K41 30
4:2
Nur bei EMRIII

only EMRIII
X1:107 X1:108
87 87a
85
X1:179
X1:191
X1:193
X1:192
X1:194
X1:184
max 7A
K−Line
CAN 1 High
CAN 1 Low
CAN 2 High
CAN 2 Low
A48
X30:1
X30:5
X30:3
X30:61
X30:63
X30:60
X30:72
X30:25
X30:62
X30:28
X30:82
X30:64
X31:47
X31:46
X31:33
X31:31
X31:48
X31:32
X31:50
X31:12
X31:19
X31:40
X31:14
X31:53
X31:43
X31:8
X31:58
X31:56
X31:13
X31:11
X31:57
X31:24
X31:34
X31:16
X31:1
X31:10
X31:20
X31:27
X31:7
X31:49
X31:23
X31:26
X31:41
X31:51
X31:54
X30:2
X30:4
X30:6
Sign.
Sign.
AGND
AGND
AGND
GND
GND
GND
Signal
AGND
AGND
AGND
AGND
AGND
Signal
Signal
Signal
Signal Druck
Signal Druck
BOMAG
Signal Temperatur
X57:34
X57:35
X57:39
X57:36
X57:40
X57:42
X57:37
X57:41
X57:14
X57:13
X57:9
X57:21
X57:15
X57:1
X57:19
X57:20
X57:28
X57:23
X57:22
X57:29
X57:32
X57:25
X57:31
X57:30
X57:24
X57:27
X57:26
X57:33
X57:28
X57:23
X57:29
X1:180
X1:181
X1:182
X1:186
X66:3
X66:2
1 1 1
Y147 Y148 Y149
Y15.1 Y15.5 Y15.3 86
2 2 2 K14.2
1 2 3 2 1 3 1 4 3 2 3 2 1 1 2 3 2 1 1 2 3 4
1 1 1 1 85
Y166 Y170 Y169 Y137
Y15.6 Y15.2 Y15.4 Y19
2
2 2 2 B114 B130 B133 B93 B113 B88 B145
B40.1 B40.2 B48 B49 B43 B6 B51
X1:90
X1:91
X1:92
3x2.5
3:5
31 31 EMR
3:20 31 5:1
4:3 2:2

23.07.2007
1 1
008 911 71
Wiring diagram

23.07.2007
4:20 30 30 6:1
X1:2 4:20 CAN2+ CAN2+ 8:6
EMR Deutz Fahrhebel
FM3 7:5
4:20 CAN2− CAN2− 8:6
X1:145
F24:2 6:3 CAN1+ 6:8
CAN1− 6:8
X1:119 X1:120
008 911 71
S01
2:15
120 OHM 120 OHM
X1:146 32 1 2 1 2
X52:1
X52:2
R22 R20
Wiring diagram
rt sw X1:17E X1:34E
1 1 1 diagnosis interface equipment
F67 F84 X34:G X34:H X34:C X34:D X34:A X34:B
B112
15A 10A
2 2 2
X1:34A
X1:63 FM3 X1:62

X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
9:2
120 OHM 120 OHM
1 2 1 2
R23 R21
Drucksensor
Leistung
Elektronik
TxD
RxD
CAN2+
CAN2−
CAN1+
CAN1−
Pot. 15
A34
Fahr−Steuerung
X35:5
driving controller
X35:4
X35:31
X35:56
X35:57
X35:59
X35:60
X35:53
X35:33
X35:58
X35:27
X35:26
X35:28
X35:54
X35:38
X35:12
X35:37
X35:34
X35:30
X35:15
X35:24
X35:49
X35:64
X35:46
X35:47
X35:55
X35:65
X35:66
X35:67
X35:68
speed
speed
BOMAG
Neigung
Richtung
Richtung
Gehäuse
housing
Achsmotor
Sitzkontakt
X1:45 X1:44
Bandagenmotor
Fahrpumpe vorw.
Fahrpumpe rückw.
Rückfahrwarnsum.
+45_G=4,5V X1:158 X1:114 X1:121 X1:122 X1:143 X1:141
+ −45_G=0,5V
B57 1V
X1:171
X1:173
X1:175
X1:177
X1:176
bl
br
ws
br
ws
bl
+ +
dir. dir.
0,46A
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
B60 B59 2,5V X14:B X9:1
speed
9:2 speed
DIR MESX S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
Y17 Y16
13:6 4V H14 Y30 Y31
sw
sw
SPEED TAC − b a
− 2 2 2 2
X1:174 9:2 X1:178 − S X1:46 X14:A X9:2 X16:2 X15:2
SPEED MESX
X1:82
X1:124
X1:142
X1:142
X1:143
X1:143
X1:55 7:4 9:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:124

31 PITCH MESX
4:20 31 6:1

23.07.2007
1 1 582 702 39
17.3
23.07.2007
1063
30
1064
5:20 30 9:1
2:20 K11:87 K11:87 8:14
5:3 F24:2 F24:2 7:13
17.3
X1:29E 2:16 F05:2

