Service - Manual

BW 216 D-40 / PD-40

BW 218 D-40
S/N 101 583 39 .... / S/N 101 583 40 . . . .
S/N 101 583 41......>

Single drum roller

Catalogue number.
008 918 12 06/2012
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
Technical data 31
2.1 Technical data 32
Maintenance 39
3.1 General notes on maintenance 40
3.2 Fuels and lubricants 41
3.3 Table of fuels and lubricants 44
3.4 Running-in instructions 45
Caddy wiring diagrams 47
4.1 Understanding circuit diagrams 48
4.2 Circuit symbols in the circuit diagram 53
4.3 Identification of switch blocks in the Caddy wiring diagram 54
4.4 Designation of components in the wiring diagram 55
4.5 Terminal designations in wiring diagram 56
E-Plan wiring diagrams 59
5.1 Understanding wiring diagrams 60
5.2 Circuit symbols in the circuit diagram 69
5.3 Identification of switch blocks in the wiring diagram 72
5.4 Designation of components in the wiring diagram 73
5.5 Terminal designations in wiring diagram 74
Electrics 77
6.1 Designation of components in the wiring diagram 78
6.2 Terminal designations in wiring diagram 79
6.3 Battery ground and analog ground 81
6.4 Current and voltage 81
6.5 Resistance 83
6.6 Series / parallel connection 85
6.7 Ohm's law 87
6.8 Electrical energy 88
6.9 Formula diagram 89
6.10 Metrology 90
6.11 Diodes, relays, fuses 94
6.12 Telemecanique switch 97
6.13 Plug connectors 99
6.14 Magnetic coil plug 99
6.15 Deutsch plug, series DT and DTM 101
6.16 Plugs and terminals in spring clamping technology 106
6.17 Proximity switches 110
6.18 Level sensor in diesel tank (R03) 111
6.19 Differential pressure switch for hydraulic oil filter, B21 112
6.20 Acceleration transducer 114
6.21 Batteries 115

008 918 12 BOMAG 3

Table of Contents

6.22 Service the battery 119

6.23 Main battery fuse 120
6.24 Starting with jump wires 120
6.25 Generator 121
6.26 Replacing the voltage regulator 130
6.27 Electric starter 132
6.28 Coolant temperature switch 138
6.29 Oil pressure switch and low oil pressure circuitry 139
6.30 Boost fuel solenoid valve 141
6.31 Engine shut-down solenoid 142
6.32 Electric throttle control 143
6.33 Heating flange on engine 145
6.34 Checking the heating flange control 148
6.35 Engine monitoring 149
6.36 Overview of electric components 152
6.37 Operator's stand, old design 163
6.38 Operator's stand, new design 165
6.39 Cabin 166
6.40 Fuses, old design 167
6.41 Fuses, new design 168
6.42 Electronic control units 169
6.43 Checking the voltage supply for the control unit 172
6.44 Diagnostics concept 180
Electronic modules 183
7.1 BEM, BOMAG Evib-meter 185
7.2 Electrics module A68 249
7.3 Electric module K04 257
7.4 Electric module A72, old design 261
7.5 Electric module A108 267
Speedometer Module 271
8.1 Speedometer module 272
582 502 15 dust protection / 582 502 16 gasket 275
9.1 Assembling the dust protection 276
Hydraulics 281
10.1 Hydraulic circuit 282
10.2 Connection overview 284
10.3 Travel pump 075 286
10.4 Vibration pumps 42R041 & 42R055 292
10.5 Axial piston swash plate principle / pump 295
10.6 Troubleshooting axial piston pumps 297
10.7 Travel motor 51 C/D 110 300
10.8 Trouble shooting, variable displacement axial piston motor 302
10.9 Vibration motor A10FM 45 304
10.10 Vibration motor 90M 055 305
10.11 Axial piston swash plate principle / motor 307
10.12 External gear pumps 309
10.13 Travel circuit 311

4 BOMAG 008 918 12

Table of Contents

10.14 Adjust the parking brake 316

10.15 Stopping the machine, operating the parking brake 318
10.16 Towing in case of an engine failure 318
10.17 Vibration circuit 321
10.18 Steering circuit 326
10.19 Check the hydraulic oil level 332
10.20 Changing hydraulic oil and breather filter 332
10.21 Replace hydraulic oil filter 333
10.22 Changing the bypass filter 334
Tests and adjustments 335
11.1 Special tools, tests and adjustments 336
11.2 Adjusting the solenoid for engine speed control 340
11.3 Checking the rotation speeds 341
11.4 Checking / adjusting the neutral positions of the travel pump 343
11.5 Pressure tests in the travel circuit 345
11.6 Checking / adjusting the vibrator shaft speeds 347
11.7 Pressure measurements in the vibration circuit 348
11.8 Check the leakage rate of the vibration motor 349
11.9 Pressure test in steering circuit 350
Flushing and bleeding 353
12.1 Special tools for flushing 354
12.2 Flushing - general 359
12.3 Flushing schematic travel circuit (distribution travel pump) 361
12.4 Flushing the travel circuit (travel pump distribution) 363
12.5 Flushing schematic travel circuit (distribution axle motor) 369
12.6 Flushing the travel circuit (axle motor distribution) 374
12.7 Flushing schematic for vibration drive 379
12.8 Flushing the vibration circuit 380
12.9 Bleeding the travel circuit 384
12.10 Bleeding the vibration circuit 386
Air conditioning system 389
13.1 Physical basics 390
13.2 Refrigerant R134a 393
13.3 Compressor oil / refrigeration oil 394
13.4 Working principle of the air conditioning system 395
13.5 Monitoring devices 395
13.6 Description of components 396
13.7 Measuring the compressor oil level 402
13.8 Checking the magnetic clutch 402
13.9 Inspection and maintenance work 403
13.10 Checking, replacing the refrigerant compressor V-belt 404
13.11 Air conditioning service (old design) 405
13.12 Service the air conditioning 407
13.13 Drying and evacuation 410
13.14 Emptying in case of repair 410
13.15 Leak test 411
13.16 Filling instructions 412
13.17 Trouble shooting in refrigerant circuit, basic principles 415

008 918 12 BOMAG 5

Table of Contents

13.18 Trouble shooting, refrigerant circuit diagram 419

13.19 Trouble shooting procedure 420
13.20 Steam table for R134a 430
Cabin assembly 435
14.1 Preparations 437
14.2 Cabin assembly 438
14.3 Final function tests and checks 443
Replacing the cab window panes 445
15.1 Assembly of window panes 446
15.2 Special tools, cabin windows 447
15.3 Auxiliary materials 448
15.4 Removing and installing the window pane 450
Drum 455
16.1 Special tools, drum, single drum rollers 456
16.2 Repair overview for drum 458
16.3 Removing and installing the drum 467
16.4 Repairing the drum 473
16.5 Dismantling, assembling the change-over weights 504
16.6 Changing the rubber buffers and adjusting the pretension 507
Oscillating articulated joint 511
17.1 Special tools, oscillating articulated joint (BW177 to BW 216) 512
17.2 Repair overview oscillating articulated joint 514
17.3 Removing and installing the oscillating articulated joint 518
17.4 Dismantling the oscillating articulated joint 520
17.5 Assembling the oscillating articulated joint 525
Suppliers documentation 535
18.1 Travel pump 537
18.2 Vibration pump 691
18.3 Travel motor 761
18.4 Vibration motor 855
18.5 Vibration motor 879
18.6 Drum reduction gear 899
18.7 Steering valve 925
18.8 Axle 959
18.9 Diesel engine 1049
Circuit diagrams 1347
19.1 Hydraulic diagram 581 202 01 1349
19.2 Hydraulic diagram 581 202 06 1353
19.3 Wiring diagram 582 702 41 1357
19.4 Wiring diagram 9 1394

6 BOMAG 008 918 12

1 General

008 918 12 BOMAG 7

1.1 Introduction

1.1 Introduction

This manual addresses the professionally qualified

personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.

Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information

Use only 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 an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
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
!

These safety regulations must be read and ap-

plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG

8 BOMAG 008 918 12

Safety regulations 1.2
Important notes Block the articulated joint with the articulation lock.
1.2 Safety regulations
l

l Use protective clothes like hard hat, safety boots

These safety regulations must be read and ap-
and gloves.
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident l Keep unauthorized persons away from the machine
prevention instructions and the safety regulations during repair work.
in the operating and maintenance instructions l Tools, lifting gear, lifting tackle, supports and other
must be additionally observed.
auxiliary equipment must be fully functional and in
Repair work shall only performed by appropriately safe condition.
trained personnel or by the after sales service of l Use only safe and approved lifting gear of sufficient
BOMAG. load bearing capacity to remove and install parts or
components from and to the machine.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants, l Do not use easily inflammable or harmful substanc-
cleaning agents and solvent as well as gases and es, such as gasoline or paint thinners for cleaning.
chemicals are subject to legal regulations, which l Do not smoke or use open fire and avoid sparks
are intended to provide a minimum on safety. It is when cleaning or repairing a tank.
obviously your own responsibility to know and
adhere to these regulations.
l When performing welding work strictly comply with
the respective welding instructions.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan- Transport work with cranes and lifting
gers to persons, property and the environment. tackle

i Note i Note
Paragraphs marked like this contain technical infor- Cranes must only be operated by instructed persons
mation for the optimal economical use of the machine. who had been trained in handling cranes.
l Follow the operating instructions of the manufactur-
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible l Follow the operating instructions of the operator
dangers for machines or parts of the machine. when working with cranes.
l Always comply with the applicable accident preven-
Danger
!
tion instructions when working with cranes and lift-
ing tackle.
Paragraphs marked like this highlight possible
dangers for persons.
Precautions and codes of conduct for
welding work
Environment
Welding work must only be carried out by properly
Paragraphs marked like this point out practices
trained personnel.
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Danger
!
Observe the regulations for the protection of the
environment. Electric shock!
Sparks, fire hazard, burning of skin!
General Infrared or ultraviolet radiation (arc), flashing of
l
For repair and maintenance work move the ma- eyes!
chine on a firm base and shut it down. Health hazard caused by welding work on highly
l
Always secure the machine against unintended roll- alloyed work pieces, metal coatings, paint coat-
ing. ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Secure the engine reliably against unintentional
starting.
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
l Ensure good conductivity between ground cable
the dashboard. and workpiece, avoid joints and bearings.

008 918 12 BOMAG 9

1.2 Safety regulations

l Start the extraction fan before starting work and Operation of high-voltage systems
guide with the progressing work as required.
l Always isolate the burner when laying it down (re- i Note
move possible electrode residues).
The rules and statutory regulations valid in the corre-
l Protect cables from being damaged, use cables sponding do apply in addition to the notes given here.
with insulated couplings.
l Ensure sufficient fire protection, keep a fire extin- !Caution
guisher at hand. The high-voltage system must only be operated
l Welding work in areas where there is a risk of fire or and serviced by qualified and authorized person-
explosion, must only be carried out with welding nel.
permission.
Before starting operation the operator must check
l Remove any combustible materials from the weld- the proper condition of the system.
ing area or cover such items appropriately.
l Name a fire watch during and after welding work. !Danger
l Place welding rod holders and inert gas welding Possibility of injury or even death caused by elec-
guns only on properly insulated bases. tric shock:
l Place the inert gas bottles in a safe place and se- l if persons come into contact with live parts,
cure them against falling over. l in case of faulty insulation of live parts,
l
Use a protective screen or hand shield with welding l
inadequate, unsuitable insulation,
filter, wear welding gloves and clothes. l
if melted parts flake off in case of short circuits.
l
Switch the welding unit off before connecting weld-
ing cables. Old oils
l
Check electrode holders and electric cables at reg- Prolonged and repetitive contact with mineral oils will
ular intervals. remove the natural greases from the skin and causes
Behaviour in case of faults dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
l
In case of faults on the welding unit switch of the which could cause skin cancer. Appropriate skin pro-
welding unit immediately and have it repaired by ex- tection agents and washing facilities must therefore
pert personnel. be provided.
l
In case of failure of the extraction system switch the l
Wear protective clothes and safety gloves, if possi-
system off and have it repaired by expert personnel. ble.
Maintenance; waste disposal l
If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
l
Replace damaged insulating jaws and welding rod
full face visor; a facility suitable for rinsing the eyes
holders immediately.
should also be available.
l
Replace the welding wire reels only in de-energized l
Avoid longer and repetitive contacts with oils. In
state.
case of open incisions and injuries seek medical ad-
What to do in case of accidents; First Aid vice immediately.
l
Keep calm. l
Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Call first air helpers.
l
Wash affected skin areas with water and soap (skin
l
Report the accident.
cleansers and nail brushes will help). Lanolin con-
l
In case of an electric accident: Interrupt the power taining agents will replace natural skin oils that were
supply and remove the injured person from the lost.
electric circuit. If breathing and heart have stopped l
Do not use gasoline, kerosene, diesel, thinner or
apply reactivation measures and call for an emer-
solvents to wash the skin.
gency doctor.
l
Do not put oil soaked cloths into your pockets.
l Avoid clothes getting soiled by oil.
l
Overalls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
l
If possible degrease components before handling.

10 BOMAG 008 918 12

Safety regulations 1.2
Environment l Fire extinguishers charged with FOAM, CO2 GAS
It is strictly prohibited to drain off oil into the soil, or POWDER must be available wherever fuel is
the sewer system or into natural waters. Old oil stored, filled in, drained off, or where work on fuel
must be disposed of according to applicable envi- systems is performed.
ronmental regulations. If in doubt you should con- l The vehicle battery must always be disconnected,
sult your local authorities. BEFORE work in the fuel system is started. Do not
disconnect the battery while working on the fuel
Hydraulics system. Sparks could cause explosion of the fuel
fumes.
l Always relieve the pressure in the hydraulic system
before disconnecting any lines. Hydraulic oil escap-
l Wherever fuel is stored, filled, drained off or where
ing under pressure can penetrate the skin and work on fuel systems is carried out, all potential ig-
cause severe injury. nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
l Always make sure that all screw fittings have been against possible contact with running out fuel.
tightened properly and that hoses and pipes are in
mint condition before pressurizing the system
again.
Hot fuels
Please apply the following measures before draining
l Hydraulic oil leaking out of a small opening can
of fuel to prepare for repair work:
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When l Allow the fuel to cool down, to prevent any contact
injured by hydraulic oil escaping under pressure with a hot fluid.
consult a physician immediately, as otherwise this l
Vent the system, by removing the filler cap in a well
may cause severe infections. ventilated area. Screw the filler cap back on, until
l Do not step in front of or behind the drums, wheels the tank is finally emptied.
or crawler tracks when performing adjustment work
in the hydraulic system while the engine is running. Synthetic rubber
Block drums, wheels or crawler tracks with wedges.
Many O-rings, hoses, etc. are made of synthetic ma-
Reattach all guards and safety installations after terial, a so-called fluorocarbon elastomer. Under nor-
all work has been completed. mal 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 oil into the soil,
caustic hydrofluoric acid, which can cause severe
the sewer system or into natural waters. Oil oil
burns in contact with skin.
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con- l
If the material is in such a state it must only be
sult your local authorities. touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
Fuels cable environmental regulations immediately after
use.
l
If the material has contacted the skin despite these
!Danger
measures, take off the soiled clothes and seek
Repair work shall only performed by appropriately medical advice immediately. In the meantime cool
trained personnel or by the after sales service of and wash the affected area of skin over a sufficient
BOMAG. time with cold water or lime water.
Follow the valid accident prevention instructions when
handling fuels. Poisonous substances
The following notes refer to general safety precau- Some of the fluids and substances used are toxic and
tions for danger free handling of fuel. must under no circumstances be consumed.
Fuel vapours not only are easily inflammable, but also Skin contact, especially with open wounds, must be
highly explosive inside closed rooms and toxic; dilu- avoided.
tion with air creates an easily inflammable mixture. These fluids and substances are, amongst others,
The vapours are heavier than air and therefore sink anti-freeze agents, hydraulic oils, fuels, washing addi-
down to the ground. Inside a workshop they may eas- tives, refrigerants, lubricants and various bonding
ily become distributed by draft. Even the smallest por- agents.
tion of spilled fuel is therefore potentially dangerous.

008 918 12 BOMAG 11

1.2 Safety regulations

Engine air conditioning system. The development of heat

may cause the refrigerant to develop toxic and high-
ly corrosive breakdown products.
Danger
!
l Pungent smell! The toxic substances, which are re-
Do not work on the fuel system while the engine is
sponsible for the pungent smell, must not be in-
running. (Danger to life!)
haled, since this may cause damage to the
Once the engine has stopped wait approx. 1 min- respiratory system, the lung and other organs. Ex-
utes for the system to depressurize. The systems tract toxic breakdown products with a suitable ex-
are under high pressure. (Danger to life!) traction system (workshop extraction system).
Keep out of the danger zone during the initial test l
When blowing out components with compressed air
rung. Danger caused by high pressure in case of and when flushing with nitrogen the gas mixture es-
leaks. (Danger to life!) caping from the components must be extracted via
When performing work on the fuel system make suitable extraction facilities (workshop extraction
sure that the engine cannot be started uninten- systems).
tionally during repair work. (Danger to life!) Handling pressure vessels
l Maintenance and cleaning work on the engine must l Since the fluid container is pressurized, the manu-
only be performed with the engine stopped and facture and testing of these pressure vessels is gov-
cooled down. Make sure that the electric system is erned by the pressure vessel directive. The
switched off and sufficiently secured against being pressure vessels must be repetitively tested by an
switched on again (e.g. pull off ignition key, attach a expert as specified in TRB 532 Inspection by Ex-
warning label). perts, Repetitive Tests. In this case periodically re-
l Observe the accident prevention regulations for curring inspections consist of external
electric systems (e.g. -VDE-0100/-0101/-0104/- examinations, normally on containers in operation.
0105 Electric precautions against dangerous con- In combination with the inspection, the refrigerant
tact voltages). collector must be visually examined two times per
year. Special attention must thereby be paid to
l Cover all electric components properly before wet
signs of corrosion and mechanical damage. If the
cleaning.
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
Air conditioning system erator or third parties against the dangers when
handling or operating pressure vessels.
!Caution l
Secure pressure vessels against tipping over or roll-
Work on air conditioning systems must only be ing away.
carried out by persons who can provide sufficient l
Do not throw pressure vessels! Pressure vessels
evidence of their ability (proof of professionalism) may thereby be deformed to such an extent, that
and only with the appropriate technical equip- they will crack. The sudden evaporation and escape
ment. of refrigerant releases excessive forces. This ap-
l
Always wear goggles and protective clothing when plies also when snapping off valves on bottles. Bot-
performing maintenance and repair work on air con- tles must therefore only be transported with the
ditioning systems. Refrigerant withdraws heat from safety caps properly installed.
the environment when evaporating, which can l
Refrigerant bottles must never be placed near heat-
cause injury by freezing when in contact with skin ing radiators. Higher temperatures will cause higher
(boiling point of R134a -26,5 °C at normal pres- pressures, whereby the permissible pressure of the
sure). vessel may be exceeded.
l Perform maintenance and repair work on air condi- l Do not heat up refrigerant bottles with an open
tioning systems only in well ventilated rooms! Es- flame. Excessive temperatures can damage the
caping refrigerant vapours will mix with the ambient material and cause the decomposition of refriger-
air and displace the oxygen required for breathing ant.
(danger of suffocating).
l
Do not overfill refrigerant bottles, since any temper-
l Smoking is prohibited when performing mainte- ature increase will cause enormous pressures.
nance and repair work on air conditioning systems!
Toxic breakdown products may be generated if re-
frigerant comes into contact with heat. Environment
It is strictly prohibited to release refrigerant into
l Refrigerant should always be extracted and re-
the atmosphere during operation, maintenance
moved by flushing with nitrogen before starting
welding or soldering work near components of the

12 BOMAG 008 918 12

Safety regulations 1.2
and repair work and when taking air conditioning l Dispose of used filters in accordance with applica-
systems into or out of service. ble environmental regulations.
l When performing repair and maintenance work col-
Battery lect oils and fuels in suitable containers and dispose
l Always wear goggles and protective clothing to of in compliance with applicable environmental reg-
service or clean batteries! Battery acid can cause ulations.
severe injury by cauterization when coming in con- l Do not heat up oils higher than 160 °C because they
tact with skin. may ignite.
l Work only well ventilated rooms (formation of oxy- l Wipe off spilled or overflown oil using suitable
hydrogen gas). cleaning means and dispose of in accordance with
l Do not lean over the battery while it is under load, applicable environmental regulations.
being charged or tested (danger of explosion). l Dispose of old batteries according to applicable en-
l Keep ignition sources away from the battery. Burn- vironmental regulations.
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
l Use battery chargers etc. only in strict compliance
engine and hydraulic system to cool down to a suf-
with the operating instructions.
ficient level.
l After an accident with acid flush the skin with a suf- l Do not exceed the max. permissible tire pressure.
ficient amount of water and seek medical advice.
l Do not allow children access to batteries.
l
When mixing battery fluid always pour acid into wa-
ter, never vice-versa.

Special safety regulations

l
Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
l
The installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
l Unauthorized changes to the machine are prohibit-
ed for safety reasons.
l
Do not perform any cleaning work while the engine
is running.
l 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 crushing!).
l
If tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
l
Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
l
Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
l Always ensure an adequate supply of fresh air
when refuelling in closed rooms.

008 918 12 BOMAG 13

1.3 General repair instructions

General Electrics
1.3 General repair instructions

l
Before removing or disassembling parts, assem- General
blies, components or hoses mark these parts for
easier assembly. Due to the fast technical development electric and
electronic vehicle systems become more intelligent
l Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly
or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle
surfaces as required and in compliance with the systems.
compatibility of materials.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l 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:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
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.
l
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l
Do not disconnect or connect battery or generator
while the engine is running.
l
Do not operate the main battery switch under load.
l
Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l
It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!

14 BOMAG 008 918 12

General repair instructions 1.3
l Plug-in connectors on control units are only dust Battery
and water tight if the mating connector is plugged
on! Control units must be protected against spray Rules for the handling of batteries
water, until the mating connector is finally plugged When removing a battery always disconnect the mi-
on! nus pole before the plus pole. When installing the bat-
l Unauthorized opening of control electronics (Micro- tery connect the minus pole after the plus pole to avoid
controller MC), modifications or repairs in the wiring short circuits.
can cause severe malfunctions. Fasten the terminal clamps with a little force as possi-
l
Do not use any radio equipment or mobile phones ble.
in the vehicle cab without a proper aerial or in the vi- Always keep battery poles and terminal clams clean to
cinity of the control electronics! avoid high transition resistances when starting and
the related development of heat.
Electrics and welding
Make sure the battery is properly fastened in the vehi-
cle.
!Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
l Disconnect the minus pole of the battery or interrupt
the electric circuit with the main battery switch.
l Isolate the generator and all control units from the
electric circuit.
l Always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
l When choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.

008 918 12 BOMAG 15

1.3 General repair instructions

Generator Starter motor

Before removing the generator you must disconnect So-called jump starting (using an additional external
the ground cable from the minus pole of the battery battery) without the battery connected is dangerous.
while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in-
the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-
this may cause extremely high voltage peaks in the stroy the electrical installation.
vehicle wiring system ("Load Dump"), which could For purposes like e.g. purging the fuel systems, start-
possibly damage control units, radios or other elec- ers may be operated for maximum 1 minute without
tronic equipment. interruption. Then you should wait for at least 30 min-
When disassembling the battery cable, the B+-nut un- utes (cooling down) until trying again. During the 1
derneath on the generator side may also be loosened. minute starting period this process should not be inter-
This nut must in this case be retightened. rupted.
When connecting e.g. the battery cable to the terminal Starter motors must not be cleaned with high pressure
of the generator you must make sure that the polarity steam cleaning equipment.
is correct (generator B+ to the + pole of the battery). The contacts on starter terminals 30, 45, 50 must be
Mixing up the polarities by mistake causes short cir- protected against unintended shorting (jump protec-
cuit and damage to the rectifier elements - the gener- tion).
ator will be out of function.
When replacing the starter the ring gear on the engine
The generator can only be operated with the battery flywheel must be checked for damage and its number
connected. Under special conditions emergency op- of teeth - if necessary replace the ring gear.
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited. Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
Plus and minus cables must be disconnected during starter itself.
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.

16 BOMAG 008 918 12

General repair instructions 1.3
Hydraulic system l Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).

!Caution
l After changing a component perform a high and
charge pressure test, if necessary check the speed
Repair work on hydraulic elements shall only per-
of the exciter shaft.
formed by appropriately trained personnel or by
the after sales service of BOMAG. l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
Please note ing drum. On hard ground place the drums on a suit-
able base and check the drum pressure. Do not
i Note activate the vibration on a hard, concreted base,
danger of bearing damage.
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system. l After the completion of all tests perform a test run
and then check all connections and fittings for leaks
l Connections and screw fittings, filler neck covers
with the engine still stopped and the hydraulic sys-
and their immediate surrounding areas must be
tem depressurized.
cleaned before removal.
l Before loosening hoses, pipe lines etc. relieve all Before commissioning
pressure from the system. l Fill the housings of hydraulic pumps and motors
l During repair work keep all openings closed with with hydraulic oil. Use only hydraulic oils according
clean plastic plugs and caps. to the specification in the maintenance instructions.
l Never run pumps, motors and engines without oil or
l
After changing a component flush the hydraulic sys-
hydraulic oil. tem as described in the flushing instructions.
l When cleaning hydraulic components take care not Taking into operation
to damage any fine machine surfaces. l
Bleed the hydraulic circuits.
l Chemical and rubber soluble cleansing agents may l
Start up the hydraulic system without load.
only be used to clean metal parts. Do not let such
substances come in contact with rubber parts.
l
Check the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
l Rinse of cleaned parts thoroughly, dry them with erating and maintenance instructions or drain oil off
compressed air and apply anti-corrosion oil immedi- into a suitable container.
ately. Do not install parts that show traces of corro-
sion. After taking into operation
l Avoid the formation of rust on fine machined caused l
Check fittings and flanges for leaks.
by hand sweat. l
After each repair check all adjustment data, system
l Use new O-rings or seal rings for reassembly. pressures, rotational speeds and nominal values in
l Use only hydraulic oil as sliding agent when reas- the hydraulic system, adjust if necessary.
sembling. Do not use any grease! l
Do not adjust pressure relief valves and control
l Use only the specified pressure gauges. Risk of valves to values above their specified values.
damaging the pressure gauges under too high pres-
sure.
l Check the hydraulic oil level before and after the
work.
l Fill in only clean oil as specified in the maintenance
instructions.
l Check the hydraulic system for leaks, if necessary
find and rectify the cause.
l Before taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
l After changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.

008 918 12 BOMAG 17

1.3 General repair instructions

Air conditioning system l Damaged or leaking parts of the air conditioning

must not be repaired by welding or soldering, but
Chemicals/ozone layer regulation must generally be replaced.
The chemicals/ozone layer regulation, which became l Do not fill up refrigerant, but extract existing refrig-
effective on 01.12.2006, supplements the still directly erant and refill the system.
applicable regulation (EG) no. 2037/2000 from
29.06.2000 concerning substances, which cause de-
l Different types of refrigerant must not be mixed.
composition of the ozone layer and at the same time Only the refrigerant specified for the corresponding
replaces the previously valid German CFC-halon air conditioning system must be used.
0prohibition from 06.05.1991. l Refrigerant circuits with refrigerant type R134a
Work on air conditioning systems must only be carried must only be operated with the compressor oil / re-
out by persons who: frigeration oil approved for the compressor.
l have proven to have sufficient expert knowledge, l Used compressor oil/refrigeration oil must be dis-
l have the necessary equipment to undertake such posed of in strict compliance with applicable envi-
tasks, ronmental regulations.
l are reliable and l Due to its chemical properties compressor oil / re-
frigeration oil must never be disposed of together
l are not any directives regarding their activities when
with engine or transmission oil.
carrying out inspection and maintenance work acc.
to § 4 section 2 of the chemical/ozone layer regula- l Compressor oil / refrigeration oil is highly hydro-
tion. scopic. Oil cans must strictly be kept closed until
The inspection and maintenance tasks, including leak use. Oil rests should not be used, if the can had
tests and possible repair activities, must be recorded been opened over a longer period of time.
in the operating instructions together with information l
All O-rings/seal rings as well as pipe/ hose fittings
about the refrigerant quantities used and regained, must be oiled with compressor/refrigeration oil bfore
whereby the operator is obliged to keep these records assembly.
over a period of at least five years. l
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil/refrigeration oil
i Note lost by exchanging the components, must be re-
Cleanliness is of utmost importance. Dirt and other placed with fresh oil.
contaminations must strictly be kept out of the system. l
A too high compressor oil / refrigeration oil level ad-
l Tools used on refrigeration circuits must be of ex- versely affects the cooling performance and a too
cellent condition, thus to avoid the damage of any low oil level has a negative effect on the lifetime of
connections. the compressor.
l
During repairs on refrigerant lines and components,
l
Use new O-rings or seal rings for reassembly.
these must be kept closed, as far as this is possible, l
Always used 2 spanners to work on pipes/hoses to
to prevent the system from being contaminated by avoid damages .
air, moisture and dirt. The operational safety of the l Tighten screw fittings with the specified torque.
system can only be assured as long as all compo-
nents in the refrigerant circuit are kept internally l
Check all pipes/hoses, screw fittings or components
clean and dry. for damage, replace if necessary.
l Connections, screw fittings and their immediate sur- l Do not leave the refrigerant circuit unnecessarily
rounding areas must be cleaned before removal. open to the atmosphere.
l Before loosening hoses, pipe lines etc. relieve all l
In case of a repair on the refrigeration system you
pressure from the system. should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
l During repair work keep all openings closed with
system, before you start to refill. Moisture bonded in
clean plastic plugs and caps.
the compressor oil / refrigeration oil (PAG oil) can
l All parts to be reused should be cleaned with a only be removed from the system by changing the
gasoline free solvent and blow-dried with clean oil.
compressed air or dried with a lint-free cloth. l Compressor valves must only be opened after the
l Before opening all components should have system has been properly sealed.
warmed up to ambient temperature, to avoid that l The use of leak detection spray is not permitted. If
damp air is drawn into the component by the differ-
such substances are used the WARRANTY will be-
ence in temperatures.
come null and void.

18 BOMAG 008 918 12

General repair instructions 1.3
l If the air conditioning system had been opened for Fuel hoses
repair work, a new drier should be installed in the re-
frigerant circuit.
l After completion of repair work screw locking caps
(with seals) on all valve connections service con-
nections.
l 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 Fig. 1
speed and maximum cooling power.
l Never run the compressor with an insufficient ! Caution
amount of refrigerant. 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.

008 918 12 BOMAG 19

1.3 General repair instructions

Gaskets and mating surfaces able, you should use a plastic tube or adhesive tape
to prevent the sealing lip from being damaged.
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets. l Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal
and press it flat on the housing seat.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
in the repair instructions.
l If necessary remove any old sealing compound be-
fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
l Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the
compound does not enter into oil galleries or blind Fig. 3
threaded bores.
l
Press or knock the seal into the housing, until it is
l
Examine the contact faces for scratches and burrs, flush with the housing surface.
remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components. i Note
If possible, use a "bell" (1 (Fig. 3)), to make sure that
l
Blow out lines, ducts and gaps with compressed air,
the seal will not skew. In some cases it may be ad-
replace any O-rings and seals that have been dis-
visable to assemble the seal into the housing first, be-
lodged by the compressed air.
fore sliding it over the shaft. Under no circumstances
Assembly of radial seals should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.

Fig. 2
l
Lubricate the sealing lips (2) (Fig. 2) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l
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. 2)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-

20 BOMAG 008 918 12

General repair instructions 1.3
Feather keys and keyways Ball and roller bearings

Caution
! !Caution
Feather keys may only be reused if they are free of Ball and roller bearings may only be reused if they
damage. are free of damage and do not show any signs of
wear.

Fig. 4
l Clean and thoroughly examine the feather key.
l Deburr and thoroughly clean the edges of the key-
way with a fine file before reassembling.

Fig. 5
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.

008 918 12 BOMAG 21

1.3 General repair instructions

l Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between ball or roller
bearing and seats. Tightening torque
l Make sure that shaft and housing are free of burrs
before assembling the ball or roller bearing. !Caution
l Always mark the individual parts of separable ball or Tighten nuts or screws with the tightening tor-
roller bearings (e.g. taper roller bearings) to enable ques specified in the following tables of tighten-
correct reassembling. Never assemble the rollers to ing torques. Tightening torques deviating from
an outer race that has already been used, replace the ones in the table are specially mentioned in
the complete ball or roller bearing instead. the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
Fig. 6
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
!Caution
specified tightening torque you should first relieve
When assembling the ball or roller bearing to the by a quarter turn and then tighten to the correct
shaft load must only be applied to the inner race 1 torque.
(Fig. 6).
l Before tightening you should lightly oil the thread, in
When fitting the bearing into the housing load order to ensure low friction movement. The same
must only be applied to the outer race (2). applies for self-locking nuts.
l Make sure that no oil or grease will enter into blind
tapped bores. The hydraulic power generated when
turning in the screw could cause breakage of the ef-
fected part.

22 BOMAG 008 918 12

General repair instructions 1.3
Strength classes, 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. 8 Identification of nuts

In a connection with a screw, these nuts 1 (Fig. 8)
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. 7 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,
l
The nominal tensile strength is 12 X 100 N/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. 8) 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. 8), 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.
l 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.

008 918 12 BOMAG 23

1.3 General repair instructions

Identification in clock system Identification of UNF-threads

Fig. 9 Identification of nuts in clock system

For small nuts (Fig. 9) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
l
The strength class is identified by a dash (b).
Fig. 10

Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 10).

Nuts
An uninterrupted series of stamped in circles parallel
to the axis of the nut on a hexagon area (2).

Studs and brake rods

At the outmost end a short end of the component is re-
duced to its core diameter (1).

24 BOMAG 008 918 12

General repair instructions 1.3
Cotter pins

Fig. 11
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.