5:17 CAN1+ CAN1+ 8:14
F24 1 ESX Fahrsteuerung DIOS Platten
5:17 CAN1− CAN1− 8:14
10A
2
X1:29A
X1:87 X1:88 X1:80 X1:86
X1:41
X1:39
X1:40
11:1
X34:R
VCC
CAN1 high
CAN1 low
CAN1 high
CAN1 low
Ub "30"
Ub "15"
not connected
not connected
Ub out
X27:8
A81
X28:6
X29:8
X28:1
X27:6
X27:7
X29:7
X28:3
X28:5
X28:4
X26:3
X26:5
X26:8
X26:10
X27:2
X27:4
X27:9
X26:9
X26:1
X26:2
X26:6
X26:4
X26:11
X27:10
X27:11
X27:12
X27:1
X27:3
X29:1
X29:2
X29:4
X29:3
X29:5
X29:6
X27:5
X26:12
X28:2
GND
GND
GND
UIN1
DIN1
DIN1
AIN1
UIN3
UIN2
DIN3
DIN5
DIN9
DIN6
DIN3
DIN5
DIN6
DIN8
DIN2
DIN2
AIN2
DIN4
DIN4
DIN11
DIN10
Sepa1
Sepa2
GND/UIN3
BOMAG
X1:106 X1:111 X1:112 X1:105 X1:107 X1:108
BL 12:17 ECO
Low High 13 23 down up
BR 12:17 13 23
S127
BEL S139
12:4
14 24 14 24
Hydraulikölfilter
Luftfilter
air cleaner
Kühlmittelvorrat
coolant stock level
Füllstand Diesel
fuel−level
Wasserabscheider
water−seperator
X21:1 X10:2 X8:1
B21 1 B03 1 B55 B124
D+ R03
2:8 P P Q
Schalter Motordrehzahl Schalter Frequenzverstellung
2 2 switch engine−rpm mode switch frequency−control
X21:2 X10:3 X8:2
0 .. 67 OHM
Nur bei EMRII
only EMRII
X1:117 X1:94 X1:94 X1:117 X1:164 X1:149 X1:82
31
5:20 31 7:1
23.07.2007
1 1
008 911 71
Wiring diagram

23.07.2007
4:20 S01:22 S01:22
6:20 F24:2
8:1
X1:41
X1:201
008 911 71
S X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC B X39:2 X22:2 bl
S1 −
−
X1:160 X41:3 X40:1 X40:2 bei BW177 u. 213 m. Sauer Motor sw / bei BW213−226 m. Rexroth Motor bl
VCC B B16
Wiring diagram
bei BW177 u. 213 m. Sauer Motor bl / bei BW213−226 m. Rexroth Motor sw

X1:159 X41:4 X40:4 S2 X40:3
X1:203
B132 2 2 2 0V A ws X22:3
VIB
X1:162 X41:2 X39:4 0V A X39:3 X22:4 13:6
S1 gg sw
X1:55 X1:202
Lenkwink.
1 1 1
−
BTS BREMSE 8:2
X41:5
X41:7
X41:8
X41:6
Sig.
AGND
X34:J
X1:60 FM5 X1:61
X1:56 FM1 X1:57
X1:58 FM2 X1:59

X1:189
5:3 FM3
armrest−switch
X1:55
Schalter Armlehne
Vib.− Richtung
Vib.− Frequenz
BTS Bremse
5:6
X1:205
X1:207
X1:206
X1:208
8,5V
X1:42 X1:188
nur BVC
A34
only BVC
Fahr−Steuerung
X35:1
driving controller
X35:19
X35:17
X35:18
X35:41
X35:35
X35:29
X35:23
X35:40
X43:2 X43:1
X35:16
X35:20
X35:21
X35:43
X35:22
X35:2
X35:48
X35:3
X35:61
30
Bremse
Armlehne
Prop. out
30 K48 8:2
Warnsummer
BOMAG
X51:3
X51:2
X1:89 87 87a
Umsch. Amplitude
K43 7:12
X1:154 X1:196 X1:195 87 87a
KA MESX
9:2 X1:147
X1:38
X35:22 GA MESX 11
8:13 9:2
X1:37 S01
X35:43
8:13 X1:116 X1:115 2:15
12
X1:150
400 ... 1.200mA

400 ... 1.200mA
150mA
X6:1 X7:1 9:2

X1:113
400 ... 1.200mA
1 1 K43 86 Y08 1 Y07 1 H07 BRAKE MESX

+ Y04 1
Y93 Y92
b d
2 2 85 2 2 − a1 2
X6:2 X7:2
max.1.8A
X1:149 X1:197 X1:197 X1:82 X1:117 X1:190

X1:118
6:20 8:1
31



23.07.2007
1 1 582 702 39
17.3
23.07.2007
1065
1066
7:2 X23:1 5:17 CAN2+ 6:14 CAN1+ CAN1+ 9:16
5:17 CAN2− 6:14 CAN1− CAN1− 9:16
K11:87
17.3
6:20 K11:87 9:1

sensor plates up 2
X1:213
X1:214
X1:156
X1:157
BTS BREMSE
7:18
br
br
3 2 + +
X63:1
X63:1
7
B135 B134
4 − −
bl bl
S S
X63:2
X63:2
sw
ws
S42
+ −

S
X35:43 X1:215
Ub in CAN− 7:11
X25:2
X25:4
X25:3
Bremse zu = 0V 1 7
3 S55 6 X35:22
7:11
X1:153 4 5
travel lever
2 8 A54
X62:1
X62:3
X62:9
X62:2
9 11
X62:4
X62:10
Add2 AK Ext2
plate−controller
10 12
Stecker X23
BOMAG
Stecker X24
1 2 3 4 5 6 7 8
X62:5
X62:6
X62:7
X62:8
X62:11
X62:13
X62:15
X62:14
Ub out
OV out
DK Ext1
DK Ext3
DK Ext5
DK Ext6
DK Ext2
DK Ext4
X50:2
X50:3
X50:1
S − + Y123 1 Y143 1 Y144.2 1

X1:210
S35 K0G S09 13 S64 13 S36 13 S139
13 23 2 2 2
400 .. 1.200 mA
86 86 1 Y122 1 Y142 1 Y144.1 1 Y145 1

K48 K05 Y98
14 14 14 14
24
2 2 2 2 2
85 85
X1:149 X1:211 X1:212

7:20 31
9:1
7:17 2:12 31
23.07.2007
1 1
008 911 71
Wiring diagram

23.07.2007
X1:34A
5:9
6:20 30 30 12:1
Pot 30
8:20 K11:87 K11:87 12:1

Pot 15
008 911 71
X2:47 X2:48 X2:49
F146:1 10:2 + −
X2:66
X2:70 X42:1 X42:2 X42:3
X46:B X46:A X46:E

Wiring diagram
X1:32E X1:35E
X2:77 P16 F1 F2
1 1 1
F148 F146
nur bei BEM
only at BEM
10A 15A
X2:56 X2:53 X2:60 X2:57 FM4 X2:71
2 2 2
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33
CAN+
CAN−
F148:2 B62 B62 X2:67 X2:68

10:2
X4:C
X4:E
X4:D
+/sw
+/sw
−/gg −/gg X47:A X47:B
X46:D X46:F
X42:4 X42:5
15g/bl 15g/bl
−/sw
X74:3
X74:5
X74:4
8:20
X2:57 B61 P11 CAN1−
20g/br
20g/br
+/rt 8:20
DIOS Platten
X48:3 X48:4 X49:3 X49:4 S/ws

CAN1+
nur bei BTM prof

X74:1 X74:2
only at BTM prof

X2:54 X2:55 X2:58 X2:59 X47:C
X4:A X4:B
X2:50 X2:51
R24
X2:69 X2:64 X2:65 1 2
Pot. 15
Leistung
Elektronik
8.5V
AGND MESX
Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
Erregerpos.
BOMAG
X44:1
X44:7
X44:9
X44:5
X44:27
X44:26
X44:4
X44:31
X44:56
X44:57
X44:59
X44:60
X44:30
X44:58
X44:29
X44:23
X44:28
X44:54
A83
X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:25
X44:53
X44:33
X44:3
X44:55
X44:65
X44:66
X44:67
X44:68
CAN3+ CAN3−
7:15 KA MESX
EVIB
GPS
GA MESX
Prop.
Prop.
GND
0..6VDC
7:15
5:3 CAN3−
400 .. 1.200mA
400 .. 1.200mA
DIR MESX X2:75 X2:73 X2:52 +

5:3
PITCH MESX Y140 1 Y141 1 P07 E X2:79 10:2
5:8 VIB CAN3+
BRAKE MESX
v.l.
v.r.
7:17 − X44:25 10:2

2:8 12:4 X2:49 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 10:1
8:20

23.07.2007
1 1 582 702 39
17.3
23.07.2007
1067
1068
9:18 CAN3−
9:18 CAN3+
17.3
9:4 F148:2
9:17 X44:25
9:5 F146:1
X2 80E
1 CAN3+ R25 CAN3−
F150 1 2
5A
2 60 OHM
X2 80A
X2 X2 X2 X2 X2
43 44 70 61 62
X4 X4 X4 X4 X4
H J G N M
X75:7 X75:2
X78:1
X78:2
X78:3
X78:4
X71:12 X72:A X73:A
A93 30 A87
X71:6 X72:B X73:B USB−CAN Schnittst.
15 USB−CAN Interface BCM
X71:5
BOMAG
TxD2 X76:1
X71:8
RxD2
X71:10 X72:E X70:3
TxD1
X71:3 X72:D X70:2
RxD1
X71:7 X72:C X70:5
GND
GPS Empfänger StarFire P15
X73:C X76:2
GPS Receiver StarFire
BCM 05
nur bei BCM
only at BCM
X4:F
nur bei StarFire GPS X2:63

only at StarFire GPS
9:20 31 31 11:1
23.07.2007
1 1
008 911 71
Wiring diagram
Vogt Bomag Compaction Management BCM, GPS 582 702 39