008 918 12 BOMAG 25

1.4 Tightening torques

The values specified in the table apply for screws:

1.4 Tightening torques

l black oiled
l with surface protection A4C
l 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 thread*

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
* Coefficient of friction μ tot. = 0,14

Tightening torques for screws with metric unified fine thread*

Tightening torques Nm
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
* Coefficient of friction μ tot. = 0,14

26 BOMAG 008 918 12

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)

Tightening torques Nm
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
* 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) * **

Tightening torques Nm
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
* Coefficient of friction μ tot. = 0,14
** These values result in a 90% utilization of the yield point

008 918 12 BOMAG 27

1.4 Tightening torques

The values specified in the table apply for screws:

l black oiled
l with surface protection A4C
l 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, * UNC Unified Coarse Thread Series, American Unified
Coarse Thread

Tightening torques Nm
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
* Coefficient of friction μ tot. = 0,14

Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread

Tightening torques Nm
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 008 918 12

Tightening torques 1.4
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread

Tightening torques Nm
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
* Coefficient of friction μ tot. = 0,14

008 918 12 BOMAG 29

1.4 Tightening torques

30 BOMAG 008 918 12

2 Technical data

008 918 12 BOMAG 31

2.1 Technical data

2.1 Technical data

Fig. 12

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 216 D-40 2960 2300 1500 2268 2985 490 5930 85 85 35 2130
BW 216 PD-40 2960 2300 1480 2268 2985 490 5930 85 85 25 2130

* BW 216 D-40 BW 216 PD-40

Weights
Max. operating weight kg 17100 16400
Max. axle load, drum (CECE) kg 11700 11000
Max. axle load, wheels (CECE) kg 5400 5400
Operating weight (CECE) kg 15200 15700
Axle load, drum (CECE) kg 10200 10700
Axle load, wheels (CECE) kg 5000 5000
Max. static linear load (CECE) kg/cm 54.9 -

Travel characteristics
Travel speed (1) km/h 0 ... 4 0 ... 4
Travel speed (2) km/h 0 ... 5 0 ... 5
Travel speed (3) km/h 0 ... 7 0 ... 7
Travel speed (4) km/h 0 ... 11 0 ... 11
Max. gradability without/with vibration (soil de- % 48/45 50/47
pendent)

Drive
Engine manufacturer Deutz Deutz
Type BF4M 1013 C BF4M 1013 C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO 3046 kW 114 114
Rated power SAE J 1995 hp 153 153
Rated speed rpm 2200 2200
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Permissible ambient temperatures °C -20 ... +50 -20 ... +50

32 BOMAG 008 918 12

Technical data 2.1
*
BW 216 D-40 BW 216 PD-40
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.

Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Steering/oscillation angle ±° 35/12 35/12
Inner track radius mm 3494 3494

Vibration
Drive system hydrostatic hydrostatic
Frequency (1/2) Hz 30/36 30/36
Amplitude (1/2) mm 1.80/0.90 1.70/0.86
Centrifugal force (1/2) kN 275/202 275/202

Tires
Tire size 23.1-26/12PR TL C7 23.1-26/12PR TL R1
Air pressure bar 1.4 1.4

Filling capacities
motor l approx. 14 approx. 14
Fuel l approx. 250 approx. 250
Hydraulic oil l approx. 60 approx. 60
Coolant l approx. 16 approx. 16
* The right for technical modifications remains reserved

008 918 12 BOMAG 33

2.1 Technical data

Fig. 13

Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 218 D-40 2960 2480 1500 2268 2985 490 5930 175 175 35 2130

*
BW 218 D-40
Weights
Max. operating weight kg 19100
Max. axle load, drum (CECE) kg 13400
Max. axle load, wheels (CECE) kg 5700
Operating weight (CECE) kg 17200
Axle load, drum (CECE) kg 12000
Axle load, wheels (CECE) kg 5200
Static linear load (CECE) kg/cm 56.3
Max. static linear load (CECE) kg/cm 62.9

Travel characteristics
Travel speed (1) km/h 0 ... 4
Travel speed (2) km/h 0 ... 5
Travel speed (3) km/h 0 ... 7
Travel speed (4) km/h 0 ... 11
Max. gradability without/with vibration % 48/45
(soil dependent)

Drive
Engine manufacturer Deutz
Type BF4M 1013 EC
Cooling Water
Number of cylinders 4
Rated power DIN ISO 3046 kW 114
Rated power SAE J 1995 hp 153
Rated speed rpm 2200
Fuel Diesel
Electrical equipment V 12
Drive system hydrostatic
Permissible ambient temperatures °C -20 ... +50

Brakes

34 BOMAG 008 918 12

Technical data 2.1
*
BW 218 D-40
Service brake hydrostatic
Parking brake hydr.-mech.

Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic

Vibration
Vibrating drum 1
Drive system hydrostatic
Frequency (1/2) Hz 30/36
Amplitude (1/2) mm 1.80/0.90
Centrifugal force (1/2) kN 275/202

Tires
Tire size 23.1-26/12PR TL C7
Air pressure, nominal value bar 1.4
Air pressure, span bar 0.8 - 1.4

Filling capacities
motor l approx. 14
Fuel l approx. 250
Hydraulic oil l approx. 60
Coolant l approx. 16
* The right for technical modifications remains reserved

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 900 ± 200
High idle speed rpm 2430 ± 50
Specific fuel consumption g/kWh 235
Valve clearance intake mm 0.3
Valve clearance exhaust mm 0.5
Injection valves opening pressure bar 275
Starter power kW 3.1

Travel pump
Manufacturer Sauer
Type 90R075
System Axial piston/swash plate
Max. displacement cm3/rev 75
Max. flow capacity l/min 163.65
High pressure limitation bar 420 + 20
Charge pressure, high idle bar 26 + 3

Drum reduction gear

Type CR31
Transmission ratio 45.6

Drum drive motor

Manufacturer Sauer
Type 51C 110
System Axial piston – bent axle
Displacement (stage 1) cm3/rev 110

008 918 12 BOMAG 35

2.1 Technical data

Displacement (stage 2) cm3/rev 39

Perm. leak oil rate l/min 2
Flushing rate l/min 16
Flushing limitation bar 16

Axle drive motor

Manufacturer Sauer
Type 51D 110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/U 110
Min. displacement (stage 2) cm3/U 39
Perm. leak oil rate l/min 2
Flushing rate l/min 16
Flushing limitation bar 16

Vibration pump (BW216 D/PD-40)

Manufacturer Sauer
Type 42R 041
System Axial piston/swash plate
Max. displacement cm3/rev 41
Starting pressure bar 350 + 50
Operating pressure (soil dependent) bar approx. 100

Vibration pump (BW218 D-40)

Manufacturer Sauer
Type 42R 055
System Axial piston/swash plate
Max. displacement cm3/rev 55
Starting pressure bar 350 + 50
Operating pressure (soil dependent) bar approx. 100

Vibration motor (BW216 D/PD-40)

Manufacturer Bosch-Rexroth
Type A10FM45
System Axial piston/swash plate
Displacement cm3/U 45
Flushing rate l/min 6
Flushing pressure limitation bar 13

Vibration motor (BW218 D-40)

Manufacturer Sauer
Type 90M 055
System Axial piston/swash plate
Displacement cm3/U 45
Flushing rate l/min 6
Flushing pressure limitation bar 13

Steering/charge pump
Type HY/ZFFS11/16
System Gear pump
Displacement cm3/rev 16
Max. steering pressure when bar 200 + 20
steered against end stops

36 BOMAG 008 918 12

Technical data 2.1

Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool

Rear axle
Manufacturer Dana
Type CHC 193/66LD
Differential No-Spin
Degree of locking % 100
Reduction ratio 65.08

008 918 12 BOMAG 37

2.1 Technical data

38 BOMAG 008 918 12

3 Maintenance

008 918 12 BOMAG 39

3.1 General notes on maintenance

3.1 General notes on maintenance Notes on the performance of the engine

On diesel engines both combustion air and fuel injec-
When performing maintenance work always comply
with the appropriate safety regulations. tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
Thorough maintenance of the machine guarantees far gas quality of the engine.
longer safe functioning of the machine and prolongs
If your engine has to work permanently in "thin air" (at
the lifetime of important components. The effort need-
higher altitudes) and under full load, you should con-
ed for this work is only little compared with the prob-
sult the customer service of BOMAG or the customer
lems that may arise when not observing this rule.
service of the engine manufacturer.
The terms right/left correspond with travel direction
forward.
Notes on the cooling system
l Support the engine hood for all maintenance and
Prepare and check coolant with highest care, since
repair work.
otherwise the engine may be damaged by corrosion,
l Always clean machine and engine thoroughly be- cavitation and freezing.
fore starting maintenance work.
Coolant is prepared by adding an ethylene-glycol
l For maintenance work stand the machine on level based anti-freeze agent with corrosion inhibiting prop-
ground. erties to the cooling water.
l Perform maintenance work only with the motor Mixing with cooling system protection agent is neces-
switched off. sary in all climatic zones. It prevents corrosion, lowers
the freezing point and raises the boiling point of the
l
Relieve hydraulic pressures before working on hy-
coolant.
draulic lines.
l
Before working on electric parts of the machine dis- Notes on the hydraulic system
connect the battery and cover it with insulation ma-
terial. During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
l
When working in the area of the articulated joint at- dirt or other contaminating substances can enter into
tach the articulation lock (transport lock). the system. Small particles can produce flutes in
valves, cause pumps to seize, clog nozzles and pilot
Environment bores, thereby making expensive repairs inevitable.
During maintenance work catch all oils and fuels l
If, during the daily inspection of the oil level the hy-
and do not let them seep into the ground or into draulic oil level is found to have dropped, check all
the sewage system. Dispose of oils and fuels en- lines, hoses and components for leaks.
vironmentally. l
Seal external leaks immediately. If necessary in-
Keep used filters in a separate waste container form the responsible customer service.
and dispose of environmentally. l
Do not store drums with hydraulic oil outdoors, or at
Catch biodegradable oils separately. least under a cover. Water can be drawn in through
the bunghole when the weather changes.
Notes on the fuel system l We recommend to use the BOMAG filling and filter-
The lifetime of the diesel engine depends to a great ing unit with fine filter to fill the system. This ensures
extent on the cleanliness of the fuel. finest filtration of the hydraulic oil, prolongs the life-
time of the hydraulic oil filter and protects the hy-
l Keep fuel free of contaminants and water, since this draulic system.
will damage the injection elements of the engine.
l
Clean fittings, filler covers and the area around such
l Drums with inside zinc lining are not suitable to parts before disassembly to avoid entering of dirt.
store fuel.
l Do not leave the tank opening unnecessarily open,
l When choosing the storage place for fuel make but cover it so that nothing can fall in.
sure that spilled fuel will not harm the environment.
l Do not let the hose stir up the slurry at the bottom of
the drum.
l
The fuel drum must rest for a longer period of time
before drawing off fuel.
l The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes.

40 BOMAG 008 918 12

Fuels and lubricants 3.2
3.2 Fuels and lubricants

Engine oil
Quality
For use in DEUTZ engines the lubrication oils are
classified in DEUTZ Lubrication Oil Quality Classes
(DQC).

Approved engine oils

Deutz ACEA* API** DHD

DQC II-05 E3-96, CG-4, DHD-1

E5-02, CH-4,
E7-08, CI-4,
E4-07 CI-4 Plus

DQC II-05 - - -

DQC IV-05 - - -
* Association des Constructeurs European d’Automobiles
** American Petroleum Institute

The list of approved lubrication oils is also available in

the Internet under the following address:

www.deutz.com
Fig. 14
de >>SERVICE >> Fuels and lubricants and Optimal operating conditions can be achieved by us-
diagnostics >> DeutzQualityClass >> ing the oil viscosity chart (Fig. 14) as a reference.
DQC-Release list
At ambient temperatures below -40 °C the lubrication
en >>SERVICE >> Fuels and lubricants and oil must be pre-heated (e.g. by parking the machine
diagnostics >> DeutzQualityClass >>DQC- indoors).
release list The viscosity is classified acc. to SAE. Multi-purpose
oils should generally be used.
Consult your local service station if in doubt.
Oil change intervals
l Use winter grade engine oil for winter operation!
The longest permissible time a lubrication oil should
Oil viscosity remain in an engine is 1 year. If the following oil
Since lubrication oil changes its viscosity with the tem- change intervals are not reached over a period of 1
perature, the ambient temperature at the operating lo- year, the oil change should be performed at least once
cation of the engine is of utmost importance when per year, irrespective of the operating hours reached.
choosing the viscosity class (SAE-class) . DQC II, DQC
Too high viscosity can cause starting difficulties, too III, DQC IV= 500 operating hours
low ´viscosity can jeopardize the lubrication effect and
result in a high lubrication oil consumption. ! Caution
When using fuels with a sulphur content of more
than 0,5% to 1% or under permanent ambient tem-
peratures below -10°C and when using biodegrad-
able diesel fuel the oil change intervals must be
halved.

Fuels
You should only use commercially available brand
diesel fuel with a sulphur content of less than 0.5%
and ensure strict cleanliness when filling in. A higher

008 918 12 BOMAG 41

3.2 Fuels and lubricants

sulphur content has a negative effect on the oil

change intervals. Fresh water analysis values

The fuel level should always be topped up in due time Conversion to other units:
so that the fuel tank is never run dry, as otherwise filter
and injection lines need to be bled. - German degree (°dH)] max. 20

Quality - English degree (°eH)] max. 25

The following fuel specifications are permitted: - French degree (°fH)] max. 36.5
l
EN 590
corresponds with the content of max. 356
l
DIN 51628 CaCO3 (mg/l) (ppm)
l
ASTM D975 Grade-No. 1-D and 2-D.
l
JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lu- Information concerning the water quality can be ob-
brication properties acc. to EN 590 tained from the waterworks.

Winter fuel If the fresh water analysis values are unknown, these
must be determined with the help of a water analysis.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. Diesel If the values of the analysis deviate, the water must be
fuels suitable for temperatures down to -44 °C (-47 treated accordingly.
°F) are available for Arctic climates. At very low tem- l pH-value too low
peratures disturbing paraffin separation can also be Adding of caustic lye of soda or caustic potash so-
expected when using winter diesel fuel. lution.
The admixture of petroleum and the addition of "flow l
Water hardness too high:
enhancing additives" (fuel additives) is not permitted. Mix with soft, distilled or fully demineralized water
l
Chlorides and/or sulphates too high:
Coolant Mix with distilled or fully demineralized water
For fluid cooled engines the cooling fluid must be pre- l
Total hardness or carbonate hardness too low:
pared by admixing a cooling system protection agent Mix with hardened water (harder water is in most
to the fresh water and should be checked within the cases available in the form of drinking water).
specified maintenance intervals.
This prevents damage caused by corrosion, cavita-
!Caution
tion, freezing and overheating.
Another analysis must be made after the fresh wa-
Fresh water quality ter has been prepared.
The correct quality of water is highly important when
Cooling system protection agent
preparing coolant. Clear and clean water within the
boundaries of the following analysis values should As a protection against frost, corrosion and boiling
generally be used. point anti-freeze agents must be used under any cli-
matic conditions.
Coolant for fluid cooled engines is prepared by adding
Fresh water analysis values an ethylene-glycol based anti-freeze agent with corro-
sion inhibiting properties to the cooling water.
pH-value at 20 °C (68 °F) 6.5 - 8.5
We therefore highly recommend our BOMAG cooling
Chloride ion content (mg/l) (ppm) max. 100 system protection agent.
Sulphate ion content (mg/l) max. 100 If our cooling system protection agent is not available
(ppm) for any important reasons, you may, in exceptional
cases, use products that have been approved by the
Water hardness (ion content of max. 3.56 engine manufacturer.
calcium and magnesium )
The list of approved cooling system protection agents
(mmol/l)]
is also available in the Internet under the following ad-
dress:

42 BOMAG 008 918 12

Fuels and lubricants 3.2
Mineral oil based hydraulic oil
www.deutz.com The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic Viskosität von 46 mm2/s bei
de >>SERVICE >> Betriebsstoffe und Addi- 40 °C und 8 mm2/s bei 100 °C betrieben. For topping
tive >> Kühlsystemschutz >> Kühlsystem- up or for oil changes use only high-quality hydraulic
schutz Technisches Rundschreiben oil, type HVLP according to DIN 51524, part 3, or hy-
draulic oils type HV according to ISO 6743/3. The vis-
en >>SERVICE >> Operating Liquids and Ad- cosity index (VI) should be at least 150 (observe
ditives >> Cooling System Conditioner >> information of manufacturer).
Flyer Cooling System Conditioner Techni-
cal Circular
Bio-degradable hydraulic oil
Products of the same product group (see Deutz Tech- The hydraulic system can also be operated with a syn-
nical Circular Cooling System Protection Agents) can thetic ester based biodegradable hydraulic oil.
be mixed with each other. The biologically quickly degradable hydraulic oil Pan-
The BOMAG cooling system protection agent corre- olin HLP Synth.46 meets all demands of a mineral oil
sponds with product group A. based hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46
! Caution always use the same oil to top up.
Do not mix different coolants and additives of any When changing from mineral oil based hydraulic oil to
other kind. an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufactur-
Before changing the product you must clean the er for details.
entire cooling system.
Consult your local service station if in doubt.
! Caution
To ensure proper corrosion protection you must use Check the filter more frequently after this change.
the cooling system protection agent all year around,
whereby the following concentration must not be fall- Perform regular oil analyses for content of water
en short of or exceeded. and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.
Mixing ratio

Cooling sys- Fresh water Cold protec- Oil for drive axle
tem protection tion down to Quality
agent
Forthe drive axle use only multi-purpose gear oils of
min. 35% 65% -22 °C (-8 °F) API-GL5-class, SAE 90.
This is a hypoid lubricant of highest quality class for
40% 60% -28 °C (-18 °F)
extremely loaded transmissions.
45% 55% -35 °C (-31 °F) The additives in this oil ensure low wear lubrication
under all operating conditions.
max. 50% 50% -41 °C (-42 °F)

Lubrication grease
! Caution
For lubrication purposes use an EP-high pressure
A proportion of more than 50% of cooling system grease, lithium saponified (penetration 2), acc. to DIN
protection agent causes a drop in cooling power. 51502 KP 2G.
The use of corrosion protection oils as cooling
system protection agents is not permitted.

i Note
When working at temperature below -41 °C(-42 °F)
you should consult our local service representative.

Environment
Coolant must be disposed of environmentally.

008 918 12 BOMAG 43

3.3 Table of fuels and lubricants

3.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity

Summer Winter Attention

Observe the level marks

Engine

- Engine oil ACEA: E3-96, E5-02, E7-08, E4-07 approx. 14 litres

API: CG-4, CH-4, CI-4, CI-4 Plus

SAE 10W-40 (-15 °C to +40 °C)

SAE 15W-40 (-5 °C to +40 °C)

SAE 5W-40 (-30 °C to +40 °C)

- Fuel Diesel Winter diesel fuel approx. 300 litres

- Coolant Mixture of water and anti-freeze agent* approx. 16 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. Viscosity approx. 60 litres
46 mm2/s at 40 °C with viscosity index (VI) >150 or
ester based biodegradable hydraulic oil

Vibration bearings SAE 15W-40 approx. 2 x 1.0 litres

Drive axle SAE 90, API GL5 approx. 11 litres

Wheel hubs SAE 90, API GL5 approx. 2 litres (per side)

Axle reduction gear SAE 90, API GL5 approx. 1.9 litres

Drum drive reduction gear SAE 90, API GL5 approx. 3.2 litres

Tires Water approx. 295 litres

Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)

Air conditioning system Refrigerant R134a approx. 1500 g

* see chapter "Fuels and Lubricants - Colant"

44 BOMAG 008 918 12

Running-in instructions 3.4
3.4 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

l Retighten the V-belt

After 250 operating hours

l Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
l Retighten the bolted connections on the machine.
l Retighten all wheel fastening screws with the spec-
ified tightening torque.
l Change engine oil and oil filter
l 1. Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
l Oil change, axle reduction gear
l 1. Oil change in drum drive reduction gear

After 500 operating hours

l 2. Oil change vibration bearings
l
Choose 2nd Oil change in drum drive reduction
gear

008 918 12 BOMAG 45

3.4 Running-in instructions

46 BOMAG 008 918 12

4 Caddy wiring diagrams

008 918 12 BOMAG 47

4.1 Understanding circuit diagrams

4.1 Understanding circuit diagrams

Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do
not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry
logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.

Structure
l Table of contents (Fig. 15)
l Function groups (Fig. 16)
l List of components (Fig. 18)

48 BOMAG 008 918 12

Understanding circuit diagrams 4.1
Table of contents (Fig. 15)
The table of contents lists all function groups.

Fig. 15 Table of contents

Example:
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.

008 918 12 BOMAG 49

4.1 Understanding circuit diagrams

Function groups (Fig. 16)

On the individual pages the electric circuits are combined to function groups.

Arrangement of current paths

The individual current paths must be read as follows:
l From top (plus potential) to bottom (minus potential).
l From left to right.
l From function group to function group.
l Via cross references for potentials and relays.

Fig. 16 Function groups

Potential cross references

Potential cross references serve the purpose of tracking signals, which are transmitted from one function group
to another.

Example:
Potential "15" on page no. 6 is continued to the left on page no. 4 in current path "10" and to the right on page
no. 8 in current path "1“.

Relay cross reference

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is
additionally attached to the bottom of each contactor coil.

Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is trig-
gered.
The changeover contact can be found on page no. 8 in current path "3".

50 BOMAG 008 918 12

Understanding circuit diagrams 4.1
Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 17) (0 ..... 20).

Fig. 17 Current paths

008 918 12 BOMAG 51

4.1 Understanding circuit diagrams

List of components (Fig. 18)

Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).

Fig. 18 List of components

Component cross references

Example:
The warning horn "B 11" is located on page no. 8 in current path 3.

52 BOMAG 008 918 12

Circuit symbols in the circuit diagram 4.2
4.2 Circuit symbols in the circuit diagram
Circuit symbol
l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a sim-
plified representation of complete systems, from which, however, the function can be clearly identified. This
standardization is in compliance with the globally valid regulations of the IEC (International Electrical Commis-
sion). The standardization serves the purpose of global understanding and fault free connection of appliances,
especially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects,
the circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance
of mistakes.

Fig. 1 Example: Circuit 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)

008 918 12 BOMAG 53

4.3 Identification of switch blocks in the Caddy wiring diagram

4.3 Identification of switch blocks in the Caddy wiring diagram

Switches of modular design

l For normally open contacts the contact symbols "_3/_4" are used.
l For normally closed contacts the contact symbols "_1/_2" are used.
In combination with the contact block numbering described above each individual connection is clearly defined.

Example of terminal designations

Fig. 2 Terminal designations

l
Normally open contact 23 located on block 2
l
Normally open contact 24 located on block 2
l
Normally closed contact 12 located on block 1
l
Normally closed contact 11 located on block 1
l
Normally open contact 34 located on block 3
l Normally open contact 33 located on block 3
l
Normally open contact 63 located on block 6
l
Normally open contact 64 located on block 6
l Normally open contact 43 located on block 4
l
Normally open contact 44 located on block 4

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 unchanged.

54 BOMAG 008 918 12

Designation of components in the wiring diagram 4.4
4.4 Designation of components in the wiring diagram
The designation of components in the wiring diagram groups several electrical parts of the machine in one
group. The components can be identified by the following table.

Component designa- Meaning

tion
A Interval switch, indicator relay, modules, electronic component
B Pressure, pressure differential, temperature switches and sensors, transducers
C Capacitor
E Headlights, heater, air conditioning condenser
F Fuses
G Battery, generator
H Control lights, warning buzzer, warning light
K Relays
M Starter, pumps, motors
P Operating hour meter, general gauges
R Transducers, resistors
S Switches, momentary contact switches
V Diode
X Terminal
Y Solenoid valves

008 918 12 BOMAG 55

4.5 Terminal designations in wiring diagram

4.5 Terminal designations in wiring diagram

l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a
terminal designation. In Germany the designation of the individual connection terminals is determined by the
standard DIN 72552. The following table shows some examples from this DIN standard.

Terminal designation Meaning

15 Switch plus (after battery) : Output of ignition 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

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

53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding

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

61 Generator control

75 Radio, cigarette lighter

76 Loudspeaker

87 Relay contact on breaker and two-way contact, input

56 BOMAG 008 918 12

Terminal designations in wiring diagram 4.5
Terminal designation Meaning
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 positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
DF2 Dynamo field 2 (generator excitation current)

008 918 12 BOMAG 57

4.5 Terminal designations in wiring diagram

58 BOMAG 008 918 12

5 E-Plan wiring diagrams

008 918 12 BOMAG 59

5.1 Understanding wiring diagrams

5.1 Understanding wiring diagrams

Electric circuit diagrams

Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do
not contain any information on the type of wiring, their purpose is solely the clarification of control logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, etc.
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.

Structure of a wiring diagram

l Cover sheet, see section "Cover sheet"
l Table of contents, see section "Table of contents"
l Structuring symbol overview, see section "Structuring symbol overview"

i Note
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local iden-
tification!
l Sheets with illustration of function, see section"Sheets with illustration of function"
l List of fuels and lubricants, see "List of fuels and lubricants"
l Terminal strip overview, see section "Terminal strip overview"
l Plug overview, see section "Plug overview"
l Pin overview, see section "Pin overview"

60 BOMAG 008 918 12

Understanding wiring diagrams 5.1
Cover sheet
The cover sheet, see example (Fig. 3), contains general information.

Fig. 3 Example: Cover sheet

008 918 12 BOMAG 61

5.1 Understanding wiring diagrams

Table of contents
The table of contents, see example (Fig. 4), lists the individual functions and identifies the corresponding sheets
in the wiring diagram.

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Fig. 4 Example: Table of contents

62 BOMAG 008 918 12

Understanding wiring diagrams 5.1
Sheets with representations of functions
l
The main reading direction is sheet by sheet, from top to bottom and from left to right.
l All sheets are successively numbered.
l BOMAG used the resolved type of representation. In this case parts and components with different functions,
which belong to the same components (e.g. relay coil and relay contact), can be represented on different
sheets. Cross-references, which refer to the sheet and current path, serve as linkage between these partial
components (Fig. 5).

Structuring symbols
Relay cross-reference Potential cross-reference

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Mimic diagram of relay Current paths

Fig. 5 Example: Sheet with functions

Current paths (Fig. 5)

l Current paths are successively numbered from 0 to 9.

Potential cross references (Fig. 5)

l Potential cross references serve the purpose of tracking signals, which are transmitted from one representa-
tion of a function to another. Potential cross-references may additionally have structuring symbols assigned
to them.
Example: Potential 15_54 +SEAT/16.1 (on sheet 4, current path 8) continues to the right on sheet 16, current
path 1. +SEAT is the structuring symbol.

008 918 12 BOMAG 63

5.1 Understanding wiring diagrams

Relay cross references (Fig. 5)

l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring
diagram is additionally attached to the bottom of each contactor coil.
Example: The relay cross-reference (-K61/4.2) (on sheet 4, current path 4) indicates that the relay coil on sheet
4 is found in current path 2.

64 BOMAG 008 918 12

Understanding wiring diagrams 5.1
List of component
The list of components, see example (Fig. 6), is the first evaluation list that follows the representation of function.
This list contains all components used in the wiring diagram, except terminal strips and plugs.

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Fig. 6 Example: List of components

An electric component is a part, assembly or device in an electrical installation.
l
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standard DIN - EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same
component. In this context the term "component" is always considered a function specific assignment and
does not represent a parts or article number. This ensures that the component with the designation "S04" al-
ways refers to the "Brake Switch", irrespective of whether the abbreviation is used in a wiring diagram for a
single drum roller, a tandem roller, a finisher or a milling machine.
l
The component identifications are alphabetically sorted in the list of components. Each component has the
corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which in-
stallation location it is assigned to and to which part of the system it belongs to. Moreover, the functions (func-
tion text) and the technical characteristics are also described.

i Note
Component identifications are used in both the electrical and the hydraulic documentation and are identical.

008 918 12 BOMAG 65

5.1 Understanding wiring diagrams

Overview of terminal strips

The overview of terminal strips, see axample (Fig. 7), contains all terminal strips used in the circuit diagram.
Each terminal strip starts on a new page and can be localized via the cross-reference in the wiring diagram.

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Fig. 7 Example: Terminal strip overview X1

66 BOMAG 008 918 12

Understanding wiring diagrams 5.1
Overview of plugs
The overview of plugs, see example (Fig. 8), contains all plugs used in the circuit diagram.
The following information is listed for each plug:
l Contact numbering
l Structuring symbols
l Function text
l Use in wiring diagram.

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Fig. 8 Example: Plug overview X0

008 918 12 BOMAG 67

5.1 Understanding wiring diagrams

Overview of pins
The overview of pins, see example (Fig. 9), informs about the type of inputs and outputs of the electronic controls
(E-BOX) used in the machine, as well as their signals and potentials.

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Fig. 9 Example: Overview of pins, control A66

68 BOMAG 008 918 12

Circuit symbols in the circuit diagram 5.2
5.2 Circuit symbols in the circuit diagram

Circuit symbols
Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a simpli-
fied representation of complete systems, from which, however, the function can be clearly identified. This stand-
ardization is in compliance with the globally valid regulations of the IEC (International Electrical Commission).
The standardization serves the purpose of global understanding and fault free connection of appliances, espe-
cially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects, the
circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance of
mistakes.

Fig. 10 Example: Circuit 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
10Fuse
11Terminal strip
12Plug
Different symbols are used to simplify the differentiation of terminal strips 11 (Fig. 10) and plugs (12) in a wiring
diagram.

i Note
Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable
connection and mating plug.

008 918 12 BOMAG 69

5.2 Circuit symbols in the circuit diagram

Representation of electric devices

Electronic devices and components are increasingly used in the construction equipment industry. Controls with
software, control elements (e.g. joysticks and man/machine interface (e.g. screens, LC Displays) are frequently
used to represent and control machine functions. The internal construction of such components is in most cases
protected or just too complex to be illustrated in the wiring diagram within the context of the actual machine func-
tion. There are two different ways to simplify the representation of such devices in the diagram.

Black-Box representation(Fig. 11)

The Black-Box representation shows the device as a Box with the connections required for the machine function.
Connections which are not needed do not need to be represented.
The Black-Box representation is mainly used when no differentiated information (e.g. signals on pins) is availa-
ble.

Fig. 11 Example: Central lubrication system

Identification of externally supplied documentation (Fig. 12)

In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the
projecting of machines. These systems may be composed of various components and wirings. For easier differ-
entiation of BOMAG designation and manufacturer identification the latter appears under the BOMAG designa-
tion with a text frame and a reduced character height.

Fig. 12 Example: Identification of externally supplied documentation

PLC representation(Fig. 13)

The PLC-Box representation of connecting pins uses a table with associated connecting plugs, which are used
in connection with the machine functions. The table symbols can be arranged in a line, if necessary. Connections

70 BOMAG 008 918 12

Circuit symbols in the circuit diagram 5.2
which are not needed do not need to be represented. The PLC-Box representation enables the representation
of further reaching functional descriptions to the individual component connections.

Fig. 13 PLC representation

The PLC-Box representation is mainly used for controls with BOMAG software, or for electronic devices which
were specified accordingly, and where information on the assignment of signals is available.

Identification of similar, adjacent switching symbols

In wiring diagrams you will frequently find the situation that symbols of the same type appear in a line or are
arranged just next to each other. In such cases it is common practice to reduce the identification on the subse-
quent symbol to the criteria, which are different to the previous symbol to the left.

Example: -X0 36 and -X0 37 (Fig. 13)

In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right
plug symbol.

008 918 12 BOMAG 71

5.3 Identification of switch blocks in the wiring diagram

5.3 Identification of switch blocks in the wiring diagram

Switches of modular design

l For normally open contacts the contact symbols "_3/_4" are used.
l For normally closed contacts the contact symbols "_1/_2" are used.
In combination with the contact block numbering described above each individual connection is clearly defined.

5 C 6

3 B 4

1 A 2

Travel direction

Fig. 14

Example:
The contact block marked with the "circle" is referred to as "43"/ "44" if it is a normally open contact and "41" /
"42" if it is a normally closed contact.
The contact block marked with "X" is referred to as "23"/ "24" if it is a normally open contact and "21" / "22" if it
is a normally closed contact.
The contact block marked with "Z" is referred to as "13"/ "14" if it is a normally open contact and "11" / "12" if it
is a normally closed contact.
The contact block marked with "Y" is referred to as "53"/ "54" if it is a normally open contact and "51" / "52" if it
is a normally closed contact.

72 BOMAG 008 918 12

Designation of components in the wiring diagram 5.4
5.4 Designation of components in the wiring diagram
The designation of components in the wiring diagram groups several electrical parts of the machine in one
group. The components can be identified by the following table.

Component designa- Meaning

tion
A Interval switch, indicator relay, modules, electronic component
B Pressure, pressure differential, temperature switches and sensors, transducers
C Capacitor
E Headlights, heater, air conditioning condenser
F Fuses
G Battery, generator
H Control lights, warning buzzer, warning light
K Relays
M Starter, pumps, motors
P Operating hour meter, general gauges
R Transducers, resistors
S Switches, momentary contact switches
V Diode
X Terminal
Y Solenoid valves

008 918 12 BOMAG 73

5.5 Terminal designations in wiring diagram

5.5 Terminal designations in wiring diagram

l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a
terminal designation. In Germany the designation of the individual connection terminals is determined by the
standard DIN 72552. The following table shows some examples from this DIN standard.

Terminal designation Meaning

15 Switch plus (after battery) : Output of ignition 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

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

53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding

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

61 Generator control

75 Radio, cigarette lighter

76 Loudspeaker

87 Relay contact on breaker and two-way contact, input

74 BOMAG 008 918 12

Terminal designations in wiring diagram 5.5
Terminal designation Meaning
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 positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
DF2 Dynamo field 2 (generator excitation current)

008 918 12 BOMAG 75

5.5 Terminal designations in wiring diagram

76 BOMAG 008 918 12

6 Electrics

008 918 12 BOMAG 77

6.1 Designation of components in the wiring diagram

6.1 Designation of components in the wiring diagram

The designation of components in the wiring diagram groups several electrical parts of the machine in one
group. The components can be identified by the following table.

Component designa- Meaning

tion
A Interval switch, indicator relay, modules, electronic component
B Pressure, pressure differential, temperature switches and sensors, transducers
C Capacitor
E Headlights, heater, air conditioning condenser
F Fuses
G Battery, generator
H Control lights, warning buzzer, warning light
K Relays
M Starter, pumps, motors
P Operating hour meter, general gauges
R Transducers, resistors
S Switches, momentary contact switches
V Diode
X Terminal
Y Solenoid valves

78 BOMAG 008 918 12

Terminal designations in wiring diagram 6.2
6.2 Terminal designations in wiring diagram
l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a
terminal designation. In Germany the designation of the individual connection terminals is determined by the
standard DIN 72552. The following table shows some examples from this DIN standard.

Terminal designation Meaning

15 Switch plus (after battery) : Output of ignition 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

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

53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding

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

61 Generator control

75 Radio, cigarette lighter

76 Loudspeaker

87 Relay contact on breaker and two-way contact, input

008 918 12 BOMAG 79

6.2 Terminal designations in wiring diagram

Terminal designation Meaning

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 positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
DF2 Dynamo field 2 (generator excitation current)

80 BOMAG 008 918 12

Battery ground and analog ground 6.3
6.3 Battery ground and analog 6.4 Current and voltage
ground
General
GND, battery ground If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the One simply compares electric current with water.
potential of "Zero" Volt and represents the reference
potential for operating voltages. Voltage
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.

Terminal designation for GND = terminale 31

AGND, analog ground

Apart from the "normal" battery ground there is also
the analog ground, which is solely reserved for sen-
sors.