23.07.2007
Seis Bomag Compaction Management BCM, GPS 010
A67 1 2 3
Keyboard
008 911 71
keyboard
4 5 6
7 8 9
Wiring diagram
ANN 0 VAL
A66
Steuereinheit
control unit
X68:1 X68:2
BOMAG
+
H80
−
ZA
option
23.07.2007
1 1 582 702 39
Vogt Diebstahlschutz System DH−4
17.3
23.07.2007
1069
Seis anti − theft system 011
K11:87 K11:87
1070
9:3
9:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
17.3
F11 F18 F07 F08

15A 10A 15A 15A
30
X1:18A K06 X1:19A X1:25A
X1:26A
12:4 X1:305
X1:83
X1:301
switch, StvZO
13 23
S37
S15 F22 F19
32 12 24 15A 15A
X1:306
X1:307

STV1
X1:302
13:17 A02
STV2
13:17
X1:23E X1:24E
K16 30 31 82 L R
12:9 F09 F10
10A 10A
87 87a X1:23A X1:24A
BEL 6:9 BL
6:9
13 BR
6:9
S16 14
BOMAG
X1:304
13 23
01
X1:311
X1:310
X1:319
X1:313
X1:312
X1:321
X1:314
X1:309
X1:303
X1:320
X1:322
S14
werfer ohne StvZO
X1:84
BEL MESX
X61:1
X61:3
X60:1
X59:5
X60:3
X59:3
X58:5
X58:3
X59:2
X58:2

9:7
X1:43
0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 E08 1 E09 1 E10 1 E11 1
0,125A
2 2 86 2 2 2 2 86 2 2 2 2 + 2 2 2 2
K06 K16
4,6A
4,6A
4,6A
4,6A
H06
85 85 −
4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
X3:1
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
X1:323 X60:4
X1:323 X60:2
X1:324 X61:2
X1:324 X61:4
11:12 13:1
Scheinwerfer rechts
acc.to ROPS/SD
23.07.2007
1 1
008 911 71
Wiring diagram
Vogt Beleuchtung und StvZO 582 702 39

23.07.2007
F42:H 14:14 F41:5 14:14
K30 X3:6
2:14 K32:87 14:2
X3:7
K32 30 STV2
X3:8 12:13
13:1 STV1
008 911 71
12:13
87 87a
G H A B C E F
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3 6
5
Wiring diagram
F42 14:8
F130 13:9 F130 F130 14:7
13:14
A12
15
1,75A
0,83A
K141 30 1 B51 + 30 01W 7 2 01W 7 2 1 S163 5 1 S38 5
+ + + B51
01 01 E72
K32:86 13:16 E29 E70
− − − − 1
87 87a 2 2 2 1
2:20 31 S21 5 4 S20 5 4
Radio
radio
1 Tachographenmodul
R80 A2+A3
X3:17
4,6A
4,6A
4,6A
4,6A
2 4 6 A1
Nachtleuchte
5:3 P09 +
indicator
X55:1
X56:1
X55:3
X56:3
2 1 XS
X55:4
X56:4
SPEED TAC A16 night illumination E27 1 E28 1 E23 1 E25
1 B3 12V
Kontrolleuchte
Innenleuchte
inside light, cabin
−
socket
Steckdose
+ 7,8,9 2 B4 2 2 2 2
max. 13A
A01 VIB X3:18 5 3 C3
7:18
A5+A6
S45 TK −
Heizung Heckscheibe
heating rear screen
BOMAG
3,8A
3,8A
3
5A
86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 − M06 4 −
85
2,9A
3 min
ZA
4,7A
X55:2 X56:2 option

Abfallverzögert
14:11
KABINE 31
X3:1
X3:2
Schalterbel.
switch illum.
12:20 31 31 14:1


23.07.2007
1 1 582 702 39
Vogt Kabinenausrüstung, Beleuchtung, Radio, Tachograph
17.3
23.07.2007
1071
1072
13:19 K32:87
13:19 F41:5
13:17 F130 F42:H
13:4
13:9
17.3
D Potential 30 aus Kabine A B

F31 F40 BOX2 F15 BOX2
20A 20A 5A
4 1 2
2.5qmm
1 2 3 12 11 13 14 16
0123 4 3 2 5 7 11 3 10 1
S44 A72
Steuergerät
control unit
6 11 12 1 Regel aus = 0,4A
S28
E30 Kleine Stufe = 0,67A
heater timer

Schaltuhr Heizung

30 2 6 8 9 4 12
K09
X3:14
X53:L
X53:H
X53:M
2:10
87 87a X1:167 5 9 10 6 8 7 4 15
2.5qmm
X1:169 X18:1
X3:9
X3:11
X3:10
X3:12
X19:1
B131
B103 1 1 F97 1
_t 3A
BOMAG
_t 2 2
2 inline fuse
X19:2 Inline Sicherung
X20:1 X18:2
X17:1 X1:163
X17:3 X1:166
X17:2 X1:165
B104 4
P
HP X69:1 X77:1
1A
LP 3
ge rt or ge rt or +
Y138 1 1
X1:170 M17
X20:4
X20:3
V06 Y14

M09 M M09 M M
2 2 2
Stromaufnahme Lüfter / current blower br br −
X20:2 V04
X69:2 X77:2
Option
option

Y15 1
X17:4 X1:168
2 13:19
3,5A
X1:164 KABINE 31
X1:190
13:20 31 31

Kabinenlüfter
Frischluft Lüfter
cab ventilator blower fresch air
23.07.2007
1 1
008 911 71
Wiring diagram
Vogt Kabinenheizung, Klimaanlage, Zusatzheizung 582 702 39

23.07.2007
A02
Wiring diagram
A12
A16
012
013
013
17
5
6
Blinkgeber
Radio
Elektronik Tachograph
flasher
Radio
Electronic system, tachograph
17.3
Seis
23.07.2007
Vogt
23.07.2007

A93 010 7 GPS Antenne GPS antenna

component listing

Bauteilliste

B133 004 12 Sensor Ladeluftdruck / −temperatur sesnor charging air prssure / temperature

1

11
F15 014 19 Sicherung Heizgeraet Fuse, heating unit BOX2
582 702 39
101

F40 014 15 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
008 911
F41 71 013 19 Sicherung Rundumkennleuchte BOMAG
Fuse, rotary beacon 10A 1073
17.3 F42
F43
F44
013
013
013
3
10
13
Sicherung Kabineninnenleuchte
Sicherung Wischermotor hinten
Sicherung Wischermotor vorn
Fuse, inside light cab
Fuse, wipermotor rear
Fuse, wipermotor front
10A
Wiring diagram
15A
15A
F97 014 13 Sicherung Frischluftluefter fuse, blower fresh air 3A
Seis
23.07.2007
Vogt
23.07.2007

F124 002 17 Sicherung Kraftstoffvorwärmung Fuse, fuel pre−heating 25A
F150 010 14 Sicherung GPS Receiver Fuse, GPS receiver 5A

H80 011 15 Meldeleuchte Wegfahrsperre Indicator light, anti−theft device LED

K13 002 18 Relais Signalhorn Relay, warning horn BOSCHW
K43 007 12 D*Relais Vibration E*relay, vibration BOSCHW
component listing
Bauteilliste
K14.2 004 20 TYCOX


M17 014 13 Zusatzluefter Additional blower

P33 009 18 Opus 21 Opus 21

R79 002 14 Kraftstoffvorwärmung fuel pre−heater 250W
2

11

582 702 39

102

1074 S42 008 11 Stufenumschalter schnell−langsam BOMAG
Speed range selector, fast−slow 008 911 71
S44
Wiring diagram
S45
S55
014
013
008
3
3
6
Schalter Kabinenluefter
Schalter Kabineninnenleuchte
Schalter Fahrhebel
Switch, cabin ventilator
Switch, cabin inside light
Switch, travel control lever
17.3
S64 008 10 Schalter Schwimmstellung Switch, float position

Seis
23.07.2007
Vogt
23.07.2007

component listing

Bauteilliste

3

11

582 702 39

103

008 911
X1:11871 007 14 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 1075
17.3 X1:119
X1:120
X1:121
005
005
005
2
4
12
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
Wiring diagram
Seis
23.07.2007
Vogt
23.07.2007

component listing

Bauteilliste

4

11

582 702 39

104

1076 X1:19E 012 15 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 008 911 71
X1:201
Wiring diagram
X1:202
X1:203
007
007
007
4
4
4
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
17.3
Seis
23.07.2007
Vogt
23.07.2007

component listing

Bauteilliste

5

11

582 702 39

105

008 911
X2:65 71 009 14 WAGO−MESSTECHNIK BOMAG
Wago−measurement equip. 1077
17.3 X2:66
X2:66
X2:67
009
009
009
14
14
11
WAGO−MESSTECHNIK
WAGO−MESSTECHNIK
WAGO−MESSTECHNIK
Wiring diagram
Seis
23.07.2007
Vogt
23.07.2007

X2:80A 010 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:80E 010 14 WAGO−MESSTECHNIK Wago−measurement equip.
X4:H 010 14 KABINENST. MESST. con. measurem.equipm.
X4:J 010 15 KABINENST. MESST. con. measurem.equipm.
component listing