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

008 918 12 BOMAG 81

6.4 Current and voltage

The following statements concerning electric volt- Current

age can be made
Electric current generally describes the directed
l electric voltage is the pressure or force applied to movement of charge carriers.
free electrons. l The charge carriers may either be electrons or ions.
l the electric voltage is the cause of electric current l Electric current can only flow if there is a sufficient
l electric voltage is a result of the equalization at- amount of free moving charge carriers.
tempt of electric charges. l The higher the number of electrons flowing through
Voltage is measured with a Voltmeter. a conductor per second, the higher the amperage.
Unit, Volt Current is measured with an ammeter.

The electric voltage (U) is measured in Volt (V). Unit, Ampere

The electric amperage (I) is measured in Ampere

(A).

The technical flow direction is specified from

PLUS to MINUS.

i Note
Current actually flows from minus to plus, because the
current flow is made up of negatively charged elec-
trons.
But since this was only discovered after the poles of a
current source had already been designated, the as-
sumption that current flows from plus to minus was
maintained for historic reasons.

Circuit

Fig. 3 Circuit
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring.
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).

82 BOMAG 008 918 12

Resistance 6.5
Types of current 6.5 Resistance
Direct current (D.C.)
Resistance and voltage drop
While current flows through a conductor the current
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance.

Fig. 1 Direct current (D.C.)

Direct current flows with steady voltage and amper-
age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
tors or batteries.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
the consumers switched on, the voltage is not con-
stant, but drops gradually according to the battery
charge condition.
The internal resistance of the battery also causes per- Fig. 1 Various size resistors
manent changes in the vehicle voltage, as soon as
Each conductor has its specific resistance, which is
consumers are switched on or off.
characteristic for the corresponding material. A good
Alternating current (A.C.) conductor has a low resistance, a poor conductor has
a high resistance.

Fig. 2 Alternating current (A.C.)

Alternating current not only changes its direction, but
also its amperage.

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:
l
The thicker the cable cross-section, the lower the
voltage loss.
l
The shorter the cable, the better the current.

008 918 12 BOMAG 83

6.5 Resistance

l The cleaner the contacts, the better the current.

l The quality of the ground cable is of the same im-
portance as the supply line.

Unnecessary resistances
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. 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
Fig. 1 Screw-type terminals
keeps water away.
Copper wires are squashed and thus become faulty.

Better

Fig. 2 Spring clamps

Connecting clamps for flexible conductors Fig. 4 Balistol oil

BOMAG No. 057 565 72

Ampacity up to 20 Amp.
Cable cross-section 0.08 to 2.5 qmm

84 BOMAG 008 918 12

Series / parallel connection 6.6
Sometimes the flanks of flat plugs bend open. If these 6.6 Series / parallel connection
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely Series connection
break sooner or later. It is better to place a small nail In a series circuit the resistors (consumers) are lined
under the bottom of the cable lug before bending. up one after the other and the same current (I) passes
through each of the consumers However, series con-
nection of consumers is not suitable in practice, as
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.
Fig. 5
Utotal = U1 + U2 + U3
Hint for practice:
A tool you cannot buy. The pliers were converted, the Resistance
nail is permanently present. 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.

008 918 12 BOMAG 85

6.6 Series / parallel connection

l In series connection the plus pole of the first battery Parallel connection
must be connected with the minus pole of the sec- In parallel connection all resistances (consumers) are
ond battery. connected between feed and return line.
l The sum of all individual voltages is applied to the l All resistances (consumers) are supplied with the
free poles. same voltage.
l The total capacity (Ah) is identical with the capacity l Each of the resistances (consumers) draws as
of the individual battery. much current as required.

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.

86 BOMAG 008 918 12

Ohm's law 6.7
l In parallel connection the plus pole of the first bat- 6.7 Ohm's law
tery is connected with the plus pole of the second
battery and the minus pole of the first battery with In a closed electric circuit voltage, current and resist-
the minus pole of the second battery. ance must always be considered in close relation.
l Plus and minus poles have the voltage of the single This relation is represented by Ohm's Law.
battery applied.
l 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. 1
According to this law a voltage of 1V is required to let
1A (ampere) flow through a conductor with a resist-
ance of 1 (Ohm Ω).

Advice
By means of this triangle the formula can be easily re-
arranged, the value you are looking form must just be
blanked off with a finger.

Voltage U = I multiplied with R

Resistance R = U divided by I

Amperage I = U divided by R
U = Voltage in Volt
I = Current in Ampere
R = Resistance in OHM Ω

008 918 12 BOMAG 87

6.8 Electrical energy

6.8 Electrical energy

Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
If a current of 1 Ampere flows at a voltage of 1 Volt,
energy of 1 Watt is produced.

Advice
By means of this triangle the formula can be easily re-
arranged, the value you are looking form must just be
blanked off with a finger.

Energy P = I multiplied with U

Amperage I = P divided by U

Voltage U = P divided by I
U = Voltage in Volt
I = Current in Ampere
P = Power in Watt

88 BOMAG 008 918 12

Formula diagram 6.9
6.9 Formula diagram
Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate

Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
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

008 918 12 BOMAG 89

6.10 Metrology

6.10 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
l
the range selector switch must be correctly set for
the corresponding measurement.
! Caution l
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- l
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic l
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp l
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 l 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.

Fig. 2 Diode test lamp

If voltage is present, the corresponding light emitting
diode will light up.

90 BOMAG 008 918 12

Metrology 6.10
Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter

Fig. 2
The continuity tester of the multimeter can be used to Fig. 4 Measuring voltage
measure whether there is a connection between 2 l Measurement at the voltage source measures the
measuring points. currently available Voltage.
l The meter is always connected parallel to consum-
er, component or power source.

Fig. 3
The following information should be observed when
measuring resistance and continuity: Fig. 5 Voltage measurement
l The component to be measured must not be con- l
A measurement at the consumer measures the volt-
nected to the power supply during the measure- age drop at this component.
ment.
l 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.
l Polarity is of no significance.

008 918 12 BOMAG 91

6.10 Metrology

Current measurement with the multimeter Clip-on measuring instrument

The clip-on measuring instrument can be used to
measure current, voltage and resistance.

Fig. 6 Measuring current

l The meter is connected in series with the consum-
er. Fig. 1 Clip-on measuring instrument
l During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened.

Fig. 2
l
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 7 Current measurement

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.

92 BOMAG 008 918 12

Metrology 6.10
Magnet tester Power measurement
The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring of current and voltage.
However, there are also pure power meters with 4
connections available. The power meter has a electro-
dynamic measuring mechanism. The current circuit
must be opened for measuring. Take care when per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.

Fig. 1 Magnet tester

The magnet tester is used to test solenoid valves and
magnetic coils.
The test lamp responds to the magnetic fields of A.C-
voltage, D.C.-voltage and permanent magnets.
l
The component to be tested does not need to be re-
moved.
l The magnetic coil can also be tested under a pro-
tective cap.

Fig. 2

008 918 12 BOMAG 93

6.11 Diodes, relays, fuses

6.11 Diodes, relays, fuses Diode logics and free-wheeling diode

Diodes

Fig. 1
A diode consists of two different semi-conductors,
which are connected by a separating layer. The max.
conducting state current must not be exceeded.
Plus-voltage on diode:
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes
conductive.
Negative voltage on diode:
l The diode does not allow current to pass through.

Fig. 2 Marking of the cathode

Diodes are used:
l
For rectifying A.C. voltage.
l
For absorbing voltage peaks (free-wheeling diode).
l
For construction of logical circuits.

Fig. 3 Diode circuitry

l The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
l Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
l 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.

94 BOMAG 008 918 12

Diodes, relays, fuses 6.11
Light emitting diodes Relays

Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
Fig. 4 LED
A free-wheeling diode prevents induction voltage from
The light emitting diode, also referred to as LED, is a
flowing back from the coil into the vehicle wiring sys-
semi-conductor diode, which generates (emits) light
tem, which would cause interference with electronic
during operation in forward direction. A semi-conduc-
components (control units).
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the With the possibility of using breaker - maker contacts
head. Light emitting diodes are available in various the effect of an information can be reversed.
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. 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

008 918 12 BOMAG 95

6.11 Diodes, relays, fuses

85 = Ground supply for coil Fuses

30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact

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:
l
approx. 1 hour with 1.5 times the rated current
l
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

96 BOMAG 008 918 12

Telemecanique switch 6.12
6.12 Telemecanique switch
Disassembly

Fig. 1 Disassembly
l
Lift up the interlock (5).

Fig. 3 Pulling out the front element

l Lift up the interlock (2) and pull out the front element
(3).
Fig. 2 Folding down the switch block
l Fold down the switch block (4).
l Loosen screw (1).

008 918 12 BOMAG 97

6.12 Telemecanique switch

Assembly

Fig. 4 Assembly
l Insert the front element (3) into the bore in the con-
trol panel.

Fig. 6 Assemble the switch block

l Clip on the switch block (4).

Fig. 5 Observe the marks.

i Note
Hook in the switch block at the bottom first (Fig. 6).
l Clip the fastening adapter (6) onto the front element
(3).

i Note
Watch the marls on front element (Fig. 5) and fasten-
ing flange.
l
Tighten the screw (1) with a tightening torque of 0.6
Nm.

98 BOMAG 008 918 12

Plug connectors 6.13
6.13 Plug connectors 6.14 Magnetic coil plug
Duties and requirements
Magnetic coil plug with LED and suppres-
Electric plug connectors must provide a reliable con-
sor diode
nection between different system components and
thus ensure the safe function of the systems under The plug is equipped with a polarized function display
any operating condition. There design ensures that and a suppressor diode as protection against over-
they will withstand the applied loads throughout the voltages.
lifetime of the machine.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
Fig. 7
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir- The plug is reverse polarity protected, it does not mat-
cuits in neighbouring lines. Electric plug connectors ter whether Pin1 or Pin 2 is supplied with current, Pin
must therefore have the following properties: 3 is not used. The LED lights if voltage is applied to the
solenoid valve.
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
with different voltage potentials.
l
Excellent leak tightness against water and mois-
ture.

Fig. 8

Fig. 9 Switching symbol in circuit diagram

Magnetic coil plug without LED and with-

out supressor diode
The plug has no LED and no suppressor diode as pro-
tection against overvoltages.

008 918 12 BOMAG 99

6.14 Magnetic coil plug

Assembly of magnetic coil plugs

These instructions are intended to explain the correct
installation of the magnetic coil plug. The objective of
the instructions is the correct installation of the plug
and to avoid malfunctions in the field caused by mois-
ture and any related corrosion damage.

Fig. 12
l
Fasten the screw with a suitable screwdriver.

Fig. 10 Solenoid valve plug with pointed cable

Fig. 13
l
Press the plug firmly on again.

Fig. 11
l Connect the plug with the coil connection and press
it firmly onto the connecting housing.

Fig. 14
l Retighten the screw.

100 BOMAG 008 918 12

Deutsch plug, series DT and DTM 6.15
6.15 Deutsch plug, series DT and
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. 15

! Caution
There should be no gap between plug and sole-
noid coil!

Fig. 17 Crimp connections

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).
Fig. 16 Correctly installed plug without gap 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).

Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
l
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.

008 918 12 BOMAG 101

6.15 Deutsch plug, series DT and DTM

DT Series

Fig. 1 DT plug connection

Fig. 2 DT Series

Fig. 3 Sectional drawing

102 BOMAG 008 918 12

Deutsch plug, series DT and DTM 6.15
DT Series
Installing DT contacts

Fig. 4
l Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge in direction of arrow.

!Caution
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force
of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

Disassembling DT contacts

Fig. 5
l Pull the orange wedge out with long nose pliers.
l Slightly pull the lead and unlock the interlocking hook with a screw driver.
l Pull the contact out of the socket.

i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.

008 918 12 BOMAG 103

6.15 Deutsch plug, series DT and DTM

DTM Series

Fig. 6 DTM Series

Fig. 7 Sectional drawing

Installing DTM contacts

Fig. 8
l Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge, until it clicks into place.

104 BOMAG 008 918 12

Deutsch plug, series DT and DTM 6.15
!Caution
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force
of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

Removing DTM contacts

Fig. 9
l
Pull the orange wedge (interlock) out with long nose pliers.
l
Slightly pull the lead and unlock the interlocking hook with a screw driver.
l
Pull the contact out of the socket.

i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.

008 918 12 BOMAG 105

6.16 Plugs and terminals in spring clamping technology

6.16 Plugs and terminals in spring clamping technology

General

Fig. 1

!Caution
The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be eas-
ily pulled out of the spring clamp!
Spring clamp technology (Fig. 1) for quick, vibration resistant and maintenance-free connection of all conven-
tional copper conductors (single, multiple or fine stranded) with or without wire and ferrule.

Connecting terminal for quick repairs

Fig. 2 That's how it works

BOMAG part-no.: 057 565 72

The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mm2 to 4 mm2, single or multiple
strand up to 2.5 mm2. And this even without tools (Fig. 2).

That's how it works

l Strip 9-10 mm of the lead.
l
Open the actuating lever and insert the strand.
l Return the actuating lever to initial position.

! Caution
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without
any difficulties.

106 BOMAG 008 918 12

Plugs and terminals in spring clamping technology 6.16
Series clamp

Fig. 3 That's how it works

That's how it works

l Insert a screw driver into the actuating opening until it bottoms.
l Strip 9-10 mm of the lead and insert it into the clamp.
l Pull out the screw driver.

Caution
!

Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without
any difficulties.

Measuring signals
On these terminal blocks the bridge slot is most suitable 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. 4 Test adapter

008 918 12 BOMAG 107

6.16 Plugs and terminals in spring clamping technology

X-COM System
The X-COM-SYSTEM, a synthesis of plug connector and series clamp, has grown up to a construction kit for
universal system wiring, ever since it was introduced in 1997. All the familiar series clamping functions have thus
become pluggable.

X-COM plug clamp

Fig. 5 That's how it works

That's how it works

l
Insert a screw driver into the actuating opening until it bottoms.
l
Strip 9-10 mm of the lead and insert it into the plug.
l
Pull out the screw driver.

Caution
!

Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without
any difficulties.

Fig. 6 X-COM plug with measuring cable

l 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).

108 BOMAG 008 918 12

Plugs and terminals in spring clamping technology 6.16
Measuring signals

Fig. 7 X-COM plug plugged onto the series clamp

008 918 12 BOMAG 109

6.17 Proximity switches

6.17 Proximity switches cillator is thus dampened and the resulting change in
current consumption is evaluated.

PNP circuitry

Fig. 3 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
Fig. 1 Proximity switches on travel control lever open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
B13 Initiator for brake
NPN circuitry
B14 Initiator for reverse detection

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. 4 NPN circuitry
proximity switches are today indispensable. Com- On sensors with NPN-circuitry the output stage con-
pared with mechanical switches they provide almost tains a NPN-transistor, which switches the load
ideal prerequsites: contactless, wear-free operation, against the negative operating voltage. The load is
high switching frequency and switching accuracy as connected between the output and the positive oper-
well as high protection against vibration, dust and ating voltage.
moisture. Inductive sensors detect all metals without
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. 2
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
Fig. 5
cuit forms a high-frequency magnetic stray field.
Proximity switches are used as breaking or making
This stray field leaks out from the active area of the contacts. Depending on the design the switching dis-
proximity switch. If metal or non-ferrous metal enters
into the response range energy is absorbed. The os-

110 BOMAG 008 918 12

Level sensor in diesel tank (R03) 6.18
tances are 2 or 4 mm. The maximum amperage is 300 6.18 Level sensor in diesel tank
mA.
(R03)
The LED (Fig. 5) lights up, when the initiator has de-
tected metal in its stray field.

Fig. 1
The fluid of the level to be measured carries a float,
which lowers or rises with the fluid level. Contact
springs mounted on the float thereby slide along two
resistor wires arranged parallel to the movement of
the float and generate a resistance value, which is
proportionate to the fluid filling level. The correspond-
ing resistance value is measured by an electric meter
and displayed as fluid level value.

Monitoring module, old design

Fig. 6 Circuit diagram, making contact

The circuit diagram (Fig. 6) shows a proximity switch
with normally open contact.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)

Fig. 2 old design

n = Fuel level gauge
00 Ohm = Tank full
26 Ohm = Tank 1/2 full
65 Ohm = Tank empty
If no level switch is connected or the cable is broken,
the fuel level gauge will go out.

008 918 12 BOMAG 111

6.19 Differential pressure switch for hydraulic oil filter, B21

Monitoring module, new design 6.19 Differential pressure switch

for hydraulic oil filter, B21

Fig. 3 new design

m = Fuel level gauge
00 Ohm = Tank full
40 OHM = Tank 1/2 full
95 Ohm = Tank empty Fig. 1
If no level switch is connected or the cable is broken, l The differential pressure switches (Fig. 1) switch to
the fuel level gauge will go out. ground at a pressure differential of Δ 3.6 bar.
When the pressure switch switches , the monitoring
board (Pin13 old design, Pin17 new design) is con-
nected to ground. The warning lamp e(Fig. 2) or i (Fig.
3) lights up.

Monitoring module, old design

Fig. 2 old design

e yellow = Lights when the hydraulic oil filter is dirty,
the warning buzzer sounds. The engine
is shut down after 2 minutes. Check hy-
draulic system, replace hydraulic oil fil-
ter.

i Note
The warning buzzer is activated by the monitoring
board (Pin1).
The engine is shut down by the monitoring board
(Pin9) via relay (K22).

112 BOMAG 008 918 12

Differential pressure switch for hydraulic oil filter, B21 6.19
Monitoring module, new design

Fig. 3 new design

i yellow = Lights when the hydraulic oil filter is dirty,
the warning buzzer sounds. The engine
is shut down after 2 minutes. Check hy-
draulic system, replace hydraulic oil fil-
ter.

i Note
The warning buzzer is activated by the monitoring
board (Pin23).
The engine is shut down by the monitoring board
(Pin24) via relay (K22).

008 918 12 BOMAG 113

6.20 Acceleration transducer

Fig. 1 When this combination is set to oscillate, the seismic

BVC machines and machines with E-VIB meter are (sluggish) mass transfers a force to the piezo disc. Ac-
equipped with two piezo-electric acceleration trans- cording to NewtonsLawtheresultantforceisthepro-
ducers, which are mounted to the drum. ductofaccelerationandmass.'
During operation these transducers transmit the ac- A small wire connects the piezo element with the sen-
celeration signals to the measuring ESX. sor socket.
The function of the piezo electric acceleration trans- The piezo electric effect generates a charge on the
ducer is based on the self-charging effect of quartz electrodes, which is proportional to the force and thus
crystals under mechanical load (pressure, tension, also to the acceleration.
torsion) in vertical direction to the polar axes, which
was discovered in 1880 by J. and P. Curie.

Mode of action
The piezo electric acceleration transducer consists of
two basic components:
l
Piezo electric material
l Seismic mass
Once side of the piezo disc is connected with the so-
called seismic mass, the other one with a rigid carrier.

114 BOMAG 008 918 12

Batteries 6.21
6.21 Batteries
Battery – accumulator

Fig. 1
1 Seismic mass
2 Piezo electric material
3 Acceleration

Fig. 1
In vehicles batteries are used to start the engine. The
ability to start the engine depends on the charge con-
dition of the batteries.
Lead collectors or accumulators are secondary ele-
ments, i.e they can be recharged after discharging
electric current.
The basic element of a lead accumulator is the cell. It
contains the plate blocks consisting of positive and
negative plates. These plates are separated from
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of
the cells.

Fig. 2
All cells are filled with a conductive fluid, the electro-
lyte. For a 12 Volt battery 6 cells are connected in se-
ries.

Capacity
is a synonym for the amount of current taken up and
discharged by a battery over a specified period of
time.

008 918 12 BOMAG 115

6.21 Batteries

Battery maintenance Batteries with screw plugs

Checking the electrolyte level
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. 3
a subsequent charging process. 1 Upper filling level mark
In the worst case the accumulator can only be dis- 2 Lower filling level mark
posed of after such an exhaustive discharge. l If the electrolyte level only reaches up to the lower
The following therefore applies for longer downtimes: filling level mark (2), fill distilled water into the corre-
l Remove the battery and store it in a cool, dry and sponding cells.
frost protected room.
l Check the open circuit voltage on the battery at reg-
ular intervals (at least once every month).
l Recharge immediately if the open circuit voltage
has dropped to 12.25 Volt (no rapid charging).

i Note
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

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

116 BOMAG 008 918 12

Batteries 6.21
Checking the electrolyte density Do not draw too much electrolyte into the pipe.
Make sure that the float is not obstructed in its move-
ment and hold the electrolyte tester at eye level.
The electrolyte tester must be read at the highest
electrolyte level.
l If the electrolyte temperature deviates from the
electrolyte tester calibration temperature, the indi-
cated value for the specific electrolyte weight must
be corrected acc. to the formula (reference) below.

Reference
The specific weight varies slightly with temperature.
To be exact, the specific weight drops by 0.0007 per 1
°C temperature increase (by 0.0004 per 1 °F) and in-
Fig. 4
creases by 0,0007 per 1 °C temperature reduction (by
The cells are filled with diluted sulphuric acid as elec- 0,0004 per 1 °F) . If e.g. a temperature of 20 °C (68 °F)
trolyte (approx. 25 Vol% sulphuric acid in distilled wa- is used as reference, the indicated value of the specif-
ter), also referred to as accumulator acid, which has a ic weight must be corrected acc. to the following for-
density of 1.285 kg/dm3 at a temperature of +27° Cel- mula.
sius. This means that one litre of electrolyte has a l Specific weight at 20 °C = measuring value +
weight of 1.285 kg. As the cell is being discharged
0,0007 × (electrolyte temperature: 20 °C)
lead sulphate (PbSO4) will form on both electrodes
and the electrolyte will increasingly change to water.
l
Specific weight at 68 °F = measuring value + 0,0004
Since water has a lower specific weight than diluted × (electrolyte temperature: 68 °F)
sulphuric acid, the density of the electrolyte will also Acid density at 27 °C in kg/dm3
drop during the discharge and with a fully discharged
cell and a temperature of 27°C it will only be 1.18 kg/
l
1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
dm3. Battery is charged.
l
1.20 -1.24, open circuit voltage approx.12.4 to 12.5
With a lead cell the acid density is therefore a meas-
Volt, is 50% discharged. Charging is necessary.
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead bat- l
1.19 and less, open circuit voltage less than 12.3
tery. The so-called electrolyte tester (densimeter) is Volt. Battery is insufficiently charged. The battery
used for this purpose. needs to be recharged immediately.
l
If there is a deviation of the specific weight of more
than 0.05 between any of the cells, the battery
needs to be replaced.
l
If the current consumption during charging is not 1/
20 of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full recharging of the battery
results in a final electrolyte density of only 1.24 kg/
dm3 or less, the battery shows normal wear by ag-
ing. The battery was insufficient charging or ex-
haustive discharge.

Fig. 5 Checking the electrolyte density:

1) correct
2) poor
3) poor

i Note
(Hold the pipe of the electrolyte tester vertically, with-
out taking it out of the electrolyte.

008 918 12 BOMAG 117

6.21 Batteries

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:

Fig. 6 Battery and generator tester

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) integrated ther-
mal printer.

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%.

118 BOMAG 008 918 12

Service the battery 6.22
6.22 Service the battery

! Danger

Danger of cauterisation ! Danger of explosion!

When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
Fig. 7
Environment l Remove the battery (Fig. 7) and clean the battery
Dispose of the old battery environmentally. compartment.
l Clean the outside of the battery.
i Note l Clean battery poles and pole clamps and grease
Maintenance free batteries also need care. Mainte- them with pole grease (Vaseline).
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
l Check the fastening of the battery.
discharge, which may, in not checked occasionally, l On serviceable batteries check the acid level, if nec-
even cause damage to the battery as a result of ex- essary top up to the filling mark with distilled water.
haustive discharge.
Charging voltage recommendation
The following therefore applies for the service life:
l
Switch off all consumers (e.g. ignition, light, inside
light, radio).
l
Check open-circuit voltage of the battery at regular
intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform boost charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge. Fig. 8
l
After each charging process allow the battery to rest
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.

Caution
!

Exhausted batteries (batteries with formation of

sulphate on thge plates are not covered under
warranty!
l
Open the engine hood and remove the covering.

008 918 12 BOMAG 119

6.23 Main battery fuse

6.23 Main battery fuse 6.24 Starting with jump wires

Fig. 9 Fig. 10
No. 1 = Main fuse for battery
125A = (F00) Main fuse !Caution
A wrong connection will cause severe damage in
the electric system.
i Note
The main fuse is located in the battery compartment l
Bridge the machine only with a 12 Volt auxiliary bat-
tery.
l
When jump starting with an external battery connect
both plus poles first.
l
Then connect the ground cable first to the minus
pole of the current supplying auxiliary battery and
then to engine or chassis ground, as far away from
the battery as possible (Fig. 10).
l
Start as described under 'Starting the engine'.
l
Once the engine is running switch on a powerful
consumer (working light, etc.).

!Caution
If no powerful consumer is switched on voltage
peaks may occur when separating the connecting
cables between the batteries, which could dam-
age electrical components.
l
After starting disconnect the negative poles (ground
cable) first and the positive poles after.
l
Switch off the consumer.

120 BOMAG 008 918 12

Generator 6.25
6.25 Generator Three-phase generator
The AC-generator first of all produces AC-voltage /
General
AC-current.
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve- Why does AC-current need to be rectified?
hicle with electric current at a steady voltage already There are a few components for which can either be
at idling speed. operated with alternating current or direct current, be-
cause they work independently from the current flow
Terminal designations
direction.
l B61, L = charge control This includes :
l B+, B = battery plus, also with the designation "30" l
Incandescent lamps
l
B- = battery minus, also with the designation "31" l
Fluorescent lamps
l D+ = dynamo plus corresponds with terminal "61" l Glow lamps
and "L" l Electric heating elements.
l D- = dynamo minus (this designation is only found There are also a few components that could be oper-
on D.C. generators or A.C. generators with regula- ated either with alternating current, direct current or
tor removed) three-phase current, if the components were designed
accordingly.
l DF = dynamo field (this designation is only found on
D.C. generators or A.C. generators with regulator This includes :
removed). Note: The designation DF is also found l
Electric motors
on older alternators with externally arranged regula- l
Relays.
tor on the connection of the exciting coil to the reg-
ulator or on the regulator itself Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
l
DF1 = dynamo field 1 es work with alternating or three-phase current.
l
DF2 = dynamo field 2 This includes :
l
IG = "15" ignition switch l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Design and function

Fig. 11
1 Fan
2 Holding plate
3 Stator core
4 Stator winding
5 Brush

008 918 12 BOMAG 121

6.25 Generator

6 Brush holder
7 Rectifier
8 Bearing cover
9 Rotor winding
10Rotor
11V-belt pulley

Fig. 14 3-phase current

Fig. 12 Rotor with claw poles The wiring diagram (Fig. 14) shows the 3 windings in
Y-connection and the 6 associated rectifier diodes (D1
In the generator the armature windings are located in-
to D6).
side the stationary stator (Fig. 13), whereas the excit-
er winding is arranged on the internally revolving rotor The diodes D1, D2, D3 are also referred to as minus
(Fig. 12). diodes, because they have B- as common connection
(minus plate). The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.

Fig. 13 Stator
The three stator windings (Fig. 13) are electrically off-
set to each other by 120°. The excitation of the mag-
netic field requires direct current, which is fed to the
rotor via two carbon brushes and slip rings.

122 BOMAG 008 918 12

Generator 6.25
Charge control light Any other behaviour would indicate a defect on the
The charge control light has two duties: generator (rectifier, carbon brushes, regulator) or a
defect on the lamp, presumed the on-board battery is
l Indication of the correct generator function not discharged.
l External excitation of the generator during the start- A far more important function of the lamp is the transi-
ing phase tion and provision of field current. At standstill there is
no magnetic field in the de-energized generator. Since
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak
field can build up.
The current flows from the ignition switch via the
charge control light through the generator winding
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
Fig. 15 plus controlled charging regulator tery is available or the battery is discharged, external
(Fig. 15) shows the current flow with the ignition excitation is no longer possible at standstill and no
switched on, engine stopped. voltage will be generated, even when the generator is
running.
With used, older generators a weak permanent mag-
netic field may have developed over the lifetime,
which does even exist when no voltage is applied.
This type of machines can even start without charge
control light and produce current during operation.
However, this is an unintended effect and you should
not presume that a generator without charge control
light or external excitation can be started up.

Fig. 16 plus controlled charging regulator

(Fig. 16) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.

008 918 12 BOMAG 123

6.25 Generator

Charge controller
The charge controller has the following functions
l To regulate the voltage generated by the generator
l To protect against overloads caused by too high
output current
l Protection against reverse current
If the output voltage or the output current of the gen-
erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.

Electronic charge regulator

Fig. 18 plus controlled regulator

Fig. 17
In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
tached electronic charge regulator. Together with the Fig. 19 minus controlled regulator
holder for the carbon brushes this regulator forms a
unit, which transfers the field current to the sliprings of
the rotor.
The regulator compares the rectified actual current of
the generator with the a stable reference voltage in
the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
tion dependent internal resistance of the stator coils or
thermal monitoring.

124 BOMAG 008 918 12

Generator 6.25
Checking the generator Checking the pre-exciter circuit, D+ generator
First one must check whether the generator is actually The most common reason for a 3-phase alternator not
defective. charging is a too low pre-excitation current. The pre-
excitation current through connection D+ depends on
l This can be easily found out by checking whether
the connected consumer (resistance), e.g. charge
the charge control light in the dashboard lights up. If
control light or relay of a MD+ engine control.
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula- The pre-excitation current should be approx. 250 mA
tor, the wiring or the V-belt. at 12 Volt. This corresponds with a 3 Watt light bulb or
l When the engine is at rest, the charge control light an equivalent combination of light bulb + resistance or
must light up. If not, the lamp may probably be de- an LED + resistance.
fective. Defects on generator or wiring are obviously The total resistance of the disconnected dead supply
also possible. line D+ max. should not exceed 48 Ohm.
The following points allow to contain faults in the volt- In case of faults like
age supply within certain limits. l charge control light stays on
l Cable connections on the generator OK? l no voltage increase, e.g. from 12 V to 14 V
l V-belt OK?
one should check that the correct resistance is as-
l Generator ground (engine ground) OK?
sured.
l 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
replaced or the following trouble shooting procedure
must be performed.

Fig. 20 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:
l Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 20). 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.

008 918 12 BOMAG 125

6.25 Generator

Checking the rotor

Measuring the charge current
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact. i Note
The rotor coils can only be measured in disassembled
l The generator ground connection must be OK.
state.
l During the measurement switch on as many con-
sumers as possible.
1 Attach the clip-on ammeter around the B+ line.
2 Gradually increase the engine speed.
3 The generator current must be at least as high as
the total current of all switched on consumers.

Fig. 21
l Measure the resistance between the sliprings.
l If the resistance does not comply with the factory
specification, replace the rotor.
l Use the resistance range of the continuity tester to
check the continuity between slipring and core.
l Replace the rotor if no infinite value is indicated.

i Note
Factory specification for resistance: 2.8 to 5 OHM.

126 BOMAG 008 918 12

Generator 6.25
Checking the stator Checking the bearings

i Note
The stator coils can only be measured in disassem-
bled state.

Fig. 23
l Check whether the bearing rotates without obstruc-
tion.
l Replace the bearing if it does not rotate properly.
Fig. 22
l Use the resistance range of the continuity tester to
measure the resistance between the individual lines
of the stator winding.
l If the measuring value does not comply with the fac-
tory specification, replace the stator.
l Use the resistance range of the continuity tester to
check the continuity between the individual stator
windings and the core.
l Replace the stator if no infinite value is indicated.

i Note
Factory specification for resistance: Less than 1 OHM.

008 918 12 BOMAG 127

6.25 Generator

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. 25
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 24 l The generator ground connection must be OK.
The generator test assesses the regulator voltage and l
The battery should be in good condition – the idle
the ripple factor of the generator voltage. voltage of the battery should be at least 12.6 Volt.
l
All plug-and-socket connectors must be free of cor- l
If possible switch off all consumers.
rosion and intermittent contact. l
Perform the measurement at raised engine speed.
l
The generator ground connection must be OK. l
The voltage (B+) should adjust itself at 13 to 14 Volt.
l
The battery should be in good condition – the idle
voltage of the battery should be at least 12.6 Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.

128 BOMAG 008 918 12

Generator 6.25
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. 27
E.g minus controlled regulator
i Note One connects the regulator (Fig. 27) 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
l 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. 28

Fig. 29
Fig. 26
The illustrations (Fig. 28) and (Fig. 29) show two dif-
l 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).

008 918 12 BOMAG 129

6.26 Replacing the voltage regulator

Replacing carbon brushes 6.26 Replacing the voltage regula-

l On a Bosch generator unscrew two fastening tor
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 Disassembling the regulator
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.
l
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.

Fig. 1
l Loosen the hexagon nuts M5 (Fig. 1).
l Take off hexagon nuts and washers.
l Remove the plastic cover.

i Note
Optional:
Unscrew the hexagon nut M5 from terminal W, take
off washer and flat plug connector.

Fig. 2
l Check whether washers are present. Take off the
washers (3x) (Fig. 2), to prevent these from falling
into the generator.

130 BOMAG 008 918 12

Replacing the voltage regulator 6.26

Fig. 3
l Slacken the screws M3 (A) (Fig. 3). Fig. 2
l Loosen the hexagon nuts M5 (B). l Check whether the rubber seal is present on the
brush holder (Fig. 2).
l Remove screw and hexagon nuts.
l Take off the voltage regulator.

Assembling the voltage regulator

Fig. 3
l
Attach the voltage regulator (Fig. 3).
l Tighten the screw M3 (A).- Tightening torque 0.7-
1.0 Nm.
Fig. 1 l
Tighten the screw M5 (B).- Tightening torque 3.5-
l
Check for correct fit of sealing ring on protective 4.5 Nm.
cover (Fig. 1).

Fig. 4
l Install the washers (Fig. 4).

008 918 12 BOMAG 131

6.27 Electric starter

6.27 Electric starter

General
Combustion engines need to be started by means of
a special device, because they are not able to start by
themselves. Considerable resistances caused by
compression and friction must thereby be overcome.
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
Fig. 5 l to accelerate the combustion engine to start speed
with lowest possible current consumption.
l Assemble the cover (Fig. 5).
l establish the gear connection between starter and
l Install the washers. combustion engine.
l Fasten the protective cover with the hexagon nuts.- l to maintain this connection.
Tightening torque for hexagon nut M5 2.1-3.1 Nm. l to switch on the starter current.
After starting the engine:
i Note l
to return the starter pinion to initial position.
Optional: l
to switch off the starter current.
Assemble flat plug connector, washer and hexagon
nut M5 to connection W.
Tightening torque for hexagon nut 2.7-3.8 Nm.