Bauteilliste

6

11

582 702 39

106

1078 X27:4 006 6 STECKER DATENSAMMLER BOMAG
connector data collector 008 911 71
X27:5
Wiring diagram
X27:6
X27:7
006
006
006
11
9
10
17.3
Seis
23.07.2007
Vogt
23.07.2007

component listing

Bauteilliste

7

11

582 702 39

107

008 911
X31:4171 004 15 EMR−Stecker Motor BOMAG
EMR−connector engine 1079
17.3 X31:43
X31:46
X31:47
004
004
004
13
2
1
EMR−Stecker Motor
EMR−Stecker Motor
EMR−Stecker Motor
Wiring diagram
Seis
23.07.2007
Vogt
23.07.2007

component listing

Bauteilliste

8

11

582 702 39

108

1080 X39:3 007 10 STECKER 1 LENKRAD BOMAG
connector 1 steering unit 008 911 71
X39:4
Wiring diagram
X40:1
X40:2
007
007
007
9
9
10
STECKER 1 LENKRAD
STECKER 2 LENKRAD
STECKER 2 LENKRAD
17.3
Seis
23.07.2007
Vogt
23.07.2007

component listing

Bauteilliste

9

11

582 702 39

109

008 911
X56:2 71 013 13 STECKER WISCHER VORNE BOMAG
conn. wiper front 1081
17.3 X56:3
X56:4
X57:1
013
013
003
13
12
15
Stecker Motor
conn. wiper front
conn. wiper front
connector engine
Wiring diagram
Seis
23.07.2007
Vogt
23.07.2007

component listing

Bauteilliste

10

11

582 702 39

110

1082 X65:3 011 5 KEYBOARD BOMAG
Keyboard 008 911 71
X65:4
Wiring diagram
X65:5
X65:7
011
011
011
5
5
5
KEYBOARD
KEYBOARD
KEYBOARD
Keyboard
Keyboard
Keyboard
17.3
Seis
23.07.2007
Vogt
23.07.2007

X72:A 010 12 STECKER ANSCHL. GPS Connector GPS
X72:B 010 12 STECKER ANSCHL. GPS Connector GPS
X72:C 010 12 STECKER ANSCHL. GPS Connector GPS
X72:D 010 12 STECKER ANSCHL. GPS Connector GPS
X72:E 010 12 STECKER ANSCHL. GPS Connector GPS
X73:A 010 13 STECKER VERS. GPS Connector Supply GPS
X73:B 010 13 STECKER VERS. GPS Connector Supply GPS
X73:C 010 13 STECKER VERS. GPS Connector Supply GPS
component listing

Bauteilliste


Y144.1 008 19 MAX. 1.8A
Y144.2 008 19 MAX. 1.8A
11
11
582 702 39
111
008 911 71 BOMAG 1083

1084
17.3
X38
X37
X36
A80
BOMAG
Nur bei StvzO
A02 R10 K05
K11 K16 K06
Nur bei Klimaanlage

K09 K43
K48
K61
B57
K41
K13
X32:1-12 X34:1-19
008 911 71
Wiring diagram
Gez.: 23.07.2007 Seite: 1 von: 2

Name: Vogt
Übersicht Schaltkasten BW 177...226 DH/BVC-4 page: 1 from: 2
582 702 39
Name: Seis overview e-box BW 177...226 DH/BVC-4 Replaces: Sheet No.: 201
Nur bei VM8
only acc. To VM8
F1 F2 CAN 1
008 911 71
Wiring diagram
LCD+
CAN 1
Datensammler
A34
Fahrsteuerung
BOMAG
CAN 1 OPUS 21
A83
CAN 3 BCM
Gez.: 23.07.2007 Seite: 2 von: 2

582 702 39
17.3
1085
Name: Seis
17.3 Wiring diagram
1 057 564 17
2 280-315
3 2 x 057 564 25 "L" + 793-501
5 057 564 25 "L" + 057 564 20 + 793-501
6 057 564 25 "L" + 793-501
7 057 564 22
8 057 564 23 "L" + 057 564 19 + 793-501
9 057 564 23 "L" + 793-501
10 057 564 23 "L" + 057 564 19 + 793-501
11 057 564 23 "L" + 793-501
12 057 564 36 "R" + 2 x 057 564 19 + 793-501
13 5 x 057 564 36 "R" + 057 564 19 + 793-501
247,0 mm
371,0 mm
18 057 564 36 "R" + 793-501
19 057 564 36 "R" + 057 564 19 + 793-501
20 057 564 36 "R" + 793-501
21 057 564 36 "R" + 057 564 19 + 793-501
22 057 564 36 "R" + 793-501
23 6 x 057 564 36 "R" + 057 564 19 + 793-501
29 5 x 057 564 36 "R" + 793-501

Artikelnummer :
Optional3 : Plan : geprüft: :
Ort :
Optional4 :

31.07.2007 09:11:11 Seite 1
1086 BOMAG 008 911 71

Wiring diagram 17.3
247,0 mm
34 057 564 35
35 057 564 17
0,5 mm
36 057 564 21
37 2 x 057 564 25 "L" + 793-501
39 057 564 25 "L" + 057 564 20 + 793-501
40 057 564 25 "L" + 793-501
41 057 564 25 "L" + 057 564 20 + 793-501
42 5 x 057 564 25 "L" + 793-501
371,0 mm
47 057 564 25 "L" + 057 564 20 + 793-501
123,5 mm
48 057 564 25 "L" + 793-501
49 057 564 25 "L" + 057 564 20 + 793-501
50 057 564 25 "L" + 793-501
51 057 564 25 "L" + 057 564 20 + 793-501
52 057 564 25 "L" + 793-501
53 057 564 25 "L" + 057 564 20 + 793-501
54 2 x 057 564 25 "L" + 793-501
56 4 x 057 564 38 "L" + 793-501
60 057 564 17
0,0 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:11:11 Seite 2
008 911 71 BOMAG 1087

17.3 Wiring diagram
247,0 mm
371,0 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:11:15 Seite 3
1088 BOMAG 008 911 71

Wiring diagram 17.3
247,0 mm
0,5 mm
371,0 mm
123,5 mm
0,0 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:11:15 Seite 4
008 911 71 BOMAG 1089

17.3 Wiring diagram
1 057 564 17
2 3 x 057 565 40 "R" + 793-501
5 057 565 35 "R" + 793-501
6 057 565 37
7 3 x 057 565 40 "R" + 793-501
10 057 565 37
11 057 565 40 "R" + 793-501
12 057 565 35 "R" + 793-501
13 057 565 37
14 057 565 40 "R" + 793-501 + 057 565 36
15 057 565 40 "R" + 793-501
16 2 x 057 565 39 "R" + 793-501
18 057 565 37
19 4 x 057 565 40 "R" + 793-501
23 057 565 37
24 4 x 057 565 40 "R" + 793-501
345,0 mm
370,0 mm
28 2 x 057 565 39 "R" + 793-501
30 057 565 37
31 057 565 40 "R" + 793-501
32 057 565 39 "R" + 793-501
33 057 565 37
34 4 x 057 565 40 "R" + 793-501
38 057 565 35 "R" + 793-501
39 057 565 37
40 4 x 057 565 40 "R" + 793-501
44 057 565 37
45 057 565 40 "R" + 793-501
46 057 565 35 "R" + 793-501
47 057 565 37
48 057 565 40 "R" + 793-501
49 057 565 35 "R" + 793-501
50 057 565 37

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:08:54 Seite 1
1090 BOMAG 008 911 71

Wiring diagram 17.3
51 057 565 38 "R" + 793-501
52 2 x 057 565 40 "R" + 793-501
54 057 565 38 "R" + 793-501
55 057 565 37
56 3 x 057 565 40 "R" + 793-501
59 057 565 38 "R" + 793-501
60 057 565 37
61 3 x 057 565 40 "R" + 793-501
64 057 565 35 "R" + 793-501
65 057 565 37
345,0 mm
66 2 x 057 565 40 "R" + 793-501
68 057 565 35 "R" + 793-501
370,0 mm
69 057 565 37
70 3 x 057 565 40 "R" + 793-501
73 057 565 35 "R" + 793-501
74 057 565 37
75 2 x 057 565 40 "R" + 793-501
77 2 x 057 565 35 "R" + 793-501
79 057 565 37
80 057 565 40 "R" + 793-501
81 057 565 39 "R" + 793-501
82 057 565 37
83 057 564 17
25,0 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:08:54 Seite 2
008 911 71 BOMAG 1091

17.3 Wiring diagram
345,0 mm
370,0 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:08:59 Seite 3
1092 BOMAG 008 911 71

Wiring diagram 17.3
345,0 mm
370,0 mm
25,0 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:08:59 Seite 4
008 911 71 BOMAG 1093

17.3 Wiring diagram
107,8 mm
1 057 564 17
2 2 x 057 565 40 "R" + 793-501
240,0 mm
4 057 565 37
5 057 565 40 "R" + 793-501 + 057 565 36
6 057 565 40 "R" + 793-501
7 057 565 39 "R" + 793-501
8 057 565 37
9 057 565 38 "R" + 793-501
10 2 x 057 565 40 "R" + 793-501
12 057 565 38 "R" + 793-501
13 057 565 37
14 2 x 057 565 40 "R" + 793-501
130,5 mm
16 057 565 39 "R" + 793-501
17 057 565 37
18 057 565 40 "R" + 793-501
19 057 565 38 "R" + 793-501
20 057 565 40 "R" + 793-501
21 057 565 37
22 057 565 40 "R" + 793-501
23 057 565 39 "R" + 793-501
24 057 565 37
25 057 564 21
26 2 x 057 564 38 "L" + 793-501
28 057 564 25 "L" + 793-501
29 057 564 36 "R" + 793-501
30 057 564 35
31 057 564 17
1,7 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:12:14 Seite 1
1094 BOMAG 008 911 71