132 BOMAG 008 918 12

Electric starter 6.27
Directly acting electric starter 5 Ignition switch
This shows the design of this starter. It consists of a 6 Actuating lever
starter motor and a magnetic switch. 7 Ring gear
8 Pinion
9 Freewheeling clutch
10(Battery

Pinion meshes with the ring gear

Fig. 6
1 Magnetic switch
2 Armature
3 Actuating lever
4 Freewheeling clutch Fig. 8 Magnetic switch closed
5 Resetting spring When the pinion (3) meshes with the flywheel mount-
6 Brush ed ring gear (4) and the magnetic switch (2) is closed,
7 Exciting winding a strong current flows from the battery (7) directly into
8 Armature the exciting winding (6) and the armature winding, but
not into the pick-up winding.
9 Collector
This causes the armature (5) to rotate with high speed
Ignition switch in position "START" and drives the pinion, which in turn drives the ring gear
(4) with a speed of 200 to 300 rpm.
1 Pick-up winding
2 Magnetic switch
3 Pinion
4 Ring gear
5 Armature
6 Exciting winding
7 Battery

Fig. 7 Magnetic switch open

With the ignition switch (5) in "START" position cur-
rent flows from the battery (10) through the holding
winding (2) and the pick-up winding (3).
The armature (1) is magnetically picked up and forces
the pinion (8) with the actuating lever (6) to engage
with the ring gear (7).
1 Armature
2 Holding winding
3 Pick-up winding
4 Magnetic switch

008 918 12 BOMAG 133

6.27 Electric starter

Engine running 4 Resetting spring

5 Magnetic switch
6 Ignition switch
7 Pinion
8 Ring gear
9 Battery

Fig. 9
Once the engine is running and drives the pinion (1)
via the ring gear (2), the freewheeling clutch (3) will
open and prevent the armature (4) from being driven
by the engine.
1 Pinion
2 (Ring gear
3 Freewheeling clutch
4 Armature

Ignition switch released

Fig. 10
When releasing the ignition switch (6) it will return
from position "START" to "ON" and interrupt the start-
er current circuit. Current will now flow from the bat-
tery (9) through the contact plate in the pick-up
winding (3) and the holding winding (2). Since both
coils generate opposed magnetic fields, the magnetic
field will collapse and the resetting spring (4) takes the
armature (1) back to its initial position.
This opens the current circuit on the contact plate and
the pinion (7) is pulled back from the ring gear (8) and
stops.
1 Armature
2 Holding winding
3 Pick-up winding

134 BOMAG 008 918 12

Electric starter 6.27
Magnetic switch Freewheeling clutch

Fig. 11 Direct acting electric motor Fig. 13 Freewheeling clutch

The freewheeling clutch is designed in such a way,
that the flow of force is automatically interrupted if the
pinion (5) of the clutch rotates faster than the free-
wheeling ring (1) at higher engine speeds.
This makes sure that the armature will only drive the
ring gear, but can never be driven by the engine.
1 Freewheeling ring
2 Roller
3 Roller spring
4 Splined shaft
5 Pinion
6 Pinion

Fig. 12 Geared motor

Armature (4), contact plate (3) and armature guide (6)
form a closed unit. When the ignition switch is turned
to "START", the armature is picked up and causes the
pinion of the clutch to disengage.
This causes the pinion and the ring gear to mesh,
while the contact plate establishes a connection be-
tween the contacts, which enable the main current to
flow into the armature. Once the ignition switch is
opened, the resetting spring (5) will pull the armature
back to initial position.
1 Holding winding
2 Pick-up winding
3 Contact plate
4 Armature
5 Resetting spring
6 Armature guide

008 918 12 BOMAG 135

6.27 Electric starter

Trouble shooting "Starter" Testing and measuring the starter

Function control with the starter removed
i Note
The most frequent fault is definitely a fully discharged
Caution
!
battery.
Fasten the starter to make sure that it will not
If the starter rotates too slowly, either the brushes come loose during the test.
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
the magnetic switch is defect / soiled (dismantle and
clean))- the main contacts on the magnetic switch are
worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
armature and clean), cover cleaned, moveable parts
with grease.
Frequently a jammed return mechanism is the reason
for a starter failure. Fig. 14
Occasionally worn contacts are found on the magnetic l
Connect a jumper lead between start terminal (1)
return switch and battery plus (2).
Defects on the actual starter motor including pinion l
Connect a jumper cable instantaneously between
and carbon brushes are very rare. starter housing and battery minus (3).
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system i Note
can only work when many conditions are fulfilled at
If the motor does not start, the starter is defective. Re-
the same time.
pair or replace the starter.
l Immobilizer deactivated?
l Ignition switch OK? Checking the magnetic switch
l Travel lever in correct position?
l Emergency stop not actuated?
l Battery sufficiently charged?
l Battery poles OK?
l Main battery fuse OK?
l Main battery switch closed?
l Main starter cable (terminal 30) OK?
l Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l Switching of magnetic switches OK?
Fig. 15
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l the experience of the specialist
l
Connect a jumper cable instantaneously between
l the failure probability of the component to be tested
starter housing and battery minus (3).
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- i Note
paired or replaced. If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.

136 BOMAG 008 918 12

Electric starter 6.27
Continuity test for the magnetic switch

Fig. 16
l
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
l Replace the magnetic switch if no continuity is de-
tected.

008 918 12 BOMAG 137

6.28 Coolant temperature switch

6.28 Coolant temperature switch

Fig. 1 Coolant temperature switch

Pos. Designation in Designation Technical data

circuit diagram
B152 Coolant temperature switch Contact switches at approx. 110° C
to engine ground

138 BOMAG 008 918 12

Oil pressure switch and low oil pressure circuitry 6.29
6.29 Oil pressure switch and low oil
pressure circuitry

Fig. 1
1 Oil pressure switch

Pos. Designation in Designation Technical data

circuit diagram
1 B06 Oil pressure switch Below 0.8 bar the contact switches to
engine ground, closed without pres-
sure. Tightening torque 20 ± 2 Nm
with copper ring.

008 918 12 BOMAG 139

6.29 Oil pressure switch and low oil pressure circuitry

Fig. 2 Oil pressure switch

The oil pressure switch (B06) is mounted to the en-
gine oil filter. After starting it reports when a safe op-
erating pressure has been reached and causes the
warning light in the monitoring board (A15) to light, if
the engine oil pressure drops below approx. 0.8 bar.
In case of too low engine oil pressure with the engine
running, the monitoring board (A15) will send a time
delayed (10 sec.) 12 V signal to relay (K22, terminal
86). The relay interrupts the electric power supply to
the solenoid valve (Y13) and the diesel engine is shut
down.

140 BOMAG 008 918 12

Boost fuel solenoid valve 6.30
6.30 Boost fuel solenoid valve for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
During the starting process the solenoid valve is sup- sure starting of the cold engine additional fuel needs
plied with 12 Volt. to be injected at the time of starting and accelerating.
This injection adaptation serves the purpose of com-
pensating for condensation and leakage losses and

Fig. 3
1 Boost fuel solenoid valve

Pos. Designation in Designation Technical data

circuit diagram
1 Y01 Boost fuel solenoid valve 12 Volt, approx. 3,5 Amp.

008 918 12 BOMAG 141

6.31 Engine shut-down solenoid

6.31 Engine shut-down solenoid

Fig. 1
1 Engine shut-down solenoid

Pos. Designation in Designation Technical data

circuit diagram
1 Y13 Engine solenoid 12 Volt, approx. 4 Amp.

General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board in case of too low oil
pressure.

142 BOMAG 008 918 12

Electric throttle control 6.32
6.32 Electric throttle control

Fig. 1 Engine solenoid

Throttle control switch

Fig. 2 Throttle control switch

The throttle control switch (S120) is used to change
from "MIN" to "MAX" idle speed and vice versa.

008 918 12 BOMAG 143

6.32 Electric throttle control

Throttle control solenoid Y120

i Note
When switching on, the solenoid plunger is pulled
against the stop. The limit switch then switches the
pick-up and holding winding in series. The current flow
is reduced from approx. 70 A to approx. 3.5 A.

Fig. 3 Electric circuit of solenoid

The throttle control solenoid 5 (Fig. 3)) is equipped
with a pick-up winding (4) and a holding winding (3), Fig. 5
both switched in series. The holding winding has a l
Measure the gap between stop screw 1 (Fig. 5) and
much higher resistance than the pick-up winding. The
throttle lever (2).
"aux"-connection is connected between the two wind-
ings. The engine solenoid is equipped with a limit
switch (2), which is mechanically connected with the ! Caution
governor rod (1) on the diesel engine. This switch The gap should be min. 0.1 mm and max. 0.5 mm.
bridges the holding winding until the end position of
the governor rod is reached (high engine speed) If the gap is too small, the limit switch in the sole-
noid may not be able to operate.
This bridging has the effect, that the "aux"-terminal
has the same potential as the "+"-terminal. If the In case of a too wide gap the engine will not reach
bridge is open, the "aux"-terminal has almost the its maximum speed.
same potential as the "-" terminal, because of the low
resistance of the pick-up winding and the high resist-
ance of the holding winding.

Adjusting the solenoid

Fig. 4
l Switch on the ignition.
l Turn the rotary switch (Fig. 4) to position "MAX".

144 BOMAG 008 918 12

Heating flange on engine 6.33
6.33 Heating flange on engine the engine must be avoided and trouble shooting
should be performed instead.
Several successive starting attempts can cause
overheating of the heating flange .

Fig. 1 Heating flange

The heating flange is a component with an electrically
operated heating wire and high energy density used to
heat up the intake air in case of very low ambient tem-
peratures.
The heating power is approx. 2000 Watt.
The heating power improves the cold starting charac-
teristics and the exhaust emissions (white smoke) of
the diesel engine. Fig. 2 Heating flange (R19) with hose socket BF4M 2012 C
A differentiation is made between preheating, to as-
sure the cold start ability of the engine, and subse-
quent heating.

i Note
Pre-heating is triggered by switching on the ignition
(12 Volt on control unit A13, terminals 15(7) and S(2)).
With a coolant temperature of -30°C the preheating
time will be max. 52 seconds, with +5°C the minimum
time will be 38 seconds. During the preheating period
the control light in the monitoring board is permanently
on. In case of a fault the lamp will flash.
After-heating is triggered by the starting process (12
Volt on control unit A13, terminal 50(5)). With a cool-
ant temperature of -30°C the subsequent heating time
will be max. 180 seconds, with +25°C the minimum
time will be 35 seconds. This after-heating time is not
indicated by the control light.

! Caution
Multiple activation of the heater control in short
term operation (low generator running time) dis-
charges the starter battery.
If the engine does not start properly in case of au-
tomatic starting of the heating flange because the
starter does not get energized due to a fault and
does not crank the engine, the starting process
must be completely aborted (ignition key to OFF,
voltage supply to heating flange interrupted). In
order to avoid damage to heating flange or charge
air hoses caused by overheating, another start of

008 918 12 BOMAG 145

6.33 Heating flange on engine

Fig. 3
1 Heating control unit (A13)
2 Heating relay (K14)

Fig. 4 Coolant temperature sensor

1 Temperature sensor (B113) for heating flange
control (A13)
2 Coolant temperature switch (B30)

146 BOMAG 008 918 12

Heating flange on engine 6.33

Pos. Designation in Designation Technical data

circuit diagram
R19 Heating flange With a coolant temperature of -30°C
(Fig. 2) the preheating time will be max. 52
seconds, with +5°C the minimum
time will be 38 seconds.
With a coolant temperature of -30°C
the after-heating time will be max.
180 seconds, with +25°C the mini-
mum time will be 35 seconds.
12 Volt
approx. 2000 Watt
approx. 167 A
approx. 0.07 Ohm

2 (Fig. 3)) A13 Heating control unit 12 Volt

3 (Fig. 3) K14 Heating relay 12 Volt

1 (Fig. 4) B113 Temperature sensor for heating approx. 2 Ohm at 20°C

flange control (A13)
2 (Fig. 4) B30 Coolant temperature switch Contact switches at approx. 110° C
to ground

Fig. 5 Heating flange function diagram

1 Heating start
2 Signal lamp
3 Start
4 Switching relay
5 Condition
6 Terminal 15/S
7 Terminal L
8 Terminal 50
9 Terminal R
10 Start process
11 Ready for starting: 0 sec.

008 918 12 BOMAG 147

6.34 Checking the heating flange control

6.34 Checking the heating flange perature sensor is pulled off (simulated sensor fail-
ure), a coolant temperature of 0° C is assumed.
control
l Start the heating process.

Depending on the coolant temperature the control

light (K)(Fig. 1) will light between 30s and 50s, the
heating flange relay is energized.
l Place a tong-test ammeter over the heating flange
connecting line.

Rated current: 165 Amp +- 10 Amp.

i Note
The relay must remain energized for another approx.
15 seconds, after the control light has gone out.
After the engine has started the after heating time
must continue for 35 to 180 seconds. This after-heat-
Fig. 1 Monitoring module, old design (A15)
ing time is not indicated by the control light.

Fig. 2 Monitoring module, new design (A15)

i Note
During the preheating period the control light K (Fig.
1), c (Fig. 2) is permanently on. In case of a fault the
lamp will flash.
l The lamp flashes with a frequency of 1 Hz during
the pre-heating phase.

Sensor failure: Either short circuit or cable break-

age at the input to the control unit (A13), terminal
T(4)
l The lamp flashes with a frequency of 2.5 Hz over
the entire heating phase.

Heating flange failure: Either short circuit or cable

breakage at the output of the control unit (A13),
terminal R(6)

i Note
The heating flange only becomes active at a coolant
temperature below 25°C. When the plug of the tem-

148 BOMAG 008 918 12

Engine monitoring 6.35
6.35 Engine monitoring

Fig. 1 Monitoring module, old design Tank gauge, Pin 2: (0Ω ⇒ tank fuel, 65Ω ⇒ tank emp-
Output warning buzzer, Pin 1: +UB switching. ty, 26Ω ⇒ tank ½. If no level switch is connected or the
cable is broken, the gauge will go out.
Output engine shut down, Pin 9: +UB switching.
Water separator, Pin 3 and 4: Resistance <500kΩ .

Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time

10 sec. 2 min.
a Control light, over- red, flashing X X Switch off vibration, run
heating of engine Low-active engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
b Engine oil pressure red, flashing X X Check the engine oil lev-
control light Low-active el, if necessary repair the
engine.
c Control light for en- not used
gine air filter Low-active
d Charge control light yellow, lights Check V-belt, if neces-
High-active sary repair the generator
i Control light, water yellow, lights X X Check, clean the water
in diesel filter separator
k Control light, pre- yellow, lights
heating monitoring Low-active
j Coolant provision not used
Low-active
e Hydraulic oil filter yellow, lights X X Change the hydraulic oil
Low-active filter

008 918 12 BOMAG 149

6.35 Engine monitoring

Fig. 2 Monitoring module, new design Tank gauge, Pin 1: (0Ω ⇒ tank fuel, 65Ω ⇒ tank emp-
Output warning buzzer, Pin 23: +UB switching. ty, 26Ω ⇒ tank ½. If no level switch is connected or the
cable is broken, the gauge will go out.
Output engine shut down, Pin 24: +UB switching.
Water separator, Pin 21 and 22: Resistance <500kΩ .

Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time

10 sec. 2 min.
g Control light, over- red, flashing X X Switch off vibration, run
heating of engine Low-active engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
d Engine oil pressure red, flashing X X Check the engine oil lev-
control light Low-active el, if necessary repair the
engine.
h Control light for en- not used
gine air filter Low-active
f Charge control light yellow, lights Check V-belt, if neces-
High-active sary repair the generator
a Control light, water in yellow, lights X X Check, clean the water
diesel filter Low-active separator
b Control light, preheat- yellow, lights
ing monitoring Low-active
e Coolant provision not used
Low-active
i Hydraulic oil filter yellow, lights X X Change the hydraulic oil
Low-active filter

150 BOMAG 008 918 12

Engine monitoring 6.35
Water separator l Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Engine overheating

Fig. 3 Sensor water separator

l Press the plug interlock and disconnect the plug
(Deutsch plug).
l Bridge both contacts on the plug of the wiring loom.
Fig. 5 Coolant temperature switch
i Note l Press on the locking wire (Fig. 5) and pull off the
Control light i (Fig. 1) a (Fig. 2) lights up. An audible plug.
warning will sound and the engine is shut down after l Bridge both contacts on the plug of the wiring loom.
2 minutes.
l
Push the plug back together, the plug interlock
clicks into place.
i Note
Control light a (Fig. 1) g (Fig. 2) flashes. An audible
l Check the plug interlock by lightly pulling on the wir- warning will sound and the engine is shut down after
ing loom. 2 minutes.
Engine oil pressure l Push the plug back on, the plug interlock clicks into
place.
l
Check the plug interlock by lightly pulling on the wir-
ing loom.

Emergency stop switch

Fig. 4 Oil pressure switch

l Press on the locking wire and pull off the plug 1 (Fig.
4).
l
Apply the contact to engine ground. Fig. 6 Emergency stop switch
l
Press the emergency stop switch (Fig. 6). The en-
i Note gine should stop immediately.
The control light b (Fig. 1) d (Fig. 2) flashes. An audi-
ble warning will sound and the engine is shut down af-
ter 10 seconds.

008 918 12 BOMAG 151

6.36 Overview of electric components

6.36 Overview of electric components

1) Wiring loom cabin

152 BOMAG 008 918 12

Overview of electric components 6.36

1) Wiring loom engine

008 918 12 BOMAG 153

6.36 Overview of electric components

1) Wiring loom supply central electrics

2) Wiring loom battery-starter
3) Wiring loom ground, engine-frame
4) Wiring loom, battery-fuses
5) Wiring loom ground, battery-frame

154 BOMAG 008 918 12

Overview of electric components 6.36

1) Wiring loom rear frame

008 918 12 BOMAG 155

6.36 Overview of electric components

4) Wiring loom speedometer

156 BOMAG 008 918 12

Overview of electric components 6.36

4) Wiring loom wiring of frequency display

8) Wiring loom transducer for vibration frequency
9) Wiring loom adapter transducer

008 918 12 BOMAG 157

6.36 Overview of electric components

13) Wiring loom, tachograph-cabin

158 BOMAG 008 918 12

Overview of electric components 6.36

7) Wiring loom working lights

008 918 12 BOMAG 159

6.36 Overview of electric components

11) Wiring loom, lighting on railing

160 BOMAG 008 918 12

Overview of electric components 6.36

3) Wiring loom heating fan, new design

4) Wiring loom air conditioning, new design

008 918 12 BOMAG 161

6.36 Overview of electric components

1) Wiring loom acceleration transducer

5) Wiring (P16)

162 BOMAG 008 918 12

Operator's stand, old design 6.37

Fig. 7 7 S35, rotary switch vibration, high/low frequency

1 S00, ignition switch 8 S42, rotary switch, travel speed ranges
2 A15, instrument cluster 9 S01, Emergency stop switch
3 Vent for heating and ventilation, driver 10 S03, push button, warning horn
4 Vent for heating and ventilation, footwell 11 S120, rotary momentary contact switch for engine
5 S13, push button for vibration speed
6 Travel lever 12 S37, rotary switch for direction indicators left/right*

008 918 12 BOMAG 163

6.37 Operator's stand, old design

13 S14, rotary switch for hazard light system*

14 S15, rotary switch for lighting (StVZO)*
15 S53, rotary switch for working lights*
16 Steering wheel adjustment lever

* Optional equipment

164 BOMAG 008 918 12

Operator's stand, new design 6.38

Fig. 8 6 Vent for heating and ventilation, footwell

1 S00, start switch 7 S13, push button for vibration
2 A15, instrument cluster 8 Travel lever
3 A108, rotary switch for cabin fan 9 S35, rotary switch vibration, high/low frequency
* 10 S42, rotary switch, travel speed ranges
4 A108, rotary switch for air conditioning
5 Vent for heating and ventilation, driver 11 S01, Emergency Stop switch
* Optional equipment 12 S03, push button, warning horn

008 918 12 BOMAG 165

6.39 Cabin

13 S120, rotary momentary contact switch for engine 6.39 Cabin

speed
14 S37, rotary switch for direction indicators*
15 S14, rotary switch for hazard light system*
16 S15, rotary switch for lighting (StVZO)*
17 S53, rotary switch for working lights*
18 Steering wheel adjustment lever
19 Rotary switch for cabin heater

Fig. 9

a = S38, toggle switch for flashing beacon

b = S20, toggle switch for front windscreen wiper/

washer
up = windscreen wiper moves to end
position and stops.
down = Switches on front windscreen wip-
ing.
Push button = Front windscreen is sprayed dur-
ing wiping.

c = S21, toggle switch for rear windscreen wiper/

washer
up = windscreen wiper moves to end
position and stops.
down = Switches on wiping of rear wind-
screen.
Push button = Rear windscreen is sprayed dur-
ing wiping.

d = S163, toggle switch for rear windscreen heat-

ing

166 BOMAG 008 918 12

Fuses, old design 6.40
6.40 Fuses, old design

Fig. 10

g = E29, Reading and dashboard light Fig. 11

No. 2 = Fuse box, cabin
h = S45, Toggle switch for cabin lamp

i = S158, Toggle switch for reading and dashboard ! Danger

light
Fire hazard!
j = E70, Cabin lamp Do not use fuses with higher ampere ratings and
do not bridge fuses.
(1), 15A = (F43) Wiper/washer, rear
(2), 15A = (F44) Wiper/washer, front
(3), 10A = (F130) Relay for rear windscreen heat-
ing, reading light
(4), 20A = (F31) Cabin ventilator
(5), 10A = (F41) Flashing beacon
(6), 15A = (F144) Cab socket
(7), 15A = (F143) Rear windscreen heating
(8), 10A = (F42) Potential 30, cab light

Fig. 12
No. 3 = Fuses in electric installation box

i Note
Open the flap on the left hand side under the opera-
tor's stand
F03, 15A = Vibration
F05, 15A = Socket

008 918 12 BOMAG 167

6.41 Fuses, new design

F07, 15A = Hazard light* 6.41 Fuses, new design

F09, 10A = Parking tail light, left*
F10, 10A = Parking tail light, right*
F11, 15A = Head lights, StVZO*
F13, 30A = Starting
F14, 15A = Engine solenoid
F18, 10A = Working head lights, relay*
F19, 15A = Working head lights, front, left*
F22, 15A = Working head lights, rear*
F23, 10A = Warning horn
F24, 10A = Monitoring, gauges
F25, 10A = Solenoid valve brake/travel
Fig. 13
F39, 15A = Cab*
F70, 15A = Indicator*
! Danger
F105, 20A = Engine speed control
Fire hazard!
Do not use fuses with higher ampere ratings and
Danger
!
do not bridge fuses.
Fire hazard!
(1) 15A = (F43) Wiper/washer, rear
Do not use fuses with higher ampere ratings and
(2) 15A = (F44) Wiper/washer, front
do not bridge fuses.
(3) 10A = (F130) Night light
(4) 25A = (F31) Cabin ventilator
(5) 10A = (F41) Flashing beacon
(6) 15A = (F144) Cab socket
(7) 15A = (F143) Rear windscreen heating
(8) 10A = (F42) Cab lights

Fig. 14
No. 4 = Fuses in electric junction box

! Danger

Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
(15) 30A = (F13) Start switch
(16) 5A = (F68) Electronic immobilizer
* Optional equipment (17) 20A = (F105) Engine speed

168 BOMAG 008 918 12

Electronic control units 6.42
(18) 15A = (F11) Front head lights* 6.42 Electronic control units
(19) 15A = (F07) Hazard light
(21) 15A = (F22) Working headlights, rear Control units
(22) 15A = (F19) Working headlights, rear Control units (ECU = electronic control unit or ECM =
(23) 15A = (F09) Parking and tail light, left* electronic control module) are electronic modules
which are mainly installed in places where something
(24) 15A = (F10) Parking and tail light, right*
needs to be controlled or regulated. Control units are
(25) 15A = (F08) Direction indicators* used in almost any electronic sector in the automotive
(26) 10A = (F18) Pre-fuse for working head lights industry, but also to control machines, plants and oth-
er technical processes.
(27) 15A = (F14) Engine solenoid
Control units generally work according to the IPO-
(28) 10A = (F23) Warning horn
principle. IPO stands for Input-Processing-Output.
(29) 10A = (F25) solenoid valve for driving and brak- Sensors are available for input. Sensors determine a
ing physical characteristic like e.g. rotary speed, pres-
(30) 15A = (F39) Main fuse for cabin sure, temperature, etc. This value is compared with a
setpoint entered into or calculated in the control unit.
(31) 10A = (F24) Instruments
If the measured value does not match the stored val-
(32) 15A = (F03) Vibration ue, the control unit regulates the physical process by
(33) 10A = (F148) Control MESX, potential 15* means of actors, so that the measured actual values
match the setpoint again. This means that the actors
(34) 10A = (F84) control, contact 54
correctively interfere with the ongoing process.
(35) 15A = (F146) Control MESX, potential 30*
(37) 25A = (F124) Fuel pre-heating*

Fig. 1 Electronic control (ESX)

In current vehicles control units are linked via various
system buses (CAN, LIN, MOST, Flexray). The units
exchange information about operating states and oth-
Fig. 15
er relevant data in vehicle across the system. Further-
(80) 5A = (F150) GPS Receiver* more, the on-board diagnostic or the diagnostic
system of the vehicle is connected via such busses
(and possible K-lines). Furthermore, external diag-
nostic devices (alternatively Personal Computers or
Notebooks plus matching Interface) can communicate
with the control units. In this case the system will be
interrogated to find out whether the permanent self
tests of the control unit has revealed and registered
any faults in itself or on the connected sensors.

* Optional equipment

008 918 12 BOMAG 169

6.42 Electronic control units

Modules Signals
In the latest generation of machines BOMAG uses Analog signals
machine programmable modules. A module mainly
consists of a programmable microprocessor with ad- Process states are continuous (analog) when they
ditional circuitry for inputs and outputs. can be mapped by means of a real number, e.g. tem-
perature = 65.5 °C. The sensor converts a continuous
process status into an analog signal. If the control unit
needs the numerical value of the analog signal, an an-
alog-digital conversion is required.
Analog signals are needed to control, display or mon-
itor limit values. Checking the limit values of physical
quantities leads to the binary information: limit value
reached/not reached.

Binary signals
Process states are bivalent (binary) if they have only
2 possible states of truth, such as e.g. button pressed/
not pressed, object present/not present. The two
states of truth are mapped by means of defined states
of an information carrier, e.g. 'not pressed' equals 0 V,
'pressed' equals 24 V. These states are described
with {0,1} or {false, true}

Fig. 2 Module
The modules have control lights on inputs and outputs
to monitor the applied signals.

170 BOMAG 008 918 12

Electronic control units 6.42
CAN-bus, Controller Area Network
created by Bosch at the end of the eighties for auto-
mobile applications.

Development objectives:
Real-time critical, robust and low price communication
of control units, such as transmission and engine con-
trol, but also less time critical applications in the field
of convenience electronics, such as air conditioning.

Fig. 3

Why CAN?
l
Networking of control units for the realization of
complex functions.
l
Reduction of the extend of wiring and plug connec-
tions.
l
Better diagnostic possibilities (central diagnostics
socket).

Characteristics of CAN
It is a kind of serial data transmission. The individual
bits are transmitted one after the other, only 2 lines are
required.
CAN lines are twisted together 30 to 40 times per me-
tre. Electromagnetic interferences therefore always
occur simultaneously in both lines, the software is
thus able to filter out interfering signals more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow

Measuring on the CAN

Signals transmitted through the bus line can generally
not be measured with simple measuring instruments.
Testing is therefore quite complicated for the user.
Correct connection of lines can only be checked by
means of a continuity test. BOMAG display modules
are connected to the BUS to give engineers and user
the possibility to detect faults or to receive information
from the BUS.

008 918 12 BOMAG 171

6.43 Checking the voltage supply for the control unit

6.43 Checking the voltage supply for the control unit

Power supply for a control unit, general

All electronic switching and control units require an electric power supply to be able to work. If the plus or minus
supply is faulty, the control unit will work incorrectly or fail.

i Note
The following describes the electric power supply for the ESX-control.
(Fig. 4) shows a simplified representation of how the control unit (ESX, 68 pole) is connected. The complete rep-
resentation can be found in the wiring diagram of the machine.
The procedure can also be used for other controls. Pin assignment and voltage supply may be different, but the
procedures for line testing are generally the same.

Fig. 4 Circuitry example

1 = Engine block
ESX = Control unit
F00 = Main fuse
Fx,Fxx = Fuses potential 30
Fxxx = Fuses potential 15
G = Generator
G01 = Battery
GND = Housing earth
H08 = Charge control light
S00 = Ignition switch
S01 = Emergency stop switch
Pin 28 = Voltage supply for control
Pin 54 = if the signal (12/24 Volt) is applied, the control is switched on
Pin 55 = Ground supply for control
Pin 56 to 60 = Voltage supply for outputs
GND = Housing earth

172 BOMAG 008 918 12

Checking the voltage supply for the control unit 6.43
Fault in current supply, general
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides
of control units are in most cases connected to the vehicle mains supply via several cables, so that several par-
allel current branches exist. Checking the power supply is therefore slightly more difficult than expected. Another
point is the fact that every current branch has several plug connections, which could corrode over the years.
Corroded points are transition resistances and thus cause undesired voltage drops. In case of undesired voltage
drops the control unit is supplied with a lower voltage. This can lead to faulty reactions or even failure of the
control unit.

Fig. 5 Circuitry example

The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply
voltage.
The following faults may occur:
l
Line interruption in a plus supply line
l high voltage drop in a plus supply line
l
line interruption on the minus side

008 918 12 BOMAG 173

6.43 Checking the voltage supply for the control unit

Measuring principle for line testing

When a line conducts an electric current, a voltage drop will occur in the line (UV). The size of this voltage drop
UV depends on:
l the available amperage (I) and
l the electric resistance (Rline) of the current branch being checked.
In order to have reliable comparison possibilities at hand one should always work with the same amperage. Iden-
tical marginal conditions are therefore used in all of the following examples:
12 Volt – vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network.
12 V / 21 W – lamp as load in a 12 Volt vehicle network.
24 V / 21 W - lamp as load in a 24 Volt vehicle network.

Test steps
1. Switch off the ignition.
2. Unplug the control unit from wiring loom.
3. If available connect the Pinbox (Fig. 6) to the plug of the wiring loom, do not connect the control unit with the
Pinbox. If no Pinbox is available, provide measuring cables with appropriate plug-in contacts, e.g. spade-type
plugs.
4. Check with multimeter. If a setpoint is not reached, proceed step by step to identify the weak spot. Repair as
necessary. Repeat the measurement.

! Caution
The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition
first and then pull off or plug on the plug.
Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint.

Fig. 6 Pinbox for 68 pole ESX control

174 BOMAG 008 918 12

Checking the voltage supply for the control unit 6.43
General measuring setup to check a supply line (plus side)

Fig. 7 Measuring arrangement 12 Volt

1 = Supply line, plus side
2 = Plug contact in wiring loom plug on control or Pinbox (Fig. 6)
E = Lamp, 12V / 21 Watt
P = Multimeter
G01 = Battery as voltage source, 12V
UV = Voltage drop caused by the lamp current

Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.

008 918 12 BOMAG 175

6.43 Checking the voltage supply for the control unit

General measuring setup to check a return line (minus side)

Fig. 8 Measuring arrangement 12 Volt

1 = Return line, minus side
2 = Plug contact in wiring loom plug on control or Pinbox (Fig. 6)
E = Lamp, 12V / 21 Watt
P = Multimeter
G01 = Battery as voltage source, 12V
UV = Voltage drop caused by the lamp current

Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.

176 BOMAG 008 918 12

Checking the voltage supply for the control unit 6.43
Connection example to check the plus line between battery and plug pin 28

Fig. 9
X = Wiring loom plug disconnected from control unit or Pinbox (Fig. 6)
P = Multimeter
S00 = Ignition switched on. Setpoint : E is bright. UV max. 0.5 Volt
S00 = Ignition switched off. Setpoint : E is dark. UV = 0.0 Volt

008 918 12 BOMAG 177

6.43 Checking the voltage supply for the control unit

Connection example to check the minus line between battery and plug pin 55

Fig. 10
P = Multimeter
X = Wiring loom plug disconnected from control unit or Pinbox (Fig. 6)
E = Setpoint : E is bright. UV max. 0.5 Volt

178 BOMAG 008 918 12

Checking the voltage supply for the control unit 6.43
Test protocol for ESX
E lamp 12V / 21W in 12V vehicle network, to load the current branches.
E lamp 24V / 21W in 24V vehicle network, to load the current branches.
G01, battery
P multimeter, measuring range: DC

Plug pin Note Setpoints

28 Ignition ON
E between plug pin 28 and battery minus E is bright,
P between battery plus and plug pin 28 UV max. 0.5 Volt
28 Ignition OFF
E between plug pin 28 and battery plus E is dark,
P between battery minus and plug pin 28 UV = 0 Volt
54 Ignition OFF, emergency stop not operated
E between plug pin 54 and battery minus E is bright,
P between battery plus and plug pin 54 UV max. 0.5 Volt
54 Ignition OFF, emergency stop operated
E between plug pin 54 and battery minus E is dark,
P between battery plus and plug pin 54 UV = 0 Volt
55 Ignition OFF
E between plug pin 55 and battery minus E is bright,
P between battery plus and plug pin 55 UV max. 0.5 Volt
56, 57, 58, 59, Ignition OFF
60 E between plug pin 56, 57, 58, 59, 60 and battery minus E is bright,
P between battery plus and plug pin 56, 57, 58, 59, 60 UV max. 0.5 Volt

i Note
If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring
diagram.

Example 1:
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop is too high. There are two possible reasons.
Either all contacts are corroded, or the supply line between battery and fuse Fxx has poor contact.

Example 2:
Only one measuring value exceeds the setpoint. In this case the fault must be located between the last branch
and the corresponding plug pin.

008 918 12 BOMAG 179

6.44 Diagnostics concept

6.44 Diagnostics concept

Introduction
A correct and reliable diagnose is a general prerequisite for the detection of faults in system. For this to count
as a rule several points must be fulfilled. One of these points is the ability of the engine to run a systematic trouble
shooting procedure. However, this is only possible when a diagnostics concept is available and in practice. Trou-
ble shooting can generally be performed in various ways.

Fault description and questioning of the customer

After the customer has explained his complaint(s) the engineer has to ask further questions to track down the
cause of the fault. If the complaint is additionally related to electric/electronic components, the visual examina-
tion and a possible test drive must be subsequently followed by an interrogation of the error log. The further pro-
cedure in this case depends on the outcome of this interrogation.

Description of fault,
Questioning of customer

Visual inspection,
possible test drive

Interrogation of error log

(1)
Fault memorized in
error log
(2)
No fault memorized in
error log

Fig. 11

(1) Fault memorized in error log

Clear cause?
l If the fault message leaves no doubt, repair work may be started immediately.

(2) No fault memorized in the error log at the time of initial questioning
Even if the fault is in the electric/electronic part of the vehicle, a control unit will very often not detect a fault. Right
from the start you should be aware of the fact that a high proportion of faults is caused by contacts. This even
gets worse in case of older and neglected vehicles.
In order to examine the electric/electronic part of an electronic system it is recommended to check the incoming
sensor information and outgoing command values on a control unit. This requires profound knowledge of system
and components.

Consideration, if the error log has not recorded a fault

l
What could be the cause of the complaint?
l
Which measuring possibilities are available?

180 BOMAG 008 918 12

Diagnostics concept 6.44
Localizing faults
Line or component?

Fig. 12
l
In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the
connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense
to check the component and the connecting lines between control unit and component separately.
l
Checking the voltage supply for the control unit
l
Checking the sensor lines
l
Checking the actor lines

008 918 12 BOMAG 181

6.44 Diagnostics concept

Sequence after the fault is found

Fault found

Replace component or
repair the connecting line

Delete the error log, test drive

Read out the error log again

No fault memorized in
error log
Prepare the hand-over of the vehicle
Fault memorized in
error log
Check all work again,
rectify the fault

Fig. 13

182 BOMAG 008 918 12

7 Electronic modules

008 918 12 BOMAG 183

184 BOMAG 008 918 12
7.1 BEM, BOMAG Evib-meter

008 918 12 BOMAG 185

7.1 BEM, BOMAG Evib-meter

Bild 14

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.

186 BOMAG 008 918 12

BEM, BOMAG Evib-meter 7.1

Service Training
Electrics
MESX

P/N 00809705
Version 4.01

Status: 14.12.2009 Page 1 of 61

Author: T.Löw / TE
Dateiname: p:\schulung\elektrik_doc\wz\mesx_bvc\englisch\schulung elektrik mesx_v4.01_gb.doc

008 918 12 BOMAG 187

7.1 BEM, BOMAG Evib-meter

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 .............................................................................41
13 Fault codes of the ESX control ....................................................................................................47
13.1 Overview ..................................................................................................................................47
13.2 Description of fault reactions ...................................................................................................48
13.3 Detailed description of fault codes and their possible causes................................................49
14 Input codes for ESX control (only via BEM display module) .......................................................53
14.1 Travel system...........................................................................................................................53
14.2 Vibration ...................................................................................................................................54
14.3 Light .........................................................................................................................................54
14.4 Acceleration transducer ...........................................................................................................55
14.5 Diesel engine ...........................................................................................................................55
14.6 Setting the machine type .........................................................................................................56
14.7 Parameter change ...................................................................................................................57
15 Terminology in connection with ESX...........................................................................................58

Status:14.12.2009 Page 2 of 61
Author: T.Löw / TE

188 BOMAG 008 918 12

BEM, BOMAG Evib-meter 7.1

Service Training MESX

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

4.01 20.11.2009 Î further SN added Vogt,

Î List of machine types extended Löw
Î Software version history extended

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2 Proof of software change MESX

Version Date Description of changes resp.

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 Löw

BW179DH/PDH corrected
3.05 19.05.2005 Î Phase response correction acceleration transducer Löw
activated
Î "Flash Request" activated

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Version Date Description of changes resp.

4.00 01.05.2005 Î Languages Slovakian, Slovenian, Czech, Romanian Löw
added
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_40,21
3DHC,213PDHC,213PD_40,214DHC,214PDHC,216DHC
,216PDHC,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
4.01 23.05.2007 Î Vibration detection low/high amplitude adapted Löw
4.02 07.05.2008 Î Pulse numbers for BW213DHC and PDHC adapted Löw,
Î Faulty input for VM8 for machine type BW219DHC Nick
corrected
4.03 27.01.2009 Î Minimum Evib-value limited to 1, so that BCM does no Löw
longer interpret this value incorrectly
4.04 17.11.2009 Î Machine types BW216D_40, BW216PD_40 and Löw
BW218D_40 implemented

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3 Proof of software change BOP

Version Date Description of changes resp.

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

4.01 04.11.2008 Î - additional variable for brightness control OPUS21C Löw

added
Î - Representation of SW TN instead of "High-TN"
Î - Return to diagnostic page corrected for French
version
Î - SimulScreen activated for French version
Î - Changeover of GPS-mode prevented (jump to
page GPS-mode deactivated)
4.02 13.01.2009 Î Return to selection page "Scale type" corrected. Löw

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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"

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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.

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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
101 583 27 1001
177 PD 101 583 43 1001 XXX XXX XX XXXX
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
101 583 32 1001
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
101 583 31 1001
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
101 583 28 1001
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
101 583 33 1001
179 PDH 101 582 25 1001 XXX XXX XX XXXX 7512 3.03
101 583 35 1001
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
101 583 37 1001
213 PD 101 582 46 1001 XXX XXX XX XXXX 7539 4.00
101 583 13 1001
213 PDH 101 582 52 1001 XXX XXX XX XXXX 7532 3.03
101 583 15 1001
213 BVC 101 582 53 1001 XXX XXX XX XXXX 7533 1.02
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 D 101 583 42 1001 XXX XXX XX XXXX
214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03
101 583 19 1001
214 PDH 101 582 59 1001 XXX XXX XX XXXX 7542 3.03
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

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216 PDH 101 582 61 1001 XXX XXX XX XXXX 7552 3.03
101 582 65 1001

Machine type First serial number Last serial number Code Available from
version
219 D 101 582 72 1001 XXX XXX XX XXXX 7560 2.00
101 582 10 1001
861 582 75 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
219 PDH 101 582 71 1001 XXX XXX XX XXXX 7562 3.03
101 582 78 1001
226 DH 101 582 80 1001 XXX XXX XX XXXX 7571 3.03
101 582 83 1001
101 582 88 1001
226 PDH 101 582 81 1001 XXX XXX XX XXXX 7572 3.03
101 582 84 1001
101 582 89 1001
226 BVC 101 582 82 1001 XXX XXX XX XXXX 7573 3.01
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
332 XL 101 583 44 1001 XXX XXX XX XXXX

Machine type First serial number Last serial number Code Available from
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

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Machine type First serial number Last serial number Code Available from
version
177 D-40 901 582 26 1001 XXX XXX XX XXXX 7600 4.00
177 DH-40 901 582 27 1001
177 DHC-4 101 582 00 1001 XXX XXX XX XXXX 7601 4.00
101 583 29 1001
177 PDHC-4 101 582 01 1001 XXX XXX XX XXXX 7602 4.00
101 583 30 1001
177 PDH-40 901 582 28 1001 XXX XXX XX XXXX 7609 4.00
179 DHC-4 101 582 02 1001 XXX XXX XX XXXX 7611 4.00
101 583 34 1001
179 PDHC-4 101 582 03 1001 XXX XXX XX XXXX 7612 4.00
101 583 36 1001
211 D-40 101 582 42 1001 XXX XXX XX XXXX 7620 4.00
901 583 02 1001
901 583 25 1001
211 PD-40 101 582 47 1001 XXX XXX XX XXXX 7629 4.00
901 583 03 1001
901 583 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
901 582 55 1001
901 583 07 1001
213 DH-40 901 582 56 1001
213 DHC-4 101 582 04 1001 XXX XXX XX XXXX 7631 4.00
101 583 11 1001
213 PDHC-4 101 582 05 1001 XXX XXX XX XXXX 7632 4.00
101 583 12 1001
213 PD-40 101 582 49 1001 XXX XXX XX XXXX 7639 4.00
213 PDH-40 901 582 57 1001
214 DHC-4 101 582 06 1001 XXX XXX XX XXXX 7641 4.00
101 583 17 1001
214 PDHC-4 101 582 07 1001 XXX XXX XX XXXX 7642 4.00
101 583 18 1001
216 D-40 101 583 39 1001 XXX XXX XX XXXX 7650 4.04
216 DHC-4 101 582 08 1001 XXX XXX XX XXXX 7651 4.00
101 583 21 1001
216 PD-40 101 583 40 1001 XXX XXX XX XXXX 7659 4.04
216 PDHC-4 101 582 09 1001 XXX XXX XX XXXX 7652 4.00
101 583 22 1001
218 D-40 101 583 34 1001 XXX XXX XX XXXX 7670 4.04

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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).
Vorzeichen

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:

1. 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.
2. 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 0 .
3. 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.

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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“.

The display module now permanently shows the code 7 0 1 0 .

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.

Switch the ignition off and on again.

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 a default machine type setting 7 5 0 0 .

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6.4 Inverting the direction signal (only via display module)

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 the travel direction correspond with the actual travel direction.

Note: Parameter adjustments can only be performed when the engine is not running!

Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.

The display module now permanently shows the code 7 6 0 0 .

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:

Note: Parameter adjustments can only be performed when the engine is not running!

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 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.

Switch the ignition off and on again.

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 the travel direction correspond with the actual travel direction.

Note: Parameter adjustments can only be performed when the engine is not running!

Press key "?" to open the screen page "MENU". The following screen is displayed:

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 "?" to open the screen page "MENU". The following screen is displayed:

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".

Press "ESC" to leave the page.

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 = 12V)

Ligths: Status MESX input light detection (LED on = 12V)

MD+ Status MESX input MD+ (detection engine running) (LED on = 12V)

Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)

+01234 Distance pulses detected by the MESX (10cm 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: current voltage 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 = 12V)

Ligths: Status MESX input light detection (LED on = 12V)

MD+ Status MESX input MD+ (detection engine running) (LED on = 12V)

Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)

+01234 Distance pulses detected by the MESX (10cm 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 "?" to open the screen page "MENU". The following screen is displayed:

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 adjustment. The symbol (F14)
lights green for a moment as a sign of confirmation.

Press "ESC" to leave the page.

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7.5 Setting the machine serial number

Press key "?" to open the screen page "MENU". The following screen is displayed:

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 adjustment. The symbol (F14) lights green for a
moment as a sign of confirmation.

Press "ESC" to leave the page.

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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 "?" to open the screen page "MENU". The following screen is displayed:

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:

Press "ESC" to leave the page.

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 "?" to open the screen page "MENU". The following screen is displayed:

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").

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.

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7.8 Changing the display mode (metric/imperial)

Press key "?" to open the screen page "MENU". The following screen is displayed:

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").

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.

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7.9 Switching the GPS Receiver Voltage Supply Mode

Press key "?" to open the screen page "MENU". The following screen is displayed:

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
touchscreen "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 touchscreen now shows 4 switches near the right hand edge, choose 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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9 Block diagram BEM
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BOMAG
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10 Block diagram BTMplus / VARIOCONTROL

BOMAG
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11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile
BEM, BOMAG Evib-meter

BOMAG
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BOMAG
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008 918 12
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.

ESX terminal Signal description Nominal values (voltage / current)

BEM, BOMAG Evib-meter

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): ) ca. 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

Analog input / voltage input 0..8.5 V
X44:8

X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analog input / voltage input 0..8.5 V Stop bottom ) approx. 2.2 V
Neutral position ) approx. 4.25 V
Stop top ) approx. 6.6 V

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ESX terminal Signal description Nominal values (voltage / current)

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) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:17 Input button STOP (option) Push button pressed ) 12 V

BOMAG
Digital input active high Button not pressed ) 2V
X44:18 Input button PRINT (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:19 Input button CLEAR (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:20

X44:21

X44:22

X44:23 Output voltage supply for sensors Nominal voltage = 8.5 V

This output supplies steering joystick, speed range selector 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

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ESX terminal Signal description Nominal values (voltage / current)
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!
BEM, BOMAG Evib-meter

operating unit.

X44:28 Input potential terminal 15 Control switched on ) 12 V

Digital input active high Control switched off ) 12 V
This signal must be present, so that the control can work.
X44:29 Input acceleration transducer VV/VL15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4.2 .. 4.3 V

Analog input / voltage input 0..8.5 V
X44:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): 4.2 .. 4.3 V

BOMAG
)
Analog input / voltage input 0..8.5 V
X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

Open circuit voltage (vibration off): ) 4.2 .. 4.3 V

Analog input / voltage input 0..8.5 V
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.
Digital input active high

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ESX terminal Signal description Nominal values (voltage / current)

X44:36

X44:37 Input D+ generator Engine running / engine being 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

BOMAG
X44:44

X44:45

X44:46 Output valve 1 front valid current range: approx. 0..1.5 A

PWM digital output (max. 4 A)
X44:47 Output valve 2 front valid current range: approx. 0..1.5 A
PWM digital output (max. 4 A)
X44:48

X44:49

X44:50

X44:51

X44:52

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ESX terminal Signal description Nominal values (voltage / current)
BEM, BOMAG Evib-meter

BOMAG
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ESX terminal Signal description Nominal values (voltage / current)

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

X44:57 Voltage supply for outputs approx. 12 V measured against ground

X44:58 Voltage supply for outputs approx. 12 V measured against ground

X44:59 Voltage supply for outputs approx. 12 V measured against ground

X44:60 Voltage supply for outputs approx. 12 V measured against ground

BOMAG
X44:61

X44:62

X44:63

X44:64

X44:65 Mouse port Baby Boards approx. 0 V

X44:66 Mouse port Baby Boards approx. 0 V

X44:67 Mouse port Baby Boards approx. 0 V

X44:68 Mouse port Baby Boards approx. 0 V

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13 Fault codes of the ESX control

13.1 Overview

Fault code Description of fault

4501 - Position controller (exciter potentiometer, valves)
4540
4601 - Acceleration transducer
4620
8000 - Internal software errors
8250

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13.2 Description of fault reactions

Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Impairment of function, the faulty function is overridden by an emergency function.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
3 Fault of a partial function, the partial function cannot be overridden 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.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
4 Fault of a partial function, the partial function cannot be overridden by an emergency function.
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.
Fault code is displayed.
Signal light in BOP (option) lights in 1 second intervals.
5 Fatal fault. The function of the control is no longer assured.
The control will be 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 saved in the error log!

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13.3 Detailed description of fault codes and their possible causes

Fault Description of fault Possible cause Termina Input Fault

code l on code for reaction
ESX 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
BEM, BOMAG Evib-meter

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
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Fault Description of fault Possible cause Termina Input Fault

code l on code for reaction
ESX 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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Fault Description of fault Possible cause Termina Input Fault
code l on code for reaction
ESX 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
BEM, BOMAG Evib-meter

) 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
specified range (see signal description). ) Transducer defective X44:31

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
specified range (see signal description). ) Transducer defective X44:07

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
specified range (see signal description). ) Transducer defective X44:07

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Fault Description of fault Possible cause Termina Input Fault

code l on code for reaction
ESX diagnose
8 0 0 0 Error message "Incorrect BOP Software version" - - 2
The software version of the BOP is too old, i.e.
various functions cannot be displayed.
This fault cannot be rectified 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 rectified 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 +12 V 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 +12 V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)

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14 Input codes for ESX control (only via BEM display module)

14.1 Travel system

Input code Description of display function Display values

1000 Transducer for travel direction 0000 ) 0V
Show status of transducer. 0001 ) 12 V
BEM, BOMAG Evib-meter

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

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14.2 Vibration

Input code Description of display function Display values

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

Input code Description of display function Display values

3010 Input light switch 0000 ) Light OFF
The status of the lighting is displayed. 0001 ) Light ON

BOMAG
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14.4 Acceleration transducer

Input code Description of display function Display values

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.
BEM, BOMAG Evib-meter

14.5 Diesel engine

Input code Description of display function Display values

5000 Input MD+ 0000 ) Engine OFF
Show status of diesel engine. 0001 ) Engine ON

BOMAG
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14.6 Setting the machine type

Input code Description of display function Display values

7000 Shows the adjusted machine type
7010 Switches on function "Set machine type"
7011 Confirms entered machine type
7500..76 Pre-select machine type
99

BOMAG
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14.7 Parameter change

Input code Description of display function Display values

7600 Switch on function "Invert travel direction" Display value 7 6 0 0
7601 Inverts the actually adjusted travel direction see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
BEM, BOMAG Evib-meter

BOMAG
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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

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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 states are permitted within a certain range. E.g. room temperature
0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 to 300 ; valve 0% to
100% opened (proportional valve)

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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 (closed loop control open (control chain)
circuit)
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 expense: 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.

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Current and voltage measurement

Ohm’s law:
U =R∗I
U = Voltage
R = Resistance U
I=
I = Current 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 38, "")

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: 14.12.2009 Terminology Page 61 of 61

Author: T.Löw / TE

008 918 12 BOMAG 247

7.1 BEM, BOMAG Evib-meter

248 BOMAG 008 918 12

7.2 Electrics module A68

008 918 12 BOMAG 249

7.2 Electrics module A68

250 BOMAG 008 918 12

Electrics module A68 7.2

Seat contact switch

Only machines with cabin are equipped with the seat contact circuitry.
This circuit also contains the vibration relay. Machines with ROPS or sun canopy are not equipped with
the seat contact circuitry.

The following applies in general:

When the seat is not occupied it can be assumed that in the worst case the machine may perform
uncontrolled movements. In such an instance the machine must be shut down at the latest after 4
seconds. During these 4 seconds the driver must be warned about this condition by the warning buzzer
in the dashboard and the area around the machine by the backup alarm. To start travel movement of
the machine the driver's seat must be occupied, as otherwise the diesel engine will be shut down
immediately. This prevents the machine from being started from the outside (e.g. through the open
window).

1. Starting of the engine should only be possible with the travel lever in position "Brake".

2. Driver standing (seat contact control light does not light up): While the engine is running shift the travel
lever to travel operation --- then engine shut be shut down immediately, the seat contact light lights up,
warning buzzer and backup alarm sound. If the travel lever is returned to "Brake" position during the
shut-down process, the fuel solenoid is switched on again and the engine will automatically start.
Otherwise the engine must be restarted.

3. Driver seated: (seat contact control light does not light up): Normal operation, no warning active.
Driver gets up --- control light comes on and both warning buzzers sound. Driver sits down again within
4 seconds --- machine returns to normal operation. Driver does not sit down again within 4 s --- engine
is shut down. If the driver sits down again while the engine is being shut down, the fuel solenoid is
switched on again and the engine will automatically start. Otherwise the engine must be restarted.

In addition to the seat monitoring system all

monitoring functions are implemented by the

Module UPM2

008 918 12 BOMAG 251

7.2 Electrics module A68

The hardware us available under BOMAG part-number 057 664 81.

Stay-Alive LED

Programmierstecker

Spannungs- Status-
versorgung Leuc htdioden
1

4
3

5
2

7
8
9

14
15
6

10

13
12
11

Vibrationstaster
Versorgungsspannung (+UB)

Sitzkontaktschalter
Versorgungsspannung (+UB)

Vibration
Haltewicklung Abstellmagnet

Masseanschluß

Generator / D+ Signal
Anzugswicklung Abstellmagnet
Bremsventil
Warnsummer

Masseanschluß

Öldruck
Fahrhebel

Fig. 1: Module

The complete module (including the specific software) is available under

BOMAG part-number 582 701 68.
The following applies when measuring the signal levels:

PIN Potential with LED on Potential with LED off

Inputs Ground 0V Input open
Output PIN8 Ground 0V Output open
Outputs general ≈ operating voltage (UB- 0,7V) Ground 0V (<< 1V)

252 BOMAG 008 918 12

Electrics module A68 7.2

Emergency operation

If a bridge is inserted between PIN 2 and PIN 3 of the module, the bias coil is permanently
supplied with current (as long as the ignition is on) and the vibration is switched on (vibration
can be switched on/off with the vibration selector switch).
Inserting a bridge between PIN 10 and the connecting cable to PIN 8 opens the brake (the
brake can then be switched on/off e.g. via the parking position of the travel lever). The
module is then bridged (only with motors without pickup winding.

Description of function

In addition to m onitoring the seat occupation this m odule can also be used to control the
hydraulic brake and the function of the vibration relay.
The following sequences were used in the UPM2 software to realize the seat occupation
m onitoring system :

Sw itching on the ignition

- The Stay-Alive-LED on the m odule shows the software version (currently version 3) once
by m eans of a flashing code (changes to perm anent light).
- W hen the travel lever is in neutral position (PIN12 = Active-LO W ) the bias coil of the
shut-down solenoid (PIN4 = Active-HIG H) is switched on and the pickup winding (PIN7 =
Active-H IG H) is energized for 2 seconds. In this situation the seat contact switch has no
effect. T here will be no visual or audible warning if the driver's seat is not occupied.
- If the travel lever is returned to neutral position after the ignition has been switched on,
the bias coil is autom atically switched on and the pickup winding is autom atically
energized for 2 seconds (starting is now possible).
- As long as no D+ signal is detected (starting has not yet been perform ed and the engine
is therefore not yet running), the vibration can be switched on by the vibration control
switch.
- Vibration is switched off.

Starting the engine is only possible with the travel lever in neutral position. Since the starter
does still rotate despite this fact, external blockage of the starter is required when the travel
lever is operated.

Starting the engine

- If running of the engine is detected through D+, the hydraulic brake is autom atically
released (if it is no longer activated by the travel lever in parking position).
- If the travel lever is not in neutral position (irrespective of the seat contact), the bias coil
of the shut-down solenoid is switched off again.

008 918 12 BOMAG 253

7.2 Electrics module A68

Engine running
- Vibration can be switched on with the vibration push button when D+ or oil pressure is
applied (OR-linkage).
- The bias coil remains switched on.
- There will be no visual or audible warning when the driver's seat is unoccupied even
though the travel lever is out of neutral position.
- If the driver's seat is not occupied and the travel lever is actuated in this condition, the
bias coil of the shut-down solenoid is immediately switched off and the engine will stop.
The signalling device (horn) is activated.
W hen D+ is no longer applied (engine not running) the signalling device is switched off
and the hydraulic brake closes after 1.5 seconds.
- W hen leaving the driver's seat after shifting the travel lever out of neutral, the signalling
device will be activated. 4 seconds later the bias coil of the shut-down solenoid will be
switched off and the engine will stop.

Engine stops
- If the engine stops, but D+ is still applied, the bias coil is switched on again and the
pickup winding is energized for 2 seconds, as soon as the driver takes his seat or the
travel lever is returned to neutral position.
- The signalling device is switched off. The module is then in Engine Running mode and
responds as described above.

Engine has stopped

The following applies in all cases (irrespective of travel lever and seat contact) if the D+
signal is missing:
- If the D+ signal is no longer applied the module will decide that the engine has stopped.
- The bias coil of the shut down solenoid is immediately switched off and the brake closes
1.5 seconds later.
- The machine can be restarted by switching the ignition off and on again (new start).
- However, if the D+ signal (for what ever reason) returns by itself, the bias coil of the shut
down solenoid is automatically switched on and the pickup winding is energized for 2
seconds, if the driver has sat down.
- If the driver is not sitting while D+ returns, the reaction will be as described above in
Engine Running mode, depending on the history (was the driver's seat left or the travel
lever actuated first?).
- If, in addition to the missing D+, there is no oil pressure, the vibration will be shut down.
The vibration is not automatically switched on if one of the signals returns!

254 BOMAG 008 918 12

Electrics module A68 7.2

New start
A new start (after the engine has been shut down) is only possible after switching the ignition
on again (see Switching on ignition) or after D+ has returned (see Engine has stopped).

Miscellaneous
Due to the design of the Perkins engines restarting of a still turning engine by returning the
travel lever to neutral or sitting down on the driver's seat is not possible.
On machines with Perkins engine restarting always requires the ignition, if the bias coil of
the shut down solenoid hd been switched off (picking up of the winding only possible after
the engine has stopped).

The pickup winding must be triggered by an additional relay, because the module is only
able to supply a current of 4 ampere.
The module works from a supply voltage of 7 Volt.

008 918 12 BOMAG 255

7.2 Electrics module A68

0 Hardware description

The seat occupation monitoring module consists of the modified UPM2 module.
The inputs are configured to match the following table:

Input Behaviour Comment

Input PIN11 LOW-active LED lights when applying ground potential (0V)!
Input PIN12 LOW- active LED lights when applying ground potential (0V)!
Input PIN13 LOW- active LED lights when applying ground potential (0V)!
Input PIN14 LOW- active LED lights when applying ground potential (0V)!
Input PIN15 LOW- active LED lights when applying ground potential (0V)!

0.1 Pin assignment of inputs

Signal name Module Signal at input

pin
Seat contact switch 11 0V = driver sits, LED on
+U B = driver stands up, LED off
Travel lever 12 0V = travel lever neutral position LED on
+U B = travel lever actuated LED off
Oil pressure 13 0V = oil pressure fault LED on
+U B = no oil pressure fault LED off
Generator / D+ signal 14 0V = engine stopped LED on
+U B = engine running LED off
Vibration button 15 0V = Vib. on/off LED on
+U B = Vib. off/on LED off

0.2 Pin assignment of outputs

Signal name Module Signal at output

pin
Bias coil for shut down 4 +U B = ON LED on
solenoid 0V = OFF LED off
Vibration 5 +U B = Vibration should be on LED on
0V = Vibration should be off LED off
W arning buzzer/light 6 +U B = W arning buzzer on LED on
0V = W arning buzzer off LED off
Pickup winding shut 7 +U B = ON LED on
down solenoid 0V = OFF LED off
Brake valve 8 +U B = Brake applied LED off
0V = Brake released LED on

256 BOMAG 008 918 12

7.3 Electric module K04

008 918 12 BOMAG 257

7.3 Electric module K04

258 BOMAG 008 918 12

Electric module K04 7.3

008 918 12 BOMAG 259

7.3 Electric module K04

260 BOMAG 008 918 12

7.4 Electric module A72, old design

008 918 12 BOMAG 261

7.4 Electric module A72, old design

262 BOMAG 008 918 12

Electric module A72, old design 7.4

008 918 12 BOMAG 263

7.4 Electric module A72, old design

264 BOMAG 008 918 12

Electric module A72, old design 7.4

008 918 12 BOMAG 265

7.4 Electric module A72, old design

266 BOMAG 008 918 12

7.5 Electric module A108

008 918 12 BOMAG 267

7.5 Electric module A108

268 BOMAG 008 918 12

008 918 12
Rotary switch for cabin fan Rotary switch for air conditioning system
Electric module A108

BOMAG
Cabin fan 1 Cabin fan 2
7.5

269
7.5 Electric module A108

270 BOMAG 008 918 12

8 Speedometer Module

008 918 12 BOMAG 271

8.1 Speedometer module

8.1 Speedometer module

Fig. 1 Speedometer module

Description of function
With the programmable module BM UPM the software
realizes a speedometer function. To ensure that the
tachometer function is not only realized for one spe-
cial roller, there is a possibility to adapt the module to
any machine with the help of a self-teaching mode.
l Whenever the module is switched on the system
runs a self-test by passing through the entire dis-
play range in both directions. The display self-test
takes approx. 15 seconds.
l After this the module changes to measuring mode.
The frequency of the travel pulses of the roller is de-
tected and converted to a proportional output volt-
age that triggers the display.
l The output signal for the display is a PWM-signal.

Manual testing of the speedometer

When the module is in learning mode a manual dis-
play test can be performed via the input "Test". For
this purpose the input "IN" must be energized with 12
Volt, whereupon the speedometer is constantly trig-
gered with 3 Volt.

272 BOMAG 008 918 12

Speedometer module 8.1

Pin-no. module Pin name Description

Test E_ANZEIGENTEST Input HIGH active: Activate manual display test

IN E_WEGIMPULSE Input: Path pulses
Learn E_LERNMODUS Input: HIGH active: Activate teach mode

OUT - Display - Output: Ground connection for speedometer

OUT + Display + Output: Output voltage for speedometer

GND (2X) Ground Input: Module ground connection

15/45 (2X) 15/54 Input: Module voltage supply

Teaching the module

In self-teach mode the number of arriving path pulses
is detected at the input (IN). The number of recorded
pulses is referred to as pulse number per 10 or 18 m
(machine dependent) travel distance of the roller.
l Connect the ground cable (-).
l Connect the sensor signal (speed sensor) to fre-
quency input (IN).
l Install a cable bridge from terminal "15/54" to the
connection "Teach".
l Connect potential "Ignition / 15" to connection "15/
54".
l Switch on the ignition, start the engine and travel a
distance of exactly 10 m.

Caution
!

BW24RH, BW27RH, C550H and C560H = travel 18

meters.
All other machines = travel 10 meters.

i Note
If the module is in teach mode the LED on output
"OUT +" will flash with the frequency of the path puls-
es arriving at input (IN).
l
Disconnect the cable bridge from "Teach" to "15/
54“.
l
Switch the ignition off and on again (Reset).

The module has now learned the pulses of the

speed sensor.
l
Connect the speedometer (0 to 6 Volt) to "OUT +"
and "OUT –“.

008 918 12 BOMAG 273

8.1 Speedometer module

274 BOMAG 008 918 12

9 582 502 15 dust protection / 582 502 16 gasket

008 918 12 BOMAG 275

9.1 Assembling the dust protection

9.1 Assembling the dust protection

1. Unscrew the fastening screws (Fig. 1).

Fig. 1
2. Lift the operating console up and out (Fig. 2).

Fig. 2
3. Pull the wiring loom carefully out of the dash-
board(Fig. 3).

Fig. 3
4. Attach the new gasket to the back of the operat-
ing console (Fig. 4).

i Note
Pull the adhesive strip off the gasket and stick on
the gasket.

Fig. 4

276 BOMAG 008 918 12

Assembling the dust protection 9.1
5. Pull the dust protection bag over the operating
console (Fig. 5), (Fig. 6) and (Fig. 7).

Fig. 5

Fig. 6

Fig. 7
6. Tighten the screws for the operating console
hand tight (Fig. 8).

i Note
Ensure the seal/gasket is fitted correctly.

Fig. 8

008 918 12 BOMAG 277

9.1 Assembling the dust protection

7. Disassemble the dashboard, for this purpose un-

screw the fastening screws (4X), take off spacers
and washers (Fig. 9).

Fig. 9
8. Lift the dashboard up (Fig. 10) and.....

Fig. 10
9. ... fold it back (Fig. 11).

Fig. 11
10. Wrap the dust protection bag around the wiring
looms and fasten it with cable straps (Fig. 12).

Fig. 12

278 BOMAG 008 918 12

Assembling the dust protection 9.1
11. Assemble the dashboard (Fig. 13).

Fig. 13
12. Fasten the dashboard with fastening screws (4X),
spacers and washers (Fig. 14).

Fig. 14
13. Tighten the fastening screws (Fig. 15).

i Note
Check the function of control switches.

Fig. 15

008 918 12 BOMAG 279

9.1 Assembling the dust protection

280 BOMAG 008 918 12

10 Hydraulics

008 918 12 BOMAG 281

10.1 Hydraulic circuit

10.1 Hydraulic circuit

Open circuit

Fig. 1 Open circuit

Open in this case means that the suction line of a pump) (Fig. 1) normally is situated below the fluid level, the
surface of which is in open contact with atmospheric pressure. Reliable equalization of pressure between the air
in the hydraulic oil tank and the ambient air ensures problem free suction of the pump.
In an open circuit the hydraulic fluid is fed to the consumer (2 or 3) and also returned to the tank through way
valves.

282 BOMAG 008 918 12

Hydraulic circuit 10.1
Closed circuit

Filter

Cooler (option)

Fig. 2 Closed circuit

One talks about a closed hydraulic system, when the hydraulic oil flows from the consumer (3) (Fig. 2) directly
back to the pump (2).
The closed circuit consists of a high and a low pressure side, depending on the load direction (take-off moment
on the consumer).
The high pressure side is protected by pressure relief valves (4), which release oil into the low pressure side.
The medium remains in the circuit.
Only the permanent leakage on pump and motor needs to be replenished. This is accomplished by a charge
pump (1), which permanently delivers a sufficient amount of fluid (charge capacity) through a check valve (5)
into the low pressure side of the closed circuit. Any excess oil delivered by the charge pump, which works in an
open circuit, runs through a charge pressure relief valve (6) back into the tank. Charging the low pressure side
enables the pump (2) to work with higher operating data.

008 918 12 BOMAG 283

10.2 Connection overview

Fig. 1 Travel pump

284 BOMAG 008 918 12

Connection overview 10.2
1 Control solenoid, high frequency 21 Connection D, charge pressure to filter
2 Control solenoid, low frequency 22 Muliti function valve 345 bar (boost check and
3 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive high frequen-
pressure relief valve), travel system cy
4 Connection, charge pressure to brake solenoid 23 Connection S, suction line charge pump from hy-
valve, travel speed range selection and charge oil draulic oil tank
supply for vibration pump 24 Muliti function valve 345 bar (boost check and
5 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive low frequen-
pressure relief valve), travel system cy
6 Setscrew, mechanical neutral position 25 Charge pressure relief valve, vibration pump
(blocked)
7 Connection L, leak oil connection to vibration
pump 26 Connection E, charge oil from travel pump
8 Lever, travel control 27 Connection L1, leak oil connection to travel pump
9 Charge pressure test port 28 Pressure test port MB, high pressure reverse
10 High pressure port B, high pressure reverse 29 Charge oil from filter
11 Charge pressure relief valve, 26 bar 30 Pressure test port MA, high pressure forward
12 Adjustment screw, low frequency 31 High pressure port A, high pressure forward
13 Connection L2, leak oil to tank 32 Setscrew, mechanical neutral position, vibration
14 Pressure test port MB, high frequency 33 Leak oil connection D, leak oil from axle drive mo-
tor
15 High pressure test port MA, low frequency
34 Leak oil connection A, leak oil from travel pump
16 High pressure port A, low frequency
35 Leak oil connection G, leak oil from drum drive
17 High pressure port B, high frequency
motor
18 Charge pump, internal
36 Leak oil connection F, leak oil from vibration motor
19 Connection L2, to drum drive motor (flushing)
37 Radiator inlet
20 Adjustment screw, high frequency

008 918 12 BOMAG 285

10.3 Travel pump 075

Variable displacement pumps, 90R055 and 90R075

10.3 Travel pump 075

Caution
!

The variable displacement axial piston pump must be filled with pressure fluid and purged during start-
up and operation. This must also be considered for longer periods of rest, because the system may run
empty through the hydraulic lines.
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
It has been designed for mobile applications, e.g. in construction equipment.
The pump is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed
circuits. The volumetric flow is proportional to the drive speed and the displacement.

Mechanical displacement control (MDC)

The mechanical displacement control converts a mechanical input signal (control lever position 1 (Fig. 2)) into a
position controlling output signal by means of a spring centred 4-way servo valve. This valve opens the hydraulic
pressure to one side of the control cylinder. The control piston inside the control cylinders moves the swash plate
within a swashing angle range of ±17° and thereby changes the displacement of the pump from maximuim dis-
placement to the one direction to the maximum displacement to the opposite direction.
The mechanical displacement control has no adjustment elements. The control is held in neutral position by re-
setting springs and washers at both ends of the control piston. Since there are no further resetting springs on
the input shaft of the control, the shaft will automatically be correctly positioned when it is mounted to the pump.

Fig. 2

1 Actuating lever 5 Cylinder block

2 Drive shaft 6 Valve plate
3 Bearing for swashing cradle 7 Control piston
4 Pistons with slipper pads

286 BOMAG 008 918 12

Travel pump 075 10.3

Fig. 3

1 Drive shaft 5 Cylinder block

2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump ( optional)
4 Pistons with slipper pads 8 Valve plate

008 918 12 BOMAG 287

10.3 Travel pump 075

Hydraulic diagram

Servo control

Multi-function valve

Multi-function valve

Charge pressure relief valve

Fig. 4
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.
Since the control is spring centred, the swash plate will automatically return to neutral position under the follow-
ing conditions, thereby interrupting the oil flow and braking the machine:
l
when shutting the engine down
l
if the external control cable comes loose
l
if the pressure in the charge circuit drops below a certain value.

1 to the control 6 Drive shaft

2 Multi-function valves 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Connection A
5 Charge pressure relief valve B Connection B

Multi-function valve
The multi-function valve consists of:
l the no-stroke pressure controller
l
the high pressure relief valve

288 BOMAG 008 918 12

Travel pump 075 10.3
l the boost check valve
l and the bypass function

Fig. 5 Multi-function valves

Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override and a
pressure relief valve, one after the other.
The multi-function valve contains a no-stroke pressure controller and a high pressure relief valve. When the pr-
adjusted pressure value is reached, the no-stroke pressure controller will return the pump very quickly back to-
wards neutral, thereby limiting the system pressure. In case of a unusually sudden pressure increase the high
pressure relief valve will immediately limit the system pressure by opening the system flow to the low pressure
side of the hydraulic circuit. The no-stroke pressure controller serves as pre-control unit for the piston of the high
pressure relief valve. The high pressure relief valve is designed for responding to pressures approx. 35 bar
above the nominal value of the no-stroke pressure.
Boost check valves The boost check valves are cone valves inside the multi-function valve. It enables flow
from the charge pump into the low pressure side of the working circuit, if the system pressure drops below a
certain value. With this feature pressure losses caused leakages or other factors can be compensated. Since
the variable displacement pump is able to work to either direction, two boost check valves are needed.
Bypass function The bypass function is also integrated in the multi-function valves and can be manually oper-
ated.when the vehicle (or the mechanical function) is to be moved, without the pump running.
Adjusting (opening) the bypass function

Caution
!

When working on the bypass valves switch off the drive and keep the high pressure circuit pressureless.
The bypass valves must be open on both multi-function valves to be able to achieve the bypass function.

Fig. 6
l Attach an open end spanner to the medium size hexagon of the multi-function valve and attach an open end
spanner to the large hexagon to prevent the valve body from turning. Turn the medium size hexagon for three

008 918 12 BOMAG 289

10.3 Travel pump 075

turns in anti-clockwise direction to open the bypass valve. Do not turn more than 3-1/2 turns, because oth-
erwise pressure fluid will run out.
l Before moving the vehicle set the control lever for the mechanical displacement control on the pump to full
forward. Hold the control lever in this position throughout the bypass function.

! Caution
"Towing" only at very low speed and only over short distances.

Charge pressure relief valve

Pumps of series 90 are equipped with a charge pressure relief valve that can be adjusted from outside. Charge
pressure is adjusted by loosening the counter nut and turning the setscrew accordingly with a large screwdriver
or a 1/2" open end spanner.
Turning the setscrew clockwise increases the value, turning anti-clockwise reduces the value (by approx. 3.9
bar per revolution). The counter nut needs to be tightened with 52 Nm.

Fig. 7
The charge pressure relief valve has the function of maintaining the charge pressure at a specified value. A cone
valve reduces the charge pressure if this value is exceeded. This nominal value is measured against case pres-
sure and adjusted at 1500 rpm. This nominal setting assumes that the pump is running in idle position (zero
flow); the charge pressureb is slightly lower in forward or reverse.

290 BOMAG 008 918 12

Travel pump 075 10.3
Connections

Fig. 8

1 Pressure test port M2 system pressure, B 8 Suction port S

2 Leak oil connection L1 9 System pressure, port B
3 Pressure test port M4 control pressure 10 Speed transducer (option)
4 Pressure test port M5 control pressure 11 Charge pressure port
5 Leak oil connection L2 12 Charge pressure test port, M3
6 Pressure test port M1 system pressure, A 13 Control pressure port, X3
7 System pressure, port A

008 918 12 BOMAG 291

10.4 Vibration pumps 42R041 & 42R055

Variable displacement pumps, 42R041 / 42R055

10.4 Vibration pumps 42R041 & 42R055

Caution
!

The variable displacement axial piston pump must be filled with pressure fluid and purged during start-
up and operation. This must also be considered for longer periods of rest, because the system may run
empty through the hydraulic lines.
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
It has been designed for mobile applications, e.g. in construction equipment.
The 42R 041 is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed
circuits. The volumetric flow is proportional to the drive speed and the displacement.

EZ, electric two-point control, with control solenoid

Fig. 9

1 Control 4 Attachment plate

2 Servo piston 5 Spool valve
3 Swash plate bearing 6 Charge pump

292 BOMAG 008 918 12

Vibration pumps 42R041 & 42R055 10.4
Hydraulic diagram

Charge pump

Pump drive
High pressure limitation

4/3 way valve

Fig. 10
When operating a 4/3-way solenoid valve on the pump control pilot oil from the charge circuit is guided to one
of the two control piston sides. The swash plate inside the pump will swash to the corresponding side and the
pump will deliver oil to the vibration motor. The vibration motor starts and rotates the vibrator shaft inside the
drum.
When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will
change its direction and the vibration motor will change its sense of rotation.
Since the end stops for the swash plate are set to different swashing angles to both directions, the angle for the
piston stroke is also different to both sides. This angle influences the length of the piston stroke and thereby the
actual displacement of the pump.
l
Large angle = high displacement = high vibrator shaft speed (frequency)
l
Small angle = low displacement = slow vibrator shaft speed (frequency)

High pressure relief valves (Fig. 10)

1 From the charge pump 3 High pressure relief valve with integrated
boost check valve
2 Closed circuit

Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safe-
guarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and re-

008 918 12 BOMAG 293

10.4 Vibration pumps 42R041 & 42R055

lieve oil into the low pressure side. The fluid quantity always remains constant in the closed hydraulic circuit.
Leakages in pump and motor are compensated by the charge pump.
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure
side and allow cool and filtered oil flow from the charge oil circuit to flow into the closed hydraulic circuit, in order
to compensate leaks and flushing quantities.

Charge pump
The charge pump is needed to supply the system with cool hydraulic fluid, to maintain a positive pressure in the
working circuit, to ensure a certain pressure level, to operate the control system and to compensate internal leak-
ages.
The charge pump is a fixed displacement Gerotor-type pump, integrated in the variable displacement pump and
driven by the pump shaft.

294 BOMAG 008 918 12

Axial piston swash plate principle / pump 10.5
Swash plate principle, pump
10.5 Axial piston swash plate principle / pump

Fig. 11
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive
shaft. The pistons are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic
pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used
in motor mode the hydrostatic energy is converted to mechanical energy. When used as a pump, the flow volume
is proportional to the drive speed and the swashing angle. The available (pump) torque increases with the pres-
sure drop between high and low pressure side.
Variable displacement pumps and motors can be change their displacement, i.e. the pump delivery rate or motor
throughput, by simply changing the angle of the swash plate.

Description of function

Fig. 12

008 918 12 BOMAG 295

10.5 Axial piston swash plate principle / pump

1 Drive shaft 8 Through drive

2 Piston 9 Valve plate
3 Piston area 10 Top dead centre TDC
4 Piston stroke 11 Bottom dead centre BTC
5 Slipping disc 12 Control slots in suction side of swash plate (for
sense of rotation shown)
6 Adjusting angle 13 Control slot on pressure side
7 Cylinder

Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection. The cylinder rotates
with the drive shaft and drives the 9 pistons. The pistons rest with their slipper pads on the sliding face of the
swashing cradle and perform an axial movement. The slipper pads are held on the sliding face and are positively
guided by a retaining device. During a complete rotation of the cylinder block each piston moves through the
bottom and top dead centre back to its initial position. From dead centre to dead centre is performs a full piston
stroke. During this process the flow volume determined by the stroke is drawn in through the control slots in the
valve plate or pumped out. During the suction stroke the hydraulic fluid is drawn into the increasing piston cham-
ber, i.e. it is actually pressed in. On the opposite side the oil is pressed out of the piston bores into the hydraulic
system during the compression stroke.

296 BOMAG 008 918 12

Troubleshooting axial piston pumps 10.6
10.6 Troubleshooting axial piston pumps
The following table should be of help when performing troubleshooting This table is by no means complete.
In practice you may encounter problems that have not been listed here.

Procedure
l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and
changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.
l Get an overview over the function of the product in connection with the overall system.
l
Try to clarify whether the product was able to deliver the required function within the overall system before the
fault occurred.
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine
driver.
Try to detect changes to the overall system, the product is installed in:
l Have conditions or area of application of the product been changed?
l Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or
to the product? If yes: What kind?
l Has the product or the machine been operated as intended?
l
How does the fault occur?

Fault Possible cause Remedy

Unusual noises Insufficient suction conditions, e.g.Machine or system manufacturer
air in the suction line, inadequate di-
(e.g. optimize feed conditions, use
ameter of the suction line, excessivesuitable pressure fluid).
viscosity of the pressure fluid, ex- Completely purge the axial piston
treme suction height, too low suctionunit, fill the suction line with pres-
pressure, foreign bodies in the suc- sure fluid.
tion line. Remove foreign bodies from inside
the suction line.
Inappropriate fastening of the axial Check the fastening of the axial pis-
piston unit. ton unit as specified by the machine
or plant manufacturer. Observe the
tightening torques.
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and hy- fied by the coupling or fittings manu-
draulic lines. facturer.
Pressure relief valves of the axial Purge the axial piston unit, check
piston unit (charge pressure, high the viscosity of the pressure fluid,
pressure, pressure override). consult the service department.
Mechanical damage to the axial pis- Replace the axial piston unit, con-
ton unit. sult the service department.

008 918 12 BOMAG 297

10.6 Troubleshooting axial piston pumps

Fault Possible cause Remedy

No or insufficient volumetric flow Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Drive speed too low. Consult the service department.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure,
consult the service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.

298 BOMAG 008 918 12

Troubleshooting axial piston pumps 10.6
Fault Possible cause Remedy
No or insufficient pressure Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Poor drive power. Consult the service department.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.
Drive unit defective (e.g. hydraulic Check the drive unit, replace if nec-
motor or cylinder). essary.
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently Completely purge the axial piston
flow purged. unit.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid too hot. Excessive input temperature on axi- Check the system, e.g. malfunction
al piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief
valve, pressure override, pressure
controller).
Malfunction of the flushing valve Consult the service department.
(not for nominal size 18).
Wear of the axial piston unit. Replace the axial piston unit.

008 918 12 BOMAG 299

10.7 Travel motor 51 C/D 110

Swash plate motor with variable displacement, series 51

10.7 Travel motor 51 C/D 110

Designs: C and D

Fig. 13

Product description
A plug-in fixed displacement motor converts the hydrostatic volumetric flow into mechanical rotary motion. It has
mainly been designed for installation into mechanical gear drives.

Function
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
an axial stroke, thereby causing a rotary motion of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the low pres-
sure 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.

Flushing valve
In a closed circuit the same pressure fluid keeps permanently circulating between pump and motor. This can
cause overheating of the pressure fluid.
The flushing valve has the function to support cooling of the oil circuit by flushing the motor and thus to prolong
the service life of the motor. If the hydraulic motor is operated under load, the flushing valve opens during clock-
wise and anti-clockwise rotation, whereby a defined flushing quantity is discharged through an orifice from the
low pressure side of the circuit. This flushed out amount of oil then flows through the case drain back to the tank,
normally through a cooler. Any pressure fluid removed from the closed circuit must be replaced by cool oil from
the charge pump. The flushing valve thereby ensures permanent renewal and cooling of the pressure fluid. The
flushing pressure relief valve has a fixed setting of 16 bar and has the function of securing the minimum charge
pressure.

Control
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle between
cylinder block and output shaft.

300 BOMAG 008 918 12

Travel motor 51 C/D 110 10.7
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 piston
rod side (test port M4) is thereby permanently pressurized with the actual travel pressure. In 1st speed range
(solenoid de-energized) the piston side (pressure test port, M3) is connected with the tank. In the 2nd speed
range the solenoids are energized, the valve switches and the piston side is also pressurized with the actual
travel pressure. Due to the area differential between piston rod side and piston side and the force resulting from
this, the pilot control moves to Qmin position.

Fig. 14

1 Control piston 7 Taper roller bearing

2 4-way valve 8 SAE-flange
3 Proportional valve 9 Synchronizing joint
4 Minimum swashing angle setting 10 Speed sensor
5 Valve segment 11 Piston
6 Bearing plate 12 Flushing pressure relief valve

008 918 12 BOMAG 301

10.8 Trouble shooting, variable displacement axial piston motor

10.8 Trouble shooting, variable displacement axial piston motor

The following table should be of help when performing troubleshooting This table is by no means complete.
In practice you may encounter problems that have not been listed here.

Procedure
l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and
changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.
l Get an overview over the function of the product in connection with the overall system.
l
Try to clarify whether the product was able to deliver the required function within the overall system before the
fault occurred.
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine
driver.
Try to detect changes to the overall system, the product is installed in:
l Have conditions or area of application of the product been changed?
l Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or
to the product? If yes: What kind?
l Has the product or the machine been operated as intended?
l
How does the fault occur?

Fault Possible cause Remedy

Unusual noises
Inappropriate fastening of the axial Check the fastening of the axial pis-
piston unit ton unit as specified by the machine
or plant manufacturer. Observe the
tightening torques!
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and hy- fied by the coupling or fittings manu-
draulic lines. facturer.
Mechanical damage to the axial pis- Replace the axial piston unit
ton unit.
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently Completely purge the axial piston
flow purged. unit.

302 BOMAG 008 918 12

Trouble shooting, variable displacement axial piston motor 10.8
Fault Possible cause Remedy
Operation data are not reached. Insufficient flow from hydraulic Check the function of the hydraulic
pump pump
Minimum displacement incorrectly Consult the service department.
set
External control and setting facilities Check the external control.
defective.
Control pressure too low Check control pressure, consult the
service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
Wear of the axial piston unit Replace the axial piston unit
Mechanical damage to the axial pis- Replace the axial piston unit
ton unit.
Pressure fluid too hot. Excessive input temperature on axi- Check the system, e.g. malfunction
al piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief
valve, pressure override, pressure
controller).
Failure of the flushing valve Consult the service department.
Wear of the axial piston unit Replace the axial piston unit

008 918 12 BOMAG 303

10.9 Vibration motor A10FM 45

Vibration motor
10.9 Vibration motor A10FM 45

The vibration motor is an axial piston motor with fixed displacement in swash plate design. Since the motor can
be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
The output torque raises with increasing pressure difference between low and high pressure side in the closed
circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting exciter shaft. This resistance caus-
es a hydraulic starting pressure, which is limited by the pressure override. Once the exciter shaft has reached
its final speed, the pressure will drop to 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
Soft ground = Low operating pressure

Fig. 15 Cross-sectional drawing

1 Flushing valve block 6 Drive shaft

2 Flushing valve 7 Swash plate
3 Working pistons with slipper pads 8 Retaining plate
4 Roller bearing for output shaft 9 Pre-tensioning spring
5 Radial seal 10 Flushing pressure relief valve

The vibration motor is equipped with an integrated flushing valve. 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.
The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve makes sure that only a
certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows back to the hydraulic tank. The flushed out oil is immediately replaced with fresh and filtered oil
through the corresponding boost check valve.

304 BOMAG 008 918 12

Vibration motor 90M 055 10.10
Vibration motor
10.10 Vibration motor 90M 055

The vibration motor is an axial piston motor with fixed displacement in swash plate design. Since the motor can
be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
The output torque raises with increasing pressure difference between low and high pressure side in the closed
circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting exciter shaft. This resistance caus-
es a hydraulic starting pressure, which is limited by the pressure override. Once the exciter shaft has reached
its final speed, the pressure will drop to 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
Soft ground = Low operating pressure

Fig. 16 Cross-sectional drawing

1 Shuttle valve 6 Swash plate

2 Valve plate 7 Cylinder block
3 Piston 8 End housing
4 Anti-friction bearings 9 Shuttle valve
5 Drive shaft

Shuttle valve and flushing pressure relief valve

The flushing function consists of a shuttle valve and a flushing pressure relief valve. The shuttle valve connects
the low pressure side of the closed working circuit with the flushing pressure relief valve in the motor housing.
The flushing pressure relief valve regulates the charge pressure value, as soon as a pressure differential occurs
in the main circuit. A sping holds the shuttle valve in closed position, so that in case of a pressure reversal no
pressure fluid will exit the high pressure side.

008 918 12 BOMAG 305

10.10 Vibration motor 90M 055

Connections

Fig. 17

1 Pressure test port M3 flushing pressure 5 Speed sensor

2 Pressure test port M1 system pressure, A 6 Leak oil connection L2
3 Pressure test port M2 system pressure, B 7 System connection, B
4 Leak oil connection L1 8 System connection, A

306 BOMAG 008 918 12

Axial piston swash plate principle / motor 10.11
Swash plate principle, motor
10.11 Axial piston swash plate principle / motor

Fig. 18
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive
shaft. The pistons are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic
pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used
in motor mode the hydrostatic energy is converted to mechanical energy. Variable displacement motors can
change their displacement, i.e. the pump delivery rate or motor throughput, by simply changing the angle of the
swash plate.
If the unit is used as motor, the output speed is proportional to the supplied volume of fluid. The available (motor)
torque increases with the pressure drop between high and low pressure side.

Description of function

Fig. 19

008 918 12 BOMAG 307

10.11 Axial piston swash plate principle / motor

1 Drive shaft 8 Through drive

2 Piston 9 Valve plate
3 Piston area 10 Top dead centre TDC
4 Piston stroke 11 Bottom dead centre BTC
5 Slipping disc 12 Control slots in suction side of swash plate (for
sense of rotation shown)
6 Adjusting angle 13 Control slot on pressure side
7 Cylinder

The motor function is a reversal of the pump function. In this case the hydraulic fluid the hydraulic system directs
the oil flow to the hydraulic motor. The medium flows through control slots in the valve plate to the cylinder bores.
4 or 5 cylinder bores are opposed to the kidney shaped control slots in the pressure side. The other control slot
is in this case connected with the rest of the cylinder bores, which in turn are connected with the return flow side
or are partly covered by the connecting web between the kidney shaped control slots. By loading the piston it
slides down the slanted swash plate and drives the cylinder that guides it. The cylinder with the 9 pistons rotates
with the drive shaft, whereby the piston perform a stroke-like movement. The hydraulic pressure generates the
torque on the cylinder and thus the rotation of the drive shaft. The supplied fluid quantity determines the output
speed.

308 BOMAG 008 918 12

External gear pumps 10.12
External gear pumps
10.12 External gear pumps

External gear pumps mainly consist of the friction bearing mounted gear pair and the housing with front and rear
covers. The drive shaft, which is sealed with a radial seal, protrudes from the front cover. The bearing forces are
absorbed by friction bearings. These have been designed for high pressures and have excellent antifriction prop-
erties - particularly at low speeds. The gears have 12 teeth each. This keeps flow pulses and noise emissions
at a low level.

Axial seal Outer pressure field Inner pressure field Radial seal

Sealing zone
Cover Flange Compensation forces
Fig. 20 Axial compensation of gear pump
Internal sealing of the pressure chambers is achieved by flow volume dependent forces. This results in an ex-
cellent rate of efficiency. On the rear side the moveable bearing bushings are pressurized and thus tightly
pressed against the gears. The pressurized pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small gaps, which appears between gears and hous-
ing in dependence on the pressure.

Function

Fig. 21
The increasing volume caused by a tooth exiting a tooth gap results in a vacuum in the suction chamber. The
pressure fluid is transported into the pressure chamber. There the meshing of teeth and tooth gaps displaces
the pressure fluid into the upper supply line.

008 918 12 BOMAG 309

10.12 External gear pumps

Fig. 22

1 Cover 6 Gear (driven)

2 Seals and gaskets 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate

310 BOMAG 008 918 12

Travel circuit 10.13
Travel system
10.13 Travel circuit

The travel circuit is a closed hydraulic circuit.

Fig. 1

1 Cooler 8 Drive axle with brake

2 Steering valve 9 Rear travel motor, with speed range selector
Y31
3 Steering/charge pump 10 Travel gear with brake discs
4 Travel pump 11 Front travel motor, with speed range selector
Y30
5 Vibration pump 12 Return flow manifold with thermal element
6 Charge oil filter with differential pressure switch, 13 Hydraulic oil tank
B21
7 Brake valve, Y04

008 918 12 BOMAG 311

10.13 Travel circuit

Travel pump and vibration pump are mounted together to a tandem unit which is driven by the flywheel side of
the engine via an elastic coupling. The travel pump has the function of supplying the travel circuit with hydraulic
oil.

Travel gear with travel motor, drum drive

The drive motor is a swash plate controlled axial piston motor of series 51C110 with variable displacement.
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.

Fig. 2 Reduction gear CR 31

1 Travel motor
2 Taper roller bearing
3 Spur wheel
4 Ring gear
5 Planet gear
6 Sun gear
7 Planet carrier
8 Brake discs
9 Mechanical seal
10 Brake piston

Travel motor rear, axle motor

The drive motor is a swash plate controlled axial piston motor of series 51D110 with variable displacement.

312 BOMAG 008 918 12

Travel circuit 10.13

Fig. 3 Drive axle

1 Drive axle
2 Travel motor

Charge circuit
The gear pump driven by the auxiliary drive of the engine serves as steering pump and also as charge pump,
because the oil flow from steering valve is flowing to the charge port on travel and vibration pump. Furthermore,
the vibration pump has an integrated charge pump, both charge oil flows are united before the charge pressure
filter.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits for travel
and vibration drive, as well as to release the parking brakes.
The charge circuit is equipped with a 12µ fine filter with bypass valve. These open at a pressure differential
(pressure difference between filter inlet and filter outlet) of Δp = 3.5 bar. This pressure differential depends on
the filter contamination and the viscosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differential pressure of Δ p 2.5 bar is reached. The
fault information will therefore already be available before the bypass valve opens.

Return flows
All return flows pass through the return flow manifold with temperature controlled valve (thermostat). This ther-
mostat guides the oil flow directly back to the hydraulic oil tank, until the operating temperature is reached. At
an oil temperature of 55 °C the valve starts to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.

008 918 12 BOMAG 313

10.13 Travel circuit

Option, cabin with heating

Fig. 4

314 BOMAG 008 918 12

Travel circuit 10.13

1 Cooler 8 Drive axle with brake

2 Steering valve 9 Rear travel motor, with speed range selector
Y31
3 Steering/charge pump 10 Travel gear with brake discs
4 Travel pump 11 Front travel motor, with speed range selector
Y30
5 Vibration pump 12 Return flow manifold with thermal element
6 Charge oil filter with differential pressure switch, 13 Hydraulic oil tank
B21
7 Brake valve, Y04 14 Silencer, it is always subjected to hydraulic oil
flow and has the function of eliminating any vi-
brations and noises.

Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake.
When the travel lever is returned towards neutral position, the displacement of the travel motor is adjusted to-
wards zero accordingly and the machine is hydraulically braked.
To avoid creeping movements of the machine, the machine is additionally equipped with multi-disc parking
brakes in the axle. These close in neutral position of the travel lever and when the engine is stopped.
The parking brakes are electrically operated by proximity switches (B13) on the travel lever via relay (K48) and
the 3/2-way solenoid valve (Y04). In de-energized state the charge oil supply to the brake pistons is interrupted,
allowing the hydraulic oil to return to the tank via the 3/2-way valve. When moving the travel lever out of neutral
position, the connection to the tank is interrupted and charge oil is directed to the brake piston. This hydraulic
pressure works against the spring force applied to the brake piston by the brake springs and relieves the brake
discs.

Travel lever

Fig. 5

B13 Initiator for brake Y04 Brake valve

B14 Initiator for reverse detection

008 918 12 BOMAG 315

10.14 Adjust the parking brake

10.14Adjust the parking brake

! Caution
Have adjustment work on the brakes only carried out by a specialist! Always adjust both sides.
l Secure the machine with wheel chocks against rolling.
l Start the diesel engine to relieve the brake.

Fig. 6
l
Disengage the travel lever (Fig. 6) to the left, but do not move to position "I" or "II".
The parking brake is released

Fig. 7
l Unscrew locking plate 2 (Fig. 7).
l
Turn the square (1) in anti-clockwise direction against the stop.

316 BOMAG 008 918 12

Adjust the parking brake 10.14

Fig. 8
l In order to adjust the brake clearance turn the square 1 (Fig. 8) three turns back in clockwise direction.
l Fasten the locking plate again.
l Pull the plug off the brake solenoid valve and perform the drive test.
The machine must be braked.

008 918 12 BOMAG 317

10.15 Stopping the machine, operating the parking brake

10.15Stopping the machine, operat- 10.16Towing in case of an engine

ing the parking brake failure

Danger
!

Danger of accident! Danger of injury!

Before releasing the parking brake secure the ma-
chine against unintended rolling by using appro-
priate means (e.g. metal wheel chocks).
When using towing ropes tow the machine only
uphill.
When towing downhill you must use a rigid towing
device.
The machine cannot be steered.
Use a towing vehicle with sufficient traction and
Fig. 9
braking power for the unbraked towed load.
l Return the travel lever (Fig. 9) slowly to "neutral"-
Do not touch hot engine parts.
position and engage it to the right in braking posi-
tion.
The machine is automatically braked by the hydrostat- Caution
!

ic drive and the parking brake is applied. Tow the machine only after releasing the parking
brake.
Towing speed 1 km/h, max. towing distance 500
m.
l
Always secure the machine against unintended roll-
ing.

Fig. 10
The parking brake warning lamp (k) (Fig. 10) lights up.

i Note
The parking brake also closes automatically when
shutting the engine down. Fig. 11
l Attach chains (Fig. 11) or towing ropes to the lifting
hooks.
l
Open the engine compartment hood and secure it.

318 BOMAG 008 918 12

Towing in case of an engine failure 10.16

Fig. 12 Fig. 14
l Back out the two high pressure relief valves (1) on l Turn both screws (Fig. 14) for releasing the drum
the travel pump (Fig. 12) for approx. 3 turns. brake evenly in clockwise direction, until the drum
can turn freely.
Caution
!

Do not back out more than 3 turns!

After towing

Caution
!

Before detaching the tow bar block the machine

with chocks to prevent unintended rolling.

Fig. 13
l To release the brake turn counter nuts (1) (Fig. 13)
approx. 8 mm back.
l
Turn the brake releasing screws (2) completely in
Fig. 15
against the stop.
l Tighten the two high pressure relief valves on the
travel pump (Fig. 15) again, tightening torque: 70
! Caution Nm.
From this stop turn the screw in for maximum an-
other turn to release the brake!
Turn the screws in evenly on both sides.
l Turn the screws in alternately for ¼ turn at a time.
l Repeat this measure on the opposite wheel side.

008 918 12 BOMAG 319

10.16 Towing in case of an engine failure

i Note
If necessary replace the sealing ring under the coun-
ter nut if it is leaking.
For this purpose completely unscrew the brake re-
leasing screw, replace the seal ring and lubricate the
screw with silicone grease.
Reinstall the screw with a new seal ring and adjust the
protrusion as described above.

Fig. 16
l Turn both screws for releasing the drum brake (Fig.
16) anti-clockwise against the stop.
l Turn all brake releasing screws of the axle evenly
back out, until they are light moving again.

Fig. 17
l Turn the brake releasing screws (Fig. 17) back in
again, until they abut against the brake piston.

Fig. 18
l Unscrew the brake releasing screws (Fig. 18) for
two turns and tighten the counter nuts.
l Repeat this adjustment procedure on the opposite
wheel side.

320 BOMAG 008 918 12

Vibration circuit 10.17
Vibration circuit
10.17 Vibration circuit

The vibration circuit is a closed hydraulic circuit, it consists mainly of the vibration pump with the integrated safety
elements and the vibration motors.
Travel pump and vibration pump are mounted together to a tandem unit which is driven by the flywheel side of
the engine via an elastic coupling. The vibration pump has the function of supplying the vibration circuit with hy-
draulic oil.
When changing the swashing angle in the vibration pump through the neutral position to the opposite side, the
flow direction of the oil and the sense of rotation of the vibration motor will change.
Since the displacement of the vibration pump is different to the two flow directions, the speeds of the vibration
motor are also different.

high amplitude

low amplitude

Fig. 1
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.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending on the
sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights.
l Basic weight + change-over weight = high amplitude
l Basic weight - change-over weight = low amplitude

008 918 12 BOMAG 321

10.17 Vibration circuit

Fig. 2

1 Drum shell 8 Change-over weight

2 Vibration bearings 9 Coupling vib. motor – exciter shaft
3 Basic weight 10 Travel bearings
4 Vibration housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Exciter shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing

The vibration motor output shaft is joined with the exciter shafts in the drum via a Bowex coupling. Rotation of
the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically suspended drums.

322 BOMAG 008 918 12

Vibration circuit 10.17

Fig. 3

1 Cooler 6 Charge circuit filter

2 Steering valve 7 Vibration motor
3 Steering/charge pump 8 Return flow manifold with thermal element
4 Travel pump 9 Hydraulic oil tank
5 Vibration pump, Y07 high amplitude, Y08 low ampli-
tude

Vibration motor
The vibration motor is a fixed displacement axial piston motor type A10FM 45.

008 918 12 BOMAG 323

10.17 Vibration circuit

Fig. 4

1 High pressure port high amplitude 4 Flushing spool

2 High pressure port, low amplitude 5 Flushing valve
3 Leak oil and flushing port

Charge circuit
The gear pump driven by the auxiliary drive of the engine serves as steering pump and also as charge pump,
because the oil flow from steering valve is flowing to the charge port on travel and vibration pump. Furthermore,
the vibration pump has an integrated charge pump, both charge oil flows are united before the charge pressure
filter.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits for travel
and vibration drive, as well as to release the parking brakes and to change the travel speed ranges.
The charge circuit is equipped with a 12µ fine filter with bypass valve. These open at a pressure differential
(pressure difference between filter inlet and filter outlet) of Δp = 3.5 bar. This pressure differential depends on
the filter contamination and the viscosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differential pressure of Δ p 2.5 bar is reached. The
fault information will therefore already be available before the bypass valve opens.

Return flows
All return flows pass through the return flow manifold with temperature controlled valve (thermostat). This ther-
mostat guides the oil flow directly back to the hydraulic oil tank, until the operating temperature is reached. At
an oil temperature of 55 °C the valve starts to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.

324 BOMAG 008 918 12

Vibration circuit 10.17
Option, cabin with heating

Fig. 5

1 Cooler 6 Charge circuit filter

2 Steering valve 7 Vibration motor
3 Steering/charge pump 8 Return flow manifold with thermal element
4 Travel pump 9 Hydraulic oil tank
5 Vibration pump, Y07 high amplitude, Y08 low ampli- 10 Silencer, it is always subjected to hydraulic oil
tude flow and has the function of eliminating any vi-
brations and noises.

008 918 12 BOMAG 325

10.18 Steering circuit

BW211, one steering cylinder

10.18 Steering circuit

Fig. 1

1 Steering valve 4 Hydraulic oil tank

2 Steering and charge pump with pressure test port 5 Steering cylinder
3 Charge circuit filter

326 BOMAG 008 918 12

Steering circuit 10.18
Option, cabin with heating

Fig. 2

1 Steering valve 4 Hydraulic oil tank

2 Steering and charge pump with pressure test port 5 Steering cylinder
3 Charge circuit filter 6 Silencer, it is always subjected to hydraulic oil
flow and has the function of eliminating any vi-
brations and noises.

008 918 12 BOMAG 327

10.18 Steering circuit

BW 212/213/214/216/218/219, two steering cylinders

Fig. 1

1 Steering valve 4 Hydraulic oil tank

2 Steering and charge pump with pressure test port 5 Steering cylinder
3 Charge circuit filter

328 BOMAG 008 918 12

Steering circuit 10.18
Option, cabin with heating

Fig. 2

1 Steering valve 4 Hydraulic oil tank

2 Steering and charge pump with pressure test port 5 Steering cylinder
3 Charge circuit filter 6 Silencer, it is always subjected to hydraulic oil
flow and has the function of eliminating any vi-
brations and noises.

Articulated joint
Front and rear frames of the single drum rollers 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.
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 bear-
ings 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.

008 918 12 BOMAG 329

10.18 Steering circuit

Articulated joint
Steering cylinder
Fig. 3
When turning the steering wheel the steering cylinders will extend or retract. The piston rods swivel the front
console around the vertical bolts. This articulates the machine and results in a steering movement.

Steering valve
The steering valve consists mainly of:
l the distributor valve
l the rating pump
l the steering pressure relief valve
l
the shock valves

330 BOMAG 008 918 12

Steering circuit 10.18

Fig. 4 Steering valve

1 Neutral setting springs 6 Ring gear

2 Housing 7 Gear
3 Inner spool 8 Check valve
4 Outer spool 9 Pressure relief valve
5 Universal shaft

When turning the steering wheel the distributor valve guides the oil flow to the corresponding steering cylinder
sides. 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 valve contains also a pressure relief valve. This valve limits the steering pressure to 175 bar. Since
the oil is available for the charge circuit after it as left the steering unit, the charge pressure must be added to
this value. The maximum steering pressure is therefore approx. 200 bar.
Suddenly occurring pressure peaks, which may be caused by e.g. external influences like driving against a curb
stone, are compensated by two shock valves, which are integrated in the steering valve. Each of these shock
valves is fitted with an additional anti-cavitation valve. These anti-cavitation valves protect the system against
cavitation which could be caused by the reaction of the shock valves.
A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump if forces
are introduced from outside. In such a case the steering cylinders would act as pumps and press the oil back to
the pump.

i Note
This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min) will always flow
via the LS-line.

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 cylin-
ders or to the boost check valves for travel and vibration circuits.

008 918 12 BOMAG 331

10.19 Check the hydraulic oil level

10.19Check the hydraulic oil level 10.20Changing hydraulic oil and

breather filter
! Caution
In hydraulic systems filled with Panolin HLP i Note
Synth. 46 always use the same oil to top up. With See also the notes on the hydraulic system in the
other ester based oils consult the lubrication oil chapter "General notes on maintenance".
service of the respective oil manufacturer.

! Danger
Danger of scalding!
When draining off hot hydraulic oil!

! Caution
The hydraulic oil must also be changed after ma-
jor repairs in the hydraulic system.
Perform the oil change when the hydraulic oil is
warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Fig. 5
Change the filter only after the hydraulic oil
l
Check the hydraulic oil level in the inspection glass change and after the test run.
(Fig. 5).
Clean the area round hydraulic oil tank, filler
Normal level opening and breather filter.
approx. 3 cm below the top edge of the inspection Do not start the engine after draining the hydraulic
glass. oil.
Do not use any detergents to clean the system.
Minimum level
Use only lint-free cleaning cloths.
Middle of inspection glass.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
! Caution
When changing from mineral oil based hydraulic
If, during the daily inspection of the oil level the oil to an ester based biologically degradable oil,
hydraulic oil level is found to have dropped, check you should consult the lubrication oil service of
all lines, hoses and components for leaks. the oil manufacturer for details.
l
If necessary fill in hydraulic oil through the filler
neck. Environment
For quality and quantity of oil refer to the table of Catch running out hydraulic oil and dispose of en-
fuels and lubricants. vironmentally.

332 BOMAG 008 918 12

Replace hydraulic oil filter 10.21
10.21Replace hydraulic oil filter

! Danger

Danger of scalding!
By hot oil when unscrewing the filter.

! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after
the oil change and after the test run.

Fig. 6 Do not use the oil in the filter bowl again.

l Unscrew the plug (Fig. 6) and drain off all hydraulic
oil. Environment
l Check the seal ring, replace if necessary and turn Catch running out oil, dispose of oil and filter ele-
the plug tightly back in. ment environmentally.

i Note
Apart from the normal oil change intervals, the filter el-
ement must also be changed after major repairs in the
hydraulic system.

Fig. 7
l Remove the filler cap (Fig. 7).
l
Fill in new hydraulic oil through the screen.

i Note Fig. 8
We recommend to use the BOMAG filling and filtering l
Remove filter bowl (4) (Fig. 8) with filter element (3).
unit with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of the
l Examine the surface of the filter element thoroughly
hydraulic oil filter and protects the hydraulic system. for any visible dirt.
l Check the oil level in the inspection glass.
! Caution
Nominal value: Visible dirt may be an early sign for the failure of
approx. 3 cm below the upper edge of the inspection system components and indicate the possible fail-
glass ure of components. In this case determine the
cause and replace or repair the defective compo-
nents, if necessary. Negligence may cause de-
i Note
struction to the entire hydraulic system.
The breather filter for the hydraulic oil tank is integrat-
ed in the filler cap. You should therefore replace the Do not clean or reuse the filter element.
complete filler cap. l Take the old filter element (3) out, clean the filter
l Close the tank with a new cover. bowl and thread.
l
Reassemble the filter bowl with a new filter element
and new O-rings (1, 2).
l
After a short test run check the filter for leaks.

008 918 12 BOMAG 333

10.22 Changing the bypass filter

10.22Changing the bypass filter*

! Danger

Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.

! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after
the oil change and after the test run.
Replace the filter element at the latest after one
year

Environment
Dispose of the old filter element environmentally.

Fig. 9
l Open the engine hood (Fig. 9) completely and se-
cure it.

Fig. 10
l Unscrew the fastening screws (Fig. 10) and take off
the cover.
l
Replace the filter element, attach the cover and fas-
ten it with the screw.

* Optional equipment

334 BOMAG 008 918 12

11 Tests and adjustments

008 918 12 BOMAG 335

11.1 Special tools, tests and adjustments

11.1 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
BOMAG part-no.: 059 710 02

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

BOMAG part-no.: 050 100 75

Fig. 3
4. Digital rpm-meter for petrol engines

BOMAG part-no.: 079 948 99

Fig. 4

336 BOMAG 008 918 12

Special tools, tests and adjustments 11.1
5. Digital rpm-meter for petrol engines

BOMAG part-no.: 059 711 12

Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use

BOMAG part-no.: 079 948 98

Fig. 6
7. Infrared manual thermometer, -18 to 275°C

BOMAG part-no.: 057 668 06

Fig. 7
8. Hydraulic test case, large

BOMAG part-no.: 007 610 03

i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses

Fig. 8

008 918 12 BOMAG 337

11.1 Special tools, tests and adjustments

9. Hydraulic test case, small

BOMAG part-no.: 079 930 01

i Note
2X 60 bar pressure gauge
2X 600 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

BOMAG part-no.: 055 439 02

Fig. 12

338 BOMAG 008 918 12

Special tools, tests and adjustments 11.1
13. Gear pump testing device

BOMAG part-no.: 007 610 05

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

008 918 12 BOMAG 339

11.2 Adjusting the solenoid for engine speed control

11.2 Adjusting the solenoid for engine

speed control
15. Remove screw 3 (Fig. 1).
16. Switch on the ignition.
17. Switch on the solenoid (2) (move to full load posi-
tion).

i Note
When switched on, the plunger of the solenoid is
pulled in against the stop and the integrated limit
switch deactivates the pickup winding. The cur-
rent flow is reduced from approx. 70 A to approx.
3.5 A.
18. Push the throttle lever (1) to the right.
Fig. 1

i Note
There must be a gap of max. 0.5 mm between
stop screw (5) and throttle lever (1). Insert a dou-
ble folded piece of paper to check.
19. Keep adjusting the linkage (4), until the screw (3)
can be easily installed.
20. Retighten the screw (3).

340 BOMAG 008 918 12

Checking the rotation speeds 11.3
11.3 Checking the rotation speeds
Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines.

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.

Fig. 1

Check the engine speed

i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.

Nominal value idle speed:

Low idle speed, see technical data.
High idle speed, see technical data.
5. Switch the vibration on .

Nominal value nominal speed:

Fig. 2
See technical data.

Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.

008 918 12 BOMAG 341

11.3 Checking the rotation speeds

Checking the exciter shaft speed

1. Switch the vibration on at max. engine speed.
2. Apply the brake.
3. Measure the speed of the vibrator shaft, rest the
tester on your thumb (Fig. 3).

Nominal value:
See technical data.

Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.

Fig. 3

342 BOMAG 008 918 12

Checking / adjusting the neutral positions of the travel pump 11.4
11.4 Checking / adjusting the neutral posi-
tions of the travel pump
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
2. Unhook the travel cable (Fig. 2) from the pump.

Fig. 2
3. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.

Fig. 3

008 918 12 BOMAG 343

11.4 Checking / adjusting the neutral positions of the travel pump

4. Connect 600 bar pressure gauges to high pres-

sure test ports MA and MB (Fig. 4).

Fig. 4
5. Connect the control chamber ports X3 and X4
(Fig. 5) with a hose

Fig. 5
6. Start the engine and run it with maximum speed.

Nominal value
Both pressure gauges (Fig. 6) must show equal
pressure (charge pressure).

i Note
If necessary repeat the pressure test with 60 bar
pressure gauges, for more accurate readings.

Fig. 6
Evaluation of test

If pressure builds up on one side, adjust the me-

chanical neutral position (Fig. 7), until the pres-
sures on both pressure gauges are identical.

Fig. 7

344 BOMAG 008 918 12

Pressure tests in the travel circuit 11.5
11.5 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
2. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.

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. 2).
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.

008 918 12 BOMAG 345

11.5 Pressure tests in the travel circuit

Measurement with quickly operated travel le-

ver
6. Move the travel lever (Fig. 4) quickly forward,
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

Fig. 4
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
the high pressure test, check the components in-
dividually.

346 BOMAG 008 918 12

Checking / adjusting the vibrator shaft speeds 11.6
11.6 Checking / adjusting the vibrator shaft
speeds
Special tools
Vibration reed frequency meter

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine on an elastic base (rubber
buffers) (Fig. 1).
2. Apply the parking brake and block the wheels ad-
ditionally with suitable chocks.
3. Start the engine and run it with maximum speed.
4. Switch on vibration high frequency / low ampli-
tude or low frequency / high amplitude.

Fig. 1
5. Measure the speed (Fig. 2), rest the tester on
your thumb.

Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data

Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit and check vibration motor.
Fig. 2
6. Adjust the speed on the corresponding adjust-
ment screw (Fig. 2).

i Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.

Fig. 3

008 918 12 BOMAG 347

11.7 Pressure measurements in the vibration circuit

11.7 Pressure measurements in the vibra-

tion circuit
Special tools
Hydraulic test case

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
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".
6. Start the engine and run it with maximum speed.
7. Switch on vibration with high or low frequency.

Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up pres-
Fig. 2 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.

348 BOMAG 008 918 12

Check the leakage rate of the vibration motor 11.8
11.8 Check the leakage rate of the vibration
motor

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the drum of the machine on an elastic base
(rubber buffers) (Fig. 1) and block the wheels ad-
ditionally with suitable chocks.
2. Apply the brake.

Fig. 1
3. Block the flushing valve (Fig. 2) with washers.

Fig. 2
4. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
5. Start the engine and run it with maximum speed.
6. 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

008 918 12 BOMAG 349

11.9 Pressure test in steering circuit

11.9 Pressure test in steering circuit

Special tools
Hydraulic test case, gear pump testing equipment

! Caution
Perform measurements at operating tempera-
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
steering/charge pump.

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) (machines with one steering cylinder)
on the steering cylinder and close them with
plugs.

Fig. 2
6. Disconnect the hydraulic hoses from ports L and
R (Fig. 3) (machines with two steering cylinder)
on the steering cylinders and close them with
plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.

Nominal value
see technical data for steering/charge pump.

Fig. 3

350 BOMAG 008 918 12

Pressure test in steering circuit 11.9
Evaluation of test 2
If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
steering/charge pump.
10. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
11. Actuate the emergency stop switch.

Fig. 4
12. Close the pump outlet port (Fig. 5) with the gear
pump test equipment.
13. Crank the engine with the starter

Nominal value
see technical data for steering/charge pump.

Evaluation of test 3
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
steering/charge pump.

Fig. 5

008 918 12 BOMAG 351

11.9 Pressure test in steering circuit

352 BOMAG 008 918 12

12 Flushing and bleeding

008 918 12 BOMAG 353

12.1 Special tools for flushing

12.1 Special tools for flushing

i Note
The following list informs about special tools for
flushing. You should choose the corresponding
tool for the work to be carried out.
14. Filling and filtering unit

BOMAG part-no.: 058 240 22

Fig. 1
15. Flushing filter (S connection)

BOMAG part-no.: 007 000 01

16. Filter element 1μ

BOMAG part-no.: 079 930 52

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

BOMAG part-no.: 055 509 19

18. Screw socket R1“ - 25S (2 pieces)

BOMAG part-no.: 055 400 52

Fig. 2
19. Flushing filter (L connection)

BOMAG part-no.: 079 390 29

20. Filter element

BOMAG part-no.: 079 390 14

21. Flushing hose 15L (2 pieces)

BOMAG part-no.: 055 510 09

22. Screw socket R3/4“ -- 15L (2 pieces)

BOMAG part-no.: 055 400 89

Fig. 3
23. SAE-flange 1“ - 20S

BOMAG part-no.: 058 142 60

24. O-ring

BOMAG part-no. 062 203 30

Fig. 4

354 BOMAG 008 918 12

Special tools for flushing 12.1
25. Flanged plate 1“ - 25S

BOMAG part-no.: 007 160 18

26. O-ring

BOMAG part-no. 062 202 22

Fig. 5
27. Reducing fitting 18L - 15L

BOMAG part-no.: 055 422 92

Fig. 6
28. Reducing fitting 25S - 20S

BOMAG part-no.: 055 422 98

Fig. 7
29. Reducing fitting 20S - 16S

BOMAG part-no.: 055 423 26

Fig. 8

008 918 12 BOMAG 355

12.1 Special tools for flushing

30. Connecting socket 15L

BOMAG part-no.: 055 426 55

Fig. 9
31. Connecting socket 18L

BOMAG part-no.: 055 426 06

Fig. 10
32. Connecting socket 16S

BOMAG part-no.: 055 459 43

Fig. 11
33. Connecting fitting 20S

BOMAG part-no.: 055 459 44

Fig. 12

356 BOMAG 008 918 12

Special tools for flushing 12.1
34. Connecting fitting 25S

BOMAG part-no.: 055 459 45

Fig. 13
35. Angular fitting 18L

BOMAG part-no.: 055 421 26

Fig. 14
36. Elbow fitting 16L

BOMAG part-no.: 055 421 36

Fig. 15
37. Elbow 20S

BOMAG part-no.: 055 421 37

Fig. 16

008 918 12 BOMAG 357

12.1 Special tools for flushing

38. Elbow 25S

BOMAG part-no.: 055 421 38

Fig. 17
39. Pipe connection 16S - 16S

BOMAG part-no.: 493 301 01

Fig. 18
40. Connecting hose 15L

BOMAG part-no.: 055 510 09

Fig. 19

358 BOMAG 008 918 12

Flushing - general 12.2
12.2 Flushing - general Solid particles in the circuit will very quickly
cause damage to machine components.
Changing a component

! Caution
Always flush the complete oil circuit after
you have replaced a component.

Fig. 1 Chips (abrasion) in the oil

Effect of contamination l Open and clean all components in the oil
circuit, replace if necessary.
Coarse particles (> 15 µm)
Sudden failure of components. l Clean all high pressure hoses in the oil cir-
cuit, replace if necessary.
Fine particle contamination (5 – 15 µm)
l If abrasion is found in the travel circuit you
Wear of components, internal leaks, inaccurate
should also flush the vibration circuit.
controlling behaviour, blockage of valves.
l If abrasion is found in the vibration circuit
Extra fine particle contamination (< 2 – 5 you should also flush the travel circuit.
µm)
Silting of oil, accelerated aging of oil, corrosion.

Water in oil
Increased wear, accelerated aging of oil.

008 918 12 BOMAG 359

12.2 Flushing - general

Before flushing Bleeding

Change the filter element

Fig. 3

Fig. 1
l Always bleed closed hydraulic circuits if
lines had been removed or connected.
Clean the hydraulic tank
Servicing the flushing filter kit

Fig. 4
Fig. 2
l Replace the filter element of the flushing fil-
ter when the red control pin of the contami-
!Caution nation indicator is pressed out during the
Change the oil in case of excessive contam- filtering process.
ination, oil discoloration or if the oil change l Clean hoses and connections and store the
interval is almost due. flushing kit in a clean and protected envi-
l Filter the tank content with the filling and fil- ronment.
tering unit and pump it into an oil container.
l Mark all hoses and disconnect them from
the hydraulic oil tank.
l Clean the oil tank thoroughly from inside, if
necessary remove the tank cover.
l Reconnect all hoses.
l Fill the hydraulic oil tank again with the fill-
ing and filtering unit.

360 BOMAG 008 918 12

Flushing schematic travel circuit (distribution travel pump) 12.3

008 918 12 BOMAG 361

12.3 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)
18 Flushing hose 25S - 20S (tool)
7 Flushing hose 25S - 20S (tool)
19 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)

362 BOMAG 008 918 12

Flushing the travel circuit (travel pump distribution) 12.4
12.4 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

008 918 12 BOMAG 363

12.4 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

364 BOMAG 008 918 12

Flushing the travel circuit (travel pump distribution) 12.4
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
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 8

! 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.
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.
14. Shut down the engine.

Fig. 9 15. Remove the flushing filter and reconnect the high
pressure lines.

008 918 12 BOMAG 365

12.4 Flushing the travel circuit (travel pump distribution)

Flushing the axle drive

Installing the flushing filter
16. Disconnect the high pressure hose 14 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 16) and connect
it with the flushing hose (18) (flushing filter inlet
"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-
cuit by joining the high pressure hoses (14 and
15) on the axle drive motor together.

Fig. 11

Bleeding the travel circuit

i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".

Fig. 12

366 BOMAG 008 918 12

Flushing the travel circuit (travel pump distribution) 12.4
Flushing the hoses
19. Block drums and wheels with suitable chocks.

Fig. 13

i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 14

! 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.
20. Start the engine and shift the travel lever to travel
direction forward.
21. Perform the flushing process at various engine
speeds for approx. 10 minutes.
22. Shut down the engine.
23. Reconnect the hydraulic hoses (14 and 15) to the
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.
26. Pre-select the slow speed range.

Fig. 16

008 918 12 BOMAG 367

12.4 Flushing the travel circuit (travel pump distribution)

i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 17

! 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.
27. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
28. 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.
29. Shut down the engine.

Fig. 18 30. Remove the flushing filter and reconnect the high
pressure lines.

Bleeding the travel circuit

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

368 BOMAG 008 918 12

Flushing schematic travel circuit (distribution axle motor) 12.5

008 918 12 BOMAG 369

12.5 Flushing schematic travel circuit (distribution axle motor)

370 BOMAG 008 918 12

Flushing schematic travel circuit (distribution axle motor) 12.5

008 918 12 BOMAG 371

12.5 Flushing schematic travel circuit (distribution axle motor)

372 BOMAG 008 918 12

Flushing schematic travel circuit (distribution axle motor) 12.5
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)

008 918 12 BOMAG 373

12.6 Flushing the travel circuit (axle motor distribution)

12.6 Flushing the travel circuit (axle motor

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 14 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 16) and connect
it with the flushing hose (19) (flushing filter inlet
"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-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.

Fig. 2

374 BOMAG 008 918 12

Flushing the travel circuit (axle motor distribution) 12.6
Bleeding the travel circuit

i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".

Fig. 3
Flushing the hoses

i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 4
4. Block drums and wheels with suitable chocks.

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

008 918 12 BOMAG 375

12.6 Flushing the travel circuit (axle motor distribution)

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
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 8

! 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.
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.
14. Shut down the engine.

Fig. 9

376 BOMAG 008 918 12

Flushing the travel circuit (axle motor distribution) 12.6
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.
17. Pre-select the slow speed range.

Fig. 10

i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 11

! 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.
18. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
19. 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.
20. Shut down the engine.

Fig. 12 21. Remove the flushing filter and reconnect the high
pressure lines.

Bleeding the travel circuit

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

Keep circulating the tank content.

23. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.

008 918 12 BOMAG 377

12.6 Flushing the travel circuit (axle motor distribution)

Function test
24. Check the hydraulic oil level in the tank, fill up if
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.
27. Check all ports and connections for leak tightness
(visual inspection).

Fig. 13

378 BOMAG 008 918 12

Flushing schematic for vibration drive 12.7

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)
6 Flushing hose 25S - 20S (tool)

008 918 12 BOMAG 379

12.8 Flushing the vibration circuit

12.8 Flushing the vibration circuit

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 vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
Fig. 1
1. Disconnect the high pressure hose 10 (see chap-
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-
cuit by joining the high pressure hoses (10 and
11) on the vibration motor together.

Fig. 2

380 BOMAG 008 918 12

Flushing the vibration circuit 12.8
Bleeding the vibration circuit

i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration 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
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.
6. Start the engine and run it with maximum speed.
7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
8. Shut down the engine.
9. Reconnect the hydraulic hoses (10 and 11) to the
Fig. 6 vibration motor.

008 918 12 BOMAG 381

12.8 Flushing the vibration circuit

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
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.

Fig. 8

! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
11. Start the engine and run it with maximum speed.
12. Run the flushing procedure for approx. 10 min-
utes. Switch the vibration on and off at intervals of
approx. 30 seconds.
13. Shut down the engine.
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).

Keep circulating the tank content.

16. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.

382 BOMAG 008 918 12

Flushing the vibration circuit 12.8
Function test
17. Check the hydraulic oil level in the tank, fill up if
necessary.
18. Test drive.
19. Check all ports and connections for leak tightness
(visual inspection).

Fig. 10

008 918 12 BOMAG 383

12.9 Bleeding the travel circuit

12.9 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

384 BOMAG 008 918 12

Bleeding the travel circuit 12.9
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.

008 918 12 BOMAG 385

12.10 Bleeding the vibration circuit

12.10Bleeding 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

386 BOMAG 008 918 12

Bleeding the vibration circuit 12.10
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.

008 918 12 BOMAG 387

12.10 Bleeding the vibration circuit

388 BOMAG 008 918 12

13 Air conditioning system

008 918 12 BOMAG 389

13.1 Physical basics

13.1 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.

390 BOMAG 008 918 12

Physical basics 13.1
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-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l 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.

008 918 12 BOMAG 391

13.1 Physical basics

Excerpt from the wet steam table * R134a

* 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

392 BOMAG 008 918 12

Refrigerant R134a 13.2
13.2 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

008 918 12 BOMAG 393

13.3 Compressor oil / refrigeration oil

liquid container has absorbed approx. 8 gr. of water, 13.3 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.

394 BOMAG 008 918 12

Working principle of the air conditioning system 13.4
13.4 Working principle of the air 13.5 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.

008 918 12 BOMAG 395

13.6 Description of components

Monitoring chain 13.6 Description of components

Compressor

Fig. 2 Monitoring chain consisting of:

l 1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact Fig. 1
l 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
l
6 Relay
the function of the system. Coupling and decoupling is
l
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
l
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: clockwise
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).
When replacing a heat exchanger, e.g. evaporator
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.

396 BOMAG 008 918 12

Description of components 13.6
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.

008 918 12 BOMAG 397

13.6 Description of components

Dryer / filter / fluid container / inspection Pressure relief 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.

398 BOMAG 008 918 12

Description of components 13.6
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.+

008 918 12 BOMAG 399

13.6 Description of components

Evaporator Thermostat
Thermostat with fixed setting

Fig. 1
The evaporator is mounted inside the HKL-module in
Fig. 1
the cabin. It consists of a heat exchanger (inside air -
refrigerant), with refrigerant flowing to a pipe system The feeler of a defroster thermostat to switch off the
with cooling flanges. magnetic clutch in case of icing up or to switch the
clutch back on after defrosting, is mounted on the
As with the condenser, correct operation of all fans evaporator.
and cleanliness of the fins must be assured.
With fixed temperature controls the control switches
Air conditioning systems have a circulation air filter the compressor off at about +1 °C and back on again
mounted in the air flow in front of the evaporator, at about +2.5°C to +5.5 °C.
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. Adjustable thermostat
A condensation water filter is mounted in the air flow With adjustable temperature regulators the switching
after the evaporator. This filter has the function to col- point can be changed so that the compressor is al-
lect the water that has condensed from the air in the ready shut down at higher temperatures. This enables
evaporator block and to discharge this water into the regulation of the air temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.

! Caution
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.

Fig. 2 adjustable temperature controller

i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.

400 BOMAG 008 918 12

Description of components 13.6
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 NW10 min. 65 mm
GH 134 NW12 min. 75 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

008 918 12 BOMAG 401

13.7 Measuring the compressor oil level

13.7 Measuring the compressor oil 13.8 Checking the magnetic clutch
level l Measure the voltage.

!Caution i Note
The compressor oil level must be checked after Nominal value = vehicle voltage
replacing a system component or if a leak in the l
Check the magnetic coil locking ring for secure fit.
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404). l
Check the current consumption.
l Run the compressor for 10 minutes at engine idle
speed.
l remove the refrigerant from the air conditioning sys-
tem.

Fig. 1

Fig. 1 i Note
l
Turn the compressor, as shown in (Fig. 1), if neces- at 12 Volt vehicle voltage approx. 3.5 Amp.
sary remove V-belt and hoses.
at 24 Volt vehicle voltage approx. 1.75 Amp.
l
Remove the oil plug.
Overcurrent indicates a short circuit inside the mag-
netic coil.
i Note No current indicates an interrupted electric circuit.
The oil level must reach the bottom edge of the bore,
top up or drain off oil if necessary.
l
Close the oil plug again.

!Caution
The contact area must be clean and should be free
of damage.
Tightening torque 15 to 25 Nm
l Refill the air conditioning system.

Fig. 2 Measuring the air gap

l Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).

402 BOMAG 008 918 12

Inspection and maintenance work 13.9
i Note 13.9 Inspection and maintenance
The gap should be 0.4 to 0.8 mm. work
l
Take off the drive V-belt and rotate the V-belt pulley l Visual inspection of the complete system for dam-
by hand while the magnetic clutch is disengaged. age.
l Check the compressor mounting bracket on the ve-
i Note hicle engine for tight fit and damage.
In case of excessive flatness faults or deviations the l Check the condition, alignment and tightness of the
magnetic clutch needs to be replaced. V-belt.
l
Check the routing of refrigerant hoses and cables in
Cross-section of magnetic clutch
the area of the vehicle engine and transmission, as
Fig. 3 shows a cross-section of the magnetic clutch. If well as on the chassis for chafing and rectify any de-
the coil (7) is not supplied with operating voltage, tected faults. Ensure sufficient clearance to hot
there is no contact between the front plate of the parts, such as the exhaust; install a protective
clutch (1) and the V-belt pulley (2). A spring presses shield, if necessary.
the front plate away from the belt pulley. The V-belt l Check the routing of hoses and hoses on the at-
pulley rotates with the bearing (3) in idle speed, the
tachment box or in the cabin.
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is l Check all hose and screw fittings for leaks.
generated and pulls the front plate of the clutch. Both l Check the fastening of the condenser unit.
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works. l
Clean the condenser fins, replace the condenser
block if damaged fins are found.
l
Check the fastening of the evaporator unit.
l
Check the function of evaporator and condenser
fans.
l
Check the electric control panel. If discolorations on
conductors are found, these should be replaced
and possibly also the corresponding relays.
l
Switch on the cooling system and check the refrig-
erant level.
l
Filter/dryer and filter/dryer/fluid container combina-
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
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
l Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
Fig. 3 Cross-section of magnetic clutch out air temperature - The temperature difference
should be at least 8-10 K.
l
Measuring the pressure in the refrigerant circuit

008 918 12 BOMAG 403

13.10 Checking, replacing the refrigerant compressor V-belt

13.10Checking, replacing the refrig- l Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
erant compressor V-belt* l Retighten all fastening screws.

Danger
! Changing the V-belt
Danger of injury! l Slightly slacken the fastening screws 1, 2 and 3.
Work on the V-belt must only be performed with l Press the compressor against the direction of arrow
the engine shut down. completely against the engine.
Wear safety goggles. l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
Check the V-belt
l Tension the V-belt as previously described.

Caution
!

Check the V-belt tension after a running time of 30

minutes.

Fig. 4
l
Inspect the entire circumference of the V-belt (Fig.
4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.

Tighten the V-belt.

Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).

* Optional equipment

404 BOMAG 008 918 12

Air conditioning service (old design) 13.11
13.11Air conditioning* service (old
design)

Clean the condenser

Caution
!

A soiled condenser results in a considerable re-

duction of air conditioning power.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
day.
Fig. 7
If, during operation of the air conditioning system, l Switch the air conditioning (Fig. 7) on.
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
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. 8
l Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
l
Open the air outlet nozzles.
l
Check, whether the out flowing air is noticeably
cooler.

i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.
l Open the hood.
Fig. 6
l
Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .

Checking the refrigerant level

l
Start the engine.

* Optional equipment

008 918 12 BOMAG 405

13.11 Air conditioning service (old design)

Checking the moisture level of the drying

agent

Fig. 9
l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top. Fig. 11
l Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
i Note
The refrigerant level is correct. orange = drying agent o.k.
colourless= moisture level of drying agent too high.
l 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

Fig. 10 !Caution
l
If the white float (Fig. 10) inside the inspection glass According to the regulation for pressure reser-
of the drier/collector unit floats at the bottom, inform voirs all pressure reservoirs must be repeatedly
the service department. inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
i Note
with this inspection the drier/collector unit must
The refrigerant level is not correct.
be visually examined twice every year. During
l Refrigerant must be filled up, if necessary check the these inspections special attention must be paid
air conditioning system for leaks. 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.

406 BOMAG 008 918 12

Service the air conditioning 13.12
13.12Service the air conditioning*

Clean the condenser

! 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. 12
l Check the drier/collector unit (Fig. 12) for mechani-
! Caution
cal damage or rust.
A soiled condenser results in a considerable re-
duction of air conditioning power.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
day.
If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.

Fig. 13
l Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .

Checking the refrigerant level

l
Start the engine.

* Optional equipment

008 918 12 BOMAG 407

13.12 Service the air conditioning

Fig. 14 Fig. 16
l Turn the rotary switch for the cab ventilator (Fig. 14) l Check whether the white float (Fig. 16) inside the in-
to position "1". spection glass of the drier/collector unit floats right
at the top.

i Note
The refrigerant level is correct.

Fig. 15
l Choose a cooling temperature with the rotary switch
for the air conditioning system (Fig. 15) in the blue
section.
l
Open the air outlet nozzles. Fig. 17
l
Check, whether the out flowing air is noticeably l
If the white float (Fig. 17) inside the inspection glass
cooler. of the drier/collector unit floats at the bottom, inform
the service department.
i Note
The adjusted temperature must be below the actual i Note
temperature inside the cabin, so that the compressor The refrigerant level is not correct.
will be switched on.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.

408 BOMAG 008 918 12

Service the air conditioning 13.12
Checking the moisture level of the drying
agent

Fig. 19
l Check the drier/collector unit (Fig. 19) for mechani-
cal damage or rust.
Fig. 18
l Check the moisture indication pearl (Fig. 18) inside
the inspection glass of the drier/collector unit.
orange = Drying agent o.k.
colourless= moisture level of drying agent too high.
l 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.

008 918 12 BOMAG 409

13.13 Drying and evacuation

13.13Drying and evacuation 13.14Emptying 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.

410 BOMAG 008 918 12

Leak test 13.15
13.15Leak 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.

008 918 12 BOMAG 411

13.16 Filling instructions

13.16Filling 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.

412 BOMAG 008 918 12

Filling instructions 13.16

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

008 918 12 BOMAG 413

13.16 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.

414 BOMAG 008 918 12

Trouble shooting in refrigerant circuit, basic principles 13.17
13.17Trouble shooting in refriger-
ant circuit, basic principles

Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l 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.
l
Service station
Filling the system with refrigerant causes an excess
l
Pressure gauge pressure of Pe = 3 bar.
l
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
l
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
l
Container for old oil
l
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Hoses
l Scales
l Suction station
l 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)

008 918 12 BOMAG 415

13.17 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

416 BOMAG 008 918 12

Trouble shooting in refrigerant circuit, basic principles 13.17
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"

008 918 12 BOMAG 417

13.17 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

418 BOMAG 008 918 12

Trouble shooting, refrigerant circuit diagram 13.18
13.18Trouble 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

008 918 12 BOMAG 419

13.19 Trouble shooting procedure

13.19Trouble shooting procedure l Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l 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
l Ambient temperature above 15 °C.
about the system design, the installed components l 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
l Cooler and condenser are clean, clean if neces-
sary.
l The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.

420 BOMAG 008 918 12

Trouble shooting procedure 13.19
Measuring points and measurements

Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
l C, condenser measuring points tainer the inspection glass is most suitable to check
l E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
l O, evaporator measuring points
The hot gas temperature can be used to check wheth-
l 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
l a) Which measuring equipment is required?
can be used to derive the overheating of the evapora- l b) Where to measure with which size?
tor. Overheating is a clear indicator for the evaporator l 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 l
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- l 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 l
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used

008 918 12 BOMAG 421

13.19 Trouble shooting procedure

Solution: be a defect in the expansion valve or problems in the

l a) Pressure gauge, thermometer, steam table oil recirculation.
l 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.
l 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
l
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)
l 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
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required?
l
b) Where to measure with which size?
l
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
l
f) Evaluation of the measured supercooling.

Solution:
l
a) Pressure gauge, thermometer, steam table
l
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l 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.
l e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l 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

422 BOMAG 008 918 12

Trouble shooting procedure 13.19
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

008 918 12 BOMAG 423

13.19 Trouble shooting procedure

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

424 BOMAG 008 918 12

Trouble shooting procedure 13.19
Suction pressure normal (1), high pressure too
high (2)

Fig. 4

Cause Possible effect Remedy

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

008 918 12 BOMAG 425

13.19 Trouble shooting procedure

Suction pressure too high (1), high pressure too

low to normal (2)

Fig. 5

Cause Possible effect Remedy

Compressor defective Cooling power too low Replace the compressor

426 BOMAG 008 918 12

Trouble shooting procedure 13.19
Suction pressure too high (1), high pressure too
high (2)

Fig. 6

Cause Possible effect Remedy

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor

008 918 12 BOMAG 427

13.19 Trouble shooting procedure

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

428 BOMAG 008 918 12

Trouble shooting procedure 13.19
Inspection glass

Faults Possible cause Remedy

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

Faults Possible cause Remedy

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

008 918 12 BOMAG 429

13.20 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

430 BOMAG 008 918 12

Steam table for R134a 13.20

008 918 12 BOMAG 431

13.20 Steam table for R134a

432 BOMAG 008 918 12

Steam table for R134a 13.20

008 918 12 BOMAG 433

13.20 Steam table for R134a

434 BOMAG 008 918 12

14 Cabin assembly

008 918 12 BOMAG 435

General safety regulations for assembly ! Caution
When installing the cabin to your machine you Paragraphs marked like this highlight possible
must strictly comply with the valid accident pre- dangers for machines or parts of the machine.
vention instructions or the country specific regu-
lations. However, dangers for persons and i Note
property may still arise, if:
Paragraphs marked like this contains technical infor-
l the lifting gear used has a too low bearing capacity mation and hints for optimal assembly.
l damaged or worn lifting tackle is used
l
unqualified personnel is entrusted with the installa- Environment
tion Paragraphs marked like this point out practices
l the safety instructions are not observed for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Each person involved in the installation of the
Strictly observe the national regulations for the
cabin must therefore read and comply with these
protection of the environment.
safety regulations. If necessary, the customer
must demand a written confirmation with signa-
ture. Information and safety stickers/decals on
Moreover, the following instructions and regulations
the cabin
must obviously also be complied with: Keep stickers/decals in good and legible condition
(see spare parts catalogue) and comply with their
l
applicable accident prevention instructions
meaning.
l
generally accepted safety and road traffic regula-
Replace damaged stickers/decals
tions
l
country specific safety regulations. It is the duty of Work on heating lines
the operator to be acquainted with these instruc-
tions and to apply these accordingly. This applies Before starting work on heating pipes relieve any
also for local regulations concerning different types pressure and let them cool down - danger of scalding!
of handling work. Should the recommendations in After completing work on the heating system of the
these instructions be different from the regulations machine check all connections and fittings for leaks.
valid in your country, you must comply with the
safety regulations valid in your country. Working on electric parts of the machine
Before starting to work on electric parts of the ma-
Changes and conversions to the cabin/ chine disconnect the battery and cover it with insulat-
machine ing material.
Unauthorized changes to the cabin are prohibited for Do not use fuses with higher ampere ratings and do
safety reasons. not repair fuses with a piece of wire. Fire hazard.
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 have an adverse effect
on the active and/or passive driving safety.
The manufacturer explicitly excludes any liability for
damage caused by the use of non-original parts or ac-
cessories.

Notes on safety in the assembly instruc-

tions

! Danger

Paragraphs marked like this highlight possible

dangers for persons.

436 BOMAG 008 918 12

Preparations 14.1
14.1 Preparations

! Danger

Danger of accident!
For transport purposes the driver's seat must be
tied down with cable straps thus to operate the
seat contact switch. Before resuming operation of
the machine these cable straps must strictly be re-
moved to ensure safe and reliable function of the
seat contact switch.
Check the 4 lifting eyes on the cabin roof for tight
fit. Fig. 8
Fasten the lifting gear to all four lifting eyes. l Fasten the lifting gear to the four lifting eyes 1 (Fig.
Use lifting gear (chains or ropes) of sufficient load 8).
bearing capacity. The minimum load bearing ca- l Loosen possible fastening on the transport pallet.
pacity of the crane must be 1000 kg.
l Slowly list the crane with a crane.
Do not stand or step under loads being lifted.

Danger
!

Danger of accident!
Do not stand or step under loads being lifted.

Fig. 7
l
Make sure that all fastening screws, washers, spac-
ers and nuts to fasten the cabin are available (Fig.
7).
l
Check whether rear rack, foot mat, step plate and
fastening kit are available.

008 918 12 BOMAG 437

14.2 Cabin assembly

14.2 Cabin assembly i Note

Mount the cabin immediately after sticking on the
! Danger
sealing tape, because the sealing tape will swell.
Danger of accident!
Use lifting gear (chains or ropes) of sufficient load
bearing capacity. The minimum load bearing ca-
pacity of the crane must be 1000 kg.
Do not stand or step under loads being lifted.
l Clean the operator's stand of dirt, oil and moisture.

Fig. 11
l Spray the sealing tape with soapsuds (Fig. 11), to
be able to slide the cabin on the operator's stand.

Fig. 9
l
Stick the supplied sealing tape 1 (Fig. 9) along the
edge of the operator's stand.

!Caution
Only unroll and stick the sealing tape on just be-
fore mounting the cab to the operator's stand. The
sealing tape will swell a few minutes after being
unrolled. In this case the cabin can no longer be
Fig. 12
mounted!
l Slowly lower the cabin vertically to the operator's
stand (Fig. 12).

Caution
!

The cabine must be lowered vertically onto the op-

erator's stand.

Fig. 10
l Stick the sealing tape 1 (Fig. 10) all around the op-
erator's stand.
l Do not run the sealing tape across the front recess
in the operator's stand (2), since this is the air inlet
for the cabin ventilation.

438 BOMAG 008 918 12

Cabin assembly 14.2

Fig. 13 Fig. 16
l Tighten the bottom fastening screw on the access
Caution
! side (Fig. 16) with 578 Nm.
Take care that none of the hoses and electric ca-
bles become squashed (Fig. 13).
l Run cables and hoses from inside the cabin through
the operator's stand to the outside.

Fig. 17
l Loosen both fastening screws (Fig. 17) at the rear
of the cabin again.

Fig. 14 i Note
l Turn both fastening screws (Fig. 14) at the rear of The cabin will now slide into final assembly position.
the cabin in handtight. l Tighten both fastening screws (Fig. 17) at the rear
of the cabin with 578 Nm.

Fig. 15

Fig. 18
i Note l
Tighten the rear lateral fastening screw on the left
If the bores do not match the cabin can be moved into hand side with 578 Nm (Fig. 18).
position by means of a crow bar (Fig. 15).

008 918 12 BOMAG 439

14.2 Cabin assembly

Fig. 19 Fig. 22
l Tighten the rear lateral fastening screw on the right l Tighten the front lateral fastening screw on the right
hand side with 578 Nm (Fig. 19). hand side with 578 Nm (Fig. 22).

Fig. 20 Fig. 23
l Tighten the rear inside fastening screw on the right l Tighten the front lateral fastening screw on the left
hand side with 578 Nm (Fig. 20). hand side with 578 Nm (Fig. 23).

Fig. 21 Fig. 24
l Turn nuts with washers onto both studs and tighten l Cover all lateral fastening screws with plastic caps
with 200 Nm (Fig. 21). (Fig. 24).

440 BOMAG 008 918 12

Cabin assembly 14.2

Fig. 25 Fig. 28
l Insert the foot mat 1 (Fig. 25). l Insert the rear rack and knock both plastic fasteners
carefully into the bores with a hammer (Fig. 28).

Fig. 26
Fig. 29
l Attach the step plate 1 (Fig. 26) and tighten the
three fastening screws (2). l Connect the feed 1 (Fig. 29) and the return flow (2)
for the air conditioning system with quick release
couplings.
l Connect the feed (4) and the return flow (3) of the
heating. (Observe the marks on the hoses).

i Note
Run the connecting lines for the heating parallel to
each other (do not cross).

i Note
Check the function of air conditioning and heating
within the scope of the function test.
Fig. 27 Observe identical hose diameters when connecting.
l Insert the dashboard and fasten it with four fasten-
ing screws (Fig. 27).

008 918 12 BOMAG 441

14.2 Cabin assembly

Danger
!

Before starting to work on electric parts of the ma-

chine disconnect the battery and cover it with in-
sulating material.

Fig. 30
l Plug on both connecting plugs for the washing wa-
ter pumps (Fig. 30).

Fig. 33
l Connect the plug connection of the air conditioning
system (Fig. 33).

Fig. 31
l Plug on the hoses for the washing water supply to
front and rear windscreens 1 (Fig. 31).

i Note
Check the function of the washing water system within
the scope of the function test.

Fig. 32
l
Insert the plug 1 (Fig. 32) into the socket (2).
l
Close the bayonet catch by turning the corrugated
cap nut in clockwise direction against the stop.

442 BOMAG 008 918 12

Final function tests and checks 14.3
14.3 Final function tests and
checks

Caution
!

Make sure that all screws have been tightened

with the specified torque.

i Note
After the cabin assembly the following tests must be
performed to assure that all cables and lines are cor-
rectly connected.
l Insert the ignition key and turn clockwise to position
"1".
l Operate the switches for headlights, direction indi-
cators and interior light to check their function.
l Operate the switches for front and rear windscreen
washer system and check their correct function.

i Note
If the function of the windscreen washer system is re-
versed, the two washing water hoses must be inter-
changed.
l
Start the engine.
l Switch the air conditioning on by the switch. After a
five minute operation the cabin must become no-
ticeably cooler.
l
Switch the air heater on by the switch. After a five
minute operation the cabin must become noticeably
warmer.
l
Function of the seat contact switch.

!Caution
The machine must not be operated if the seat con-
tact switch is not functioning correctly.

008 918 12 BOMAG 443

14.3 Final function tests and checks

444 BOMAG 008 918 12

15 Replacing the cab window panes

008 918 12 BOMAG 445

15.1 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

446 BOMAG 008 918 12

Special tools, cabin windows 15.2
15.2 Special tools, cabin windows
1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2
3. Cutter

Commercial

Fig. 3

008 918 12 BOMAG 447

15.3 Auxiliary materials

15.3 Auxiliary materials

Safety gloves
4. Cutter

Commercial

Fig. 1
5. Window glass bonding agent

BOMAG part-no.: 009 780 32

Fig. 2
6. Activator

BOMAG part-no.: 009 780 33

Fig. 3

448 BOMAG 008 918 12

Auxiliary materials 15.3
7. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

008 918 12 BOMAG 449

15.4 Removing and installing the window pane

15.4 Removing and installing the window

pane
Environment
Environmental damage
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

450 BOMAG 008 918 12

Removing and installing the window pane 15.4
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

008 918 12 BOMAG 451

15.4 Removing and installing the window pane

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

452 BOMAG 008 918 12

Removing and installing the window pane 15.4
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

008 918 12 BOMAG 453

15.4 Removing and installing the window pane

454 BOMAG 008 918 12

16 Drum

008 918 12 BOMAG 455

16.1 Special tools, drum, single drum rollers

16.1 Special tools, drum, single drum roll-

ers
1. Disassembly device for side plate

BOMAG part-no.: 007 211 55

Fig. 1
2. Assembly device for side plate

BOMAG part-no.: 971 079 21

Fig. 2
3. Assembly device for coupling hub and flanged
hub

Fig. 3

456 BOMAG 008 918 12

Special tools, drum, single drum rollers 16.1
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

BOMAG part-no.: 007 215 08

Fig. 7

008 918 12 BOMAG 457

16.2 Repair overview for drum

Fig. 1

458 BOMAG 008 918 12

Repair overview for drum 16.2
1 Rubber buffer 12 Rectangular rubber buffer
2 Vibration bearings 13 Side plate
3 Housing cover, basic weight 14 Travel bearings
4 Flange 15 Oil level inspection plug
5 Flanged housing 16 Oil drain plug
6 Coupling hub 17 Basic weight
7 Mechanical seal 18 Change-over weight
8 Flanged hub 19 Radial seal
9 Vibration motor 20 Vibrator shaft
10 Compensation plates 21 Fan
11 Spacer block 22 Drum shell

008 918 12 BOMAG 459

16.2 Repair overview for drum

Fig. 2

460 BOMAG 008 918 12

Repair overview for drum 16.2

Fig. 3

008 918 12 BOMAG 461

16.2 Repair overview for drum

Fig. 4

462 BOMAG 008 918 12

Repair overview for drum 16.2

Fig. 5

008 918 12 BOMAG 463

16.2 Repair overview for drum

Fig. 6

464 BOMAG 008 918 12

Repair overview for drum 16.2

Fig. 7

008 918 12 BOMAG 465

16.2 Repair overview for drum

Fig. 8

466 BOMAG 008 918 12

Removing and installing the drum 16.3
16.3 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
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
8. Mark the hydraulic hoses (Fig. 3)on the travel mo-
tor and disconnect them from the ports.
9. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 3

008 918 12 BOMAG 467

16.3 Removing and installing the drum

10. Mark the hydraulic hoses on the vibration motor

(Fig. 4) and disconnect them from the ports.
11. Close all hydraulic hoses and motor ports with
suitable plugs.

Fig. 4

! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
Always secure the machine against unintend-
ed rolling!
12. Unscrew bolts 1 (Fig. 5) and nuts and remove the
front scraper (2).
13. Unscrew bolts (3) and nuts and remove the rear
scraper (4).

Fig. 5
14. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 6).

Fig. 6
15. Support the rear cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).

Fig. 7

468 BOMAG 008 918 12

Removing and installing the drum 16.3
16. Disassemble bracket 1 (Fig. 8) for the hydraulic
hoses.

Fig. 8
17. Fasten the lifting gear to the side plate on the vi-
bration motor side.
18. Unscrew bolts 1 (Fig. 9) from the spacer blocks
on vibration and travel motors.

Fig. 9

!Danger
Danger of squashing! Do not stand or step
under loads being loaded.
19. Force out plug 1 (Fig. 10) and unscrew the bolts
(2) from the front and rear cross-members.
20. Take off the side plate.

Fig. 10
21. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 11).

!Danger
Danger of squashing! Do not stand or step
under loads being loaded.

Fig. 11

008 918 12 BOMAG 469

16.3 Removing and installing the drum

22. Check all rubber buffers (Fig. 12), replace if nec-

essary (see corresponding chapter).

Fig. 12
23. Check rectangular rubber buffers (Fig. 13), re-
place if necessary.

Fig. 13

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. 14).

Fig. 14

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. 15)
into rear and front cross-members and tighten
with 463 Nm.
3. Close the screw holes with plugs (1).

Fig. 15

470 BOMAG 008 918 12

Removing and installing the drum 16.3
4. Fasten the spacer blocks on travel and vibration
motor sides with bolts 1 (Fig. 16) and nuts to the
side plates.

Fig. 16
5. Connect hydraulic hoses to the connections on
travel motor and vibration motor according to the
marking (Fig. 17).

Fig. 17
6. Fasten bracket 1 (Fig. 18) for the hydraulic hoses.

Fig. 18
7. Assemble the front scraper 2 (Fig. 19), fasten
with bolts (1), washers and nuts.
8. Assemble the rear scraper (4), fasten with bolts
(3), washers and nuts.

i Note
Observe the adjustment measurement 30-35 mm

Fig. 19

008 918 12 BOMAG 471

16.3 Removing and installing the drum

! Caution
Before resuming operation of the machine:
Bleed the hydraulic system and check for
function and leaks.
Adjust the pretension of the rubber buffers.
9. On the vibration drive side measure the distance
"X" between spacer block and side plate (Fig. 20).
10. Calculate the thickness of the compensation
plates.

Nominal value:

Fig. 20
Distance "X" + 2 mm

i Note
Compensation plates of 2 and 5 mm thickness
are available.
11. Turn in screws into each welded nut (Fig. 21) and
provide sufficient space to insert the compensa-
tion plates.

Fig. 21
12. Insert the compensation plates (Fig. 22).
13. Turn in the fastening screws.
14. Unscrew the screws from the welded nuts.
15. Tighten the fastening screws.

Fig. 22

472 BOMAG 008 918 12

Repairing the drum 16.4
16.4 Repairing the drum

Removing the travel motor

! Danger
Danger of squashing!
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. 4) 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

008 918 12 BOMAG 473

16.4 Repairing the drum

2. Mount bracket 1 (Fig. 10) 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
Danger of squashing!
Do not stand or step under suspended loads.
6. Pull the exciter unit out of the drum (Fig. 6).
7. Take the coupling element off the coupling half.

Fig. 6

474 BOMAG 008 918 12

Repairing the drum 16.4
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

008 918 12 BOMAG 475

16.4 Repairing the drum

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. Lift the exciter unit out of the flanged housing(Fig.
12).

Fig. 12
11. Knock the radial seal (Fig. 13) out of the flanged
housing.

Fig. 13

476 BOMAG 008 918 12

Repairing the drum 16.4
12. Unclip the circlip from the groove in the flanged
housing (Fig. 14).

Fig. 14
13. Press the cylinder roller bearing with forcing
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

008 918 12 BOMAG 477

16.4 Repairing the drum

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

478 BOMAG 008 918 12

Repairing the drum 16.4
5. To change the vibration motor loosen clamping
screw 1 (Fig. 21) and pull off coupling half (2).

Fig. 21
6. Unscrew nut 1 (Fig. 22), take off conical socket
(2) and conical disc (3).
7. Take the vibration motor off the cover.

Fig. 22
8. Remove the coupling element (Fig. 23).

Fig. 23
9. Fasten the lifting device.
10. Unscrew fastening screws 1 (Fig. 24).

! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).

Fig. 24

008 918 12 BOMAG 479

16.4 Repairing the drum

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
Danger of squashing!
Do not stand or step under suspended loads.
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

480 BOMAG 008 918 12

Repairing the drum 16.4
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

008 918 12 BOMAG 481

16.4 Repairing the drum

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

482 BOMAG 008 918 12

Repairing the drum 16.4
8. Unclip the circlip from the groove in the flanged
hub (Fig. 36).

Fig. 36
9. Knock the cylinder roller bearing out of the flang-
ed hub(Fig. 37).

Fig. 37

Environment
Environmental damage!
Catch running out oil and dispose of environ-
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

008 918 12 BOMAG 483

16.4 Repairing the drum

12. Unclip the circlip from the groove in the flanged

housing (Fig. 40).

Fig. 40
13. Press the cylinder roller bearing with forcing
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

484 BOMAG 008 918 12

Repairing the drum 16.4
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.
4. Cool the shaft down in liquid nitrogen.
5. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).

Fig. 46

008 918 12 BOMAG 485

16.4 Repairing the drum

6. Secure shaft 2 (Fig. 47) with dowel pins (1 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. 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

486 BOMAG 008 918 12

Repairing the drum 16.4
! 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.
11. Heat the inner bearing race up to approx. 100° C
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.
12. Heat the inner ring up to approx. 50° C and slide
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

008 918 12 BOMAG 487

16.4 Repairing the drum

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 of oil SAE-15W/40 into the flang-
ed housing.

Fig. 56

!Caution
Danger of squashing!
Do not stand or step under suspended loads.
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 57).

Fig. 57
18. Press cylinder roller bearing 1 (Fig. 58) with
pressing plate (2) into the flanged hub until it bot-
toms.

Fig. 58

488 BOMAG 008 918 12

Repairing the drum 16.4
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

008 918 12 BOMAG 489

16.4 Repairing the drum

26. Apply some grease to the sealing lip of radial seal

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 (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 to approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).

Fig. 65

490 BOMAG 008 918 12

Repairing the drum 16.4
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

008 918 12 BOMAG 491

16.4 Repairing the drum

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

492 BOMAG 008 918 12

Repairing the drum 16.4
11. Bolt the threaded section of the assembly device
to the flanged hub (Fig. 73).

Fig. 73

! Caution
Danger of squashing! Do not stand or step
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

008 918 12 BOMAG 493

16.4 Repairing the drum

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
Ensure strict cleanliness.
1. Cool the shaft down in liquid nitrogen.
Fig. 78
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
78).
3. Secure shaft 1 (Fig. 79) 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.

Fig. 79

494 BOMAG 008 918 12

Repairing the drum 16.4
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.
5. 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. 81).

Fig. 81

! Danger
Danger of burning!
Wear safety gloves.
6. Heat the inner ring up to approx. 50° C and slide
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.
7. Heat the inner bearing race up to approx. 100° C
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 83).

Fig. 83

008 918 12 BOMAG 495

16.4 Repairing the drum

8. Press cylinder roller bearing 1 (Fig. 84) with

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 of oil SAE-15W/40 into the flang-
ed housing.

Fig. 86

! Caution
Danger of squashing! Do not stand or step
under suspended loads.
12. Insert the exciter unit into the flanged housing
(Fig. 87).

Fig. 87

496 BOMAG 008 918 12

Repairing the drum 16.4
13. Press cylinder roller bearing 1 (Fig. 88) with
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

008 918 12 BOMAG 497

16.4 Repairing the drum

17. Apply some grease to the sealing lip of radial seal

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 t 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

498 BOMAG 008 918 12

Repairing the drum 16.4
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
Danger of squashing! Do not stand or step
under suspended loads.
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

008 918 12 BOMAG 499

16.4 Repairing the drum

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
Danger of squashing!
Do not stand or step under suspended loads.
2. Attach the drive disc 2 (Fig. 102) with the assem-
bled travel drive to the rubber buffers. Turn on
and tighten the nuts (1).

Fig. 102

500 BOMAG 008 918 12

Repairing the drum 16.4
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
Danger of squashing! Do not stand or step
under suspended loads.
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

008 918 12 BOMAG 501

16.4 Repairing the drum

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

502 BOMAG 008 918 12

Repairing the drum 16.4
11. Fasten the vibration motor to the cover so that
sockets 1 (Fig. 110) and ventilation bore (2) are
opposite each other.

Fig. 110
12. Slide on coupling half 2 (Fig. 111) and secure with
clamping screw (1).

Fig. 111
13. Attach the cover with the installed vibration mo-
tor, turn in and tighten the screws (Fig. 112).

Fig. 112
14. 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

008 918 12 BOMAG 503

16.5 Dismantling, assembling the change-over weights

16.5 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. 4).

Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.

Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 5).

Fig. 3

504 BOMAG 008 918 12

Dismantling, assembling the change-over weights 16.5
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.

Fig. 4

008 918 12 BOMAG 505

16.5 Dismantling, assembling the change-over weights

Assembling the change-over weights

!Caution
Ensure strict cleanliness.
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. 12).

Fig. 7
4. Attach the cover (Fig. 13), 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.

i Note
There must be play.

Fig. 8

506 BOMAG 008 918 12

Changing the rubber buffers and adjusting the pretension 16.6
16.6 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 (Fig. 3).

Fig. 3

008 918 12 BOMAG 507

16.6 Changing the rubber buffers and adjusting the pretension

5. Unscrew the screws (Fig. 4) from the welded

nuts.

Fig. 4

iNote
Check the rectangular rubber buffers, replace if
necessary.
Observe the assembly direction, arrow up.

Fig. 5
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. 6
Adjusting the pre-load
12. Measure distance "X" between spacer piece and
side plate (Fig. 7).
13. Calculate the thickness of the compensation
plates.

Nominal value:
Distance "X" + 2 mm

Fig. 7

508 BOMAG 008 918 12

Changing the rubber buffers and adjusting the pretension 16.6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 8).

Fig. 8
15. Assemble the compensation shims (Fig. 9).

Fig. 9
16. Unscrew the screws (Fig. 10) from the welded
nuts.

Fig. 10
17. Tighten the fastening screws (Fig. 11).
18. Lower the frame again.

Fig. 11

008 918 12 BOMAG 509

16.6 Changing the rubber buffers and adjusting the pretension

510 BOMAG 008 918 12

17 Oscillating articulated joint

008 918 12 BOMAG 511

17.1 Special tools, oscillating articulated joint (BW177 to BW 216)

17.1 Special tools, oscillating articulated

joint (BW177 to BW 216)
1. Pressing device for rocker bearings

Fig. 1
2. Pressing bushing for outer rocker bearing race

Fig. 2
3. Pressing bushing for inner rocker bearing race

Fig. 3

512 BOMAG 008 918 12

Special tools, oscillating articulated joint (BW177 to BW 216) 17.1
4. Guide pin

Fig. 4
5. Clamping device

Fig. 5
6. Disassembly device

Fig. 6

008 918 12 BOMAG 513

17.2 Repair overview oscillating articulated joint

514 BOMAG 008 918 12

Repair overview oscillating articulated joint 17.2

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 Carrier
8 Self-aligning bearing 19 Friction bearing
9 Console 20 V-ring
10 Belleville springs 21 Seal ring
11 Shim/supporting disc

008 918 12 BOMAG 515

17.2 Repair overview oscillating articulated joint

516 BOMAG 008 918 12

Repair overview oscillating articulated joint 17.2

008 918 12 BOMAG 517

17.3 Removing and installing the oscillating articulated joint

17.3 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

518 BOMAG 008 918 12

Removing and installing the oscillating articulated joint 17.3
4. Unscrew fastening screws 1 (Fig. 4) and take off
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.
8. Unscrew fastening screws 1 (Fig. 5) and take off
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

008 918 12 BOMAG 519

17.4 Dismantling the oscillating articulated joint

17.4 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

520 BOMAG 008 918 12

Dismantling the oscillating articulated joint 17.4
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
9. Unscrew fastening screws 1 (Fig. 5).
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

008 918 12 BOMAG 521

17.4 Dismantling the oscillating articulated joint

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

522 BOMAG 008 918 12

Dismantling the oscillating articulated joint 17.4
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

008 918 12 BOMAG 523

17.4 Dismantling the oscillating articulated joint

23. Check rocker bearings, if necessary press out of

the housing (Fig. 16).

Fig. 16

524 BOMAG 008 918 12

Assembling the oscillating articulated joint 17.5
17.5 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

008 918 12 BOMAG 525

17.5 Assembling the oscillating articulated joint

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
Do not use any grease.
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

526 BOMAG 008 918 12

Assembling the oscillating articulated joint 17.5
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
Do not use any grease.
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

008 918 12 BOMAG 527

17.5 Assembling the oscillating articulated joint

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.

528 BOMAG 008 918 12

Assembling the oscillating articulated joint 17.5
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.
24. Turn in screws (1) and tighten crosswise.

Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).

Fig. 17

008 918 12 BOMAG 529

17.5 Assembling the oscillating articulated joint

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

530 BOMAG 008 918 12

Assembling the oscillating articulated joint 17.5
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
Do not use any grease.
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

008 918 12 BOMAG 531

17.5 Assembling the oscillating articulated joint

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.

532 BOMAG 008 918 12

Assembling the oscillating articulated joint 17.5
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.
43. Turn in screws (2) and tighten crosswise.

Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.

Fig. 32

008 918 12 BOMAG 533

17.5 Assembling the oscillating articulated joint

45. Assemble the washer, turn on and tighten the nut

with 120 Nm (Fig. 33).

Fig. 33

534 BOMAG 008 918 12

18 Suppliers documentation

008 918 12 BOMAG 535

536 BOMAG 008 918 12
18.1 Travel pump

008 918 12 BOMAG 537

18.1 Travel pump

Bild 34

538 BOMAG 008 918 12

Travel pump 18.1

Series 90 Pumps

Service Manual

008 918 12 BOMAG 539

18.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
2EVISIONS

HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.

December 2011 69 4ORQUE VALUES CHANGED FOR % !#

!PRIL 70 4ORQUE FOR ' ' ' ' " " " " CHANGED !"
TO .M ; LBFsFT=
3EPTEMBER - &IRST PRINTING REPLACES ",. !!

¹ 3AUER $ANFOSS !LL RIGHTS RESERVED

3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND

OTHER PRINTED MATERIAL 3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT
PRIOR NOTICE 4HIS ALSO APPLIES TO PRODUCTS ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS
CAN BE MADE WITHOUT AFFECTING AGREED SPECIlCATIONS !LL TRADEMARKS IN THIS MATERIAL
ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS THE 3AUER $ANFOSS LOGOTYPE
THE 3AUER $ANFOSS 3 ICON 0,53» 7HAT REALLY MATTERS IS INSIDE¸ AND +NOW (OW IN
-OTION» ARE TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
2 520L0818 s 2EV !# s December 2011

540 BOMAG 008 918 12

Travel pump 18.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

INTRODUCTION /VERVIEW ........................................................................................................................................................... 6

7ARRANTY ............................................................................................................................................................ 6
'ENERAL INSTRUCTIONS ...................................................................................................................................... 6
3AFETY PRECAUTIONS ......................................................................................................................................... 7
5NINTENDED MACHINE MOVEMENT ....................................................................................................... 7
&LAMMABLE CLEANING SOLVENTS ............................................................................................................... 7
&LUID UNDER PRESSURE ................................................................................................................................ 7
0ERSONAL SAFETY ........................................................................................................................................... 7
3YMBOLS USED IN 3AUER $ANFOSS LITERATURE.............................................................................................
$ESIGN ................................................................................................................................................................ 9
4HE SYSTEM CIRCUIT.........................................................................................................................................10

OPERATION #HARGE PUMP .................................................................................................................................................12

#HARGE RELIEF VALVE........................................................................................................................................12
-ULTI FUNCTION VALVES ..................................................................................................................................12
0RESSURE LIMITER AND HIGH PRESSURE RELIEF VALVES ................................................................................
3YSTEM CHECK VALVES ....................................................................................................................................
"YPASS VALVES .................................................................................................................................................
3PEED SENSORS ................................................................................................................................................
&ILTRATION OPTIONS ..........................................................................................................................................
0RESSURE OVERRIDE 0/2 n FRAME SIZE ONLY...................................................................................
-ANUAL DISPLACEMENT CONTROL -$# ....................................................................................................
.ON LINEAR -$# ............................................................................................................................................
3OLENOID OVERRIDE VALVE FOR -$# ............................................................................................................
.EUTRAL START SWITCH .33 ..........................................................................................................................
(YDRAULIC DISPLACEMENT CONTROL ($# .................................................................................................
%LECTRIC DISPLACEMENT CONTROL %$# ......................................................................................................
!UTOMOTIVE CONTROL &"! )) " ...................................................................................................................
0OSITION &.2 ELECTRIC CONTROL .............................................................................................................

OPERATING /VERVIEW .........................................................................................................................................................16

PARAMETERS )NPUT SPEED ....................................................................................................................................................16
3YSTEM PRESSURE ............................................................................................................................................16
#HARGE PRESSURE ............................................................................................................................................17
#HARGE INLET PRESSURE ..................................................................................................................................17
#ASE PRESSURE .................................................................................................................................................17
4EMPERATURE AND VISCOSITY ........................................................................................................................
4EMPERATURE .............................................................................................................................................
6ISCOSITY......................................................................................................................................................
&LUID AND lLTER RECOMMENDATIONS..........................................................................................................19

TECHNICAL /VERVIEW .........................................................................................................................................................20

SPECIFICATIONS &EATURES AND OPTIONS ..................................................................................................................................20
/PERATING PARAMETERS ................................................................................................................................20
&LUID SPECIlCATIONS ......................................................................................................................................20

520L0818 s 2EV !# s December 2011 3
008 918 12 BOMAG 541
18.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

INITIAL STARTUP 'ENERAL ............................................................................................................................................................21

PROCEDURES 3TART UP PROCEDURE ......................................................................................................................................21

PRESSURE 2EQUIRED TOOLS ...............................................................................................................................................

MEASUREMENTS 0ORT LOCATIONS AND GAUGE INSTALLATION ...................................................................................................

TROUBLESHOOTING /VERVIEW .........................................................................................................................................................26

.EUTRAL DIFlCULT OR IMPOSSIBLE TO lND ...................................................................................................26
3YSTEM OPERATING HOT .................................................................................................................................26
4RANSMISSION OPERATES NORMALLY IN ONE DIRECTION ONLY ..................................................................27
3YSTEM WILL NOT OPERATE IN EITHER DIRECTION.........................................................................................27
,OW MOTOR OUTPUT TORQUE .........................................................................................................................
)MPROPER MOTOR OUTPUT SPEED ................................................................................................................
3YSTEM NOISE OR VIBRATION ..........................................................................................................................
3YSTEM RESPONSE IS SLUGGISH .....................................................................................................................29

ADJUSTMENTS 3TANDARD PROCEDURES INSPECTIONS AND ADJUSTMENTS ......................................................................

!DJUSTMENTS ...................................................................................................................................................
#HARGE PRESSURE RELIEF VALVE ADJUSTMENT .............................................................................................
-ULTI FUNCTION VALVE PRESSURE ADJUSTMENT ..........................................................................................
%NGAGING THE BYPASS FUNCTION.................................................................................................................
0RESSURE OVERRIDE 0/2 VALVE PRESSURE ADJUSTMENT OPTION FOR FRAME SIZE ..................
$ISPLACEMENT LIMITER ADJUSTMENT...........................................................................................................
3TANDARD MANUAL DISPLACEMENT CONTROL -$# ADJUSTMENT.........................................................
.ON LINEAR MANUAL DISPLACEMENT CONTROL -$# ..............................................................................
-$# NEUTRAL START SWITCH .33 ADJUSTMENTS .....................................................................................
.EUTRAL START SWITCH ECCENTRIC PLUG ADJUSTMENT CONDITION I .................................................
.33 DEADBAND ADJUSTMENT CONDITIONS II III .............................................................................
#HECKING SWITCH CONTINUITY ......................................................................................................................
(YDRAULIC DISPLACEMENT CONTROL ($# AND ELECTRIC DISPLACEMENT CONTROL %$#
ADJUSTMENT .....................................................................................................................................................
3PEED SENSOR ADJUSTMENT..........................................................................................................................

4 520L0818 s 2EV !# s December 2011

542 BOMAG 008 918 12

Travel pump 18.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
#ONTENTS

MINOR REPAIR 3TANDARD PROCEDURES ..................................................................................................................................

3HAFT SEAL AND SHAFT REPLACEMENT ...........................................................................................................
-ULTI FUNCTION VALVE CARTRIDGES ...............................................................................................................
-ULTI FUNCTION VALVE CARTRIDGES PRE ..........................................................................................
0RESSURE OVERRIDE VALVE OPTION FOR FRAME SIZE .........................................................................
#HARGE PRESSURE RELIEF VALVE .....................................................................................................................
!UXILIARY PAD ..................................................................................................................................................
#HARGE PUMP .................................................................................................................................................
!DDING AN !UXILIARY PAD TO A PUMP PREVIOUSLY WITHOUT ONE .......................................................
)NTEGRAL CHARGE PRESSURE lLTER REPLACEMENT .......................................................................................
0UMP CONTROL COVER PLATE ..........................................................................................................................60
$ISPLACEMENT CONTROL ORIlCES ..................................................................................................................61
$ISPLACEMENT CONTROL ORIlCE CHECK VALVE ...........................................................................................61
$ISPLACEMENT CONTROL ADAPTER PLATE EARLY PRODUCTION PUMPS ONLY ...............................61
-ANUAL DISPLACEMENT CONTROL -$# ....................................................................................................62
3OLENOID OVERRIDE VALVE FOR -$# ............................................................................................................
3OLENOID OVERRIDE VALVE FOR -$# WITH PRESSURE RELEASED BRAKE .................................................
(YDRAULIC AND ELECTRIC DISPLACEMENT CONTROLS ...................................................................................
0RESSURE CONTROL PILOT 0#0 FOR ELECTRIC DISPLACEMENT CONTROL %$# ........................................66
0OSITION &.2 ELECTRIC CONTROL .............................................................................................................67
$ISPLACEMENT CONTROL lLTER SCREENS .......................................................................................................
3PEED SENSOR..................................................................................................................................................

TORQUE CHART &ASTENER SIZE AND TORQUE CHART ................................................................................................................69

0LUG SIZE AND TORQUE CHART ........................................................................................................................70
&ASTENERS AND PLUGS.....................................................................................................................................70

520L0818 s 2EV !# s December 2011 5
008 918 12 BOMAG 543
18.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

OVERVIEW 4HIS MANUAL INCLUDES INFORMATION FOR THE INSTALLATION MAINTENANCE AND MINOR REPAIR OF

3ERIES AXIAL PISTON CLOSED CIRCUIT PUMPS )T INCLUDES A DESCRIPTION OF THE UNIT AND ITS
INDIVIDUAL COMPONENTS TROUBLESHOOTING INFORMATION AND MINOR REPAIR PROCEDURES

0ERFORMING MINOR REPAIRS REQUIRES YOU REMOVE THE UNIT FROM THE VEHICLEMACHINE
4HOROUGHLY CLEAN THE UNIT BEFORE BEGINNING MAINTENANCE OR REPAIR ACTIVITIES 3INCE DIRT
AND CONTAMINATION ARE THE GREATEST ENEMIES OF ANY TYPE OF HYDRAULIC EQUIPMENT FOLLOW
CLEANLINESS REQUIREMENTS STRICTLY 4HIS IS ESPECIALLY IMPORTANT WHEN CHANGING THE SYSTEM
lLTER AND WHEN REMOVING HOSES OR PLUMBING

! WORLDWIDE NETWORK OF 3AUER $ANFOSS 'LOBAL 3ERVICE 0ARTNERS '30S IS AVAILABLE FOR

MAJOR REPAIRS 3AUER $ANFOSS TRAINS '30S AND CERTIlES THEIR FACILITIES ON A REGULAR BASIS
9OU CAN LOCATE YOUR NEAREST !3# USING THE DISTRIBUTOR LOCATOR AT WWWSAUER DANFOSSCOM
#LICK ON THE Sales and Service LINK

WARRANTY 0ERFORMING INSTALLATION MAINTENANCE AND MINOR REPAIRS ACCORDING TO THE PROCEDURES IN

THIS MANUAL WILL NOT AFFECT YOUR WARRANTY -AJOR REPAIRS REQUIRING THE REMOVAL OF A UNITS
REAR OR SIDE COVER VOIDS THE WARRANTY UNLESS DONE BY A 3AUER $ANFOSS !UTHORIZED 3ERVICE
#ENTER

GENERAL INSTRUCTIONS &OLLOW THESE GENERAL PROCEDURES WHEN REPAIRING 3ERIES VARIABLE DISPLACEMENT CLOSED

CIRCUIT PUMPS

w Remove the unit

0RIOR TO PERFORMING MAJOR REPAIRS REMOVE THE UNIT FROM THE VEHICLEMACHINE #HOCK
THE WHEELS ON THE VEHICLE OR LOCK THE MECHANISM TO INHIBIT MOVEMENT "E AWARE THAT
HYDRAULIC mUID MAY BE UNDER HIGH PRESSURE ANDOR HOT )NSPECT THE OUTSIDE OF THE PUMP
AND lTTINGS FOR DAMAGE #AP HOSES AFTER REMOVAL TO PREVENT CONTAMINATION

e Keep it clean
#LEANLINESS IS A PRIMARY MEANS OF ASSURING SATISFACTORY PUMP LIFE ON EITHER NEW OR
REPAIRED UNITS #LEAN THE OUTSIDE OF THE PUMP THOROUGHLY