Wiring diagram 17.3
107,8 mm
240,0 mm
130,5 mm
1,7 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:12:17 Seite 2
008 911 71 BOMAG 1095

17.3 Wiring diagram
12,0 mm
1 057 564 17
2 4 x 057 565 40 "R" + 793-501
6 057 565 37
7 2 x 057 565 40 "R" + 793-501
74,0 mm
100,0 mm
9 4 x 057 565 38 "R" + 793-501
13 2 x 057 565 39 "R" + 793-501
15 057 565 37
16 057 564 17
14,0 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:11:41 Seite 1
1096 BOMAG 008 911 71

Wiring diagram 17.3
12,0 mm
74,0 mm
100,0 mm
14,0 mm

Artikelnummer :
Ort :
Optional4 :

31.07.2007 09:11:43 Seite 2
008 911 71 BOMAG 1097

X71 X72
X70 X73
1098
X74 X75 X77
X55
X56 X76 X53 X54
17.3
X29
X28 X21
X39 X23
X11 X24
X12 X50
X59 X40 X25 X41
X13
X58 X42 X51 X43 X57
X20
X69 X46 X14
X18 X30 X77

X33 X6 X7
X17 X52
X47 X19 X31 X4 X3
X67 X8 X15 X16
X48 X49 X10
(BVC) (BVC)
X36 X26 X60
X37 X1 X27 X61 X62
X38 X2
X9
X44
X35
X32 X34
BOMAG
X71
X61
X72
X77 X9
X21
X73 X74 X70
X59 X62
X75 X76
X67 X8
X42 X23
X11 X24
X12 X50 X57
X10
X46 X25 X41
X13 X51
X56
X53
X20
X29 X18
X17 X14
X28 X19 X55 X6 X7
X54 X15 X16
X69 X39
X43
X40
X77 X30
X58 X52 X33
X31 X4 X3
X36 X35 X1 X26
X37 X44 X2 X27
X38 X32 X60
X47
X48 X49
(BVC) (BVC)
008 911 71
Wiring diagram
Gez.: 23.07.2007 Seite: 1 von: 1

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17.4 Hydraulic diagram
008 911 71 BOMAG 1099

1100 BOMAG 008 911 71

Hydraulic diagram 17.4
008 911 71 BOMAG 1101

1102 BOMAG 008 911 71

008 911 71 BOMAG 1103

1104 BOMAG 008 911 71

Hydraulic diagram 17.5
008 911 71 BOMAG 1105

1106 BOMAG 008 911 71

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Service - Manual

BW 213 DH-4 / PDH-4

Single drum roller

008 911 71 BOMAG 3

7.11 Batteries 137

4 BOMAG 008 911 71

12.11 Service the air conditioning 523

008 911 71 BOMAG 5

6 BOMAG 008 911 71

008 911 71 BOMAG 7

1.1 Introduction * The applicable documents valid at the date of print-

You should only use genuine BOMAG spare parts.

Please observe strictly the safety regulations in

8 BOMAG 008 911 71

by attaching a clearly visible warning tag to the

Repair work shall only performed by appropriately

Workshop equipment and facilities as well as the

008 911 71 BOMAG 9

Behaviour in case of faults

10 BOMAG 008 911 71

008 911 71 BOMAG 11

12 BOMAG 008 911 71

Special safety regulations

008 911 71 BOMAG 13

Diagnostics according to plan

14 BOMAG 008 911 71

Electrical system and welding work

008 911 71 BOMAG 15

Hydraulic system ● After changing a component perform a high and

16 BOMAG 008 911 71

Old systems should be converted to refrigerants

008 911 71 BOMAG 17

Notes and measures to be applied before starting

18 BOMAG 008 911 71

008 911 71 BOMAG 19

20 BOMAG 008 911 71

008 911 71 BOMAG 21

Feather keys and keyways Ball and roller bearings

22 BOMAG 008 911 71

008 911 71 BOMAG 23

Strength classes of metric screws Strength classes of metric nuts

Nuts for screw joints with full load capability (4, 5,

Fig. 9 Identification of nuts

Strength class of Strength class of associated

Nuts for screw joints without specified load factor

24 BOMAG 008 911 71

Fig. 10 Identification of nuts in clock system

008 911 71 BOMAG 25

The values specified in the table apply for screws:

Tightening torques for screws with metric unified thread1

Tightening torques for screws with metric unified fine thread1

26 BOMAG 008 911 71

Tightening torques for wheel nuts (fine thread) 1 2

008 911 71 BOMAG 27

The values specified in the table apply for screws:

28 BOMAG 008 911 71

008 911 71 BOMAG 29

30 BOMAG 008 911 71

008 911 71 BOMAG 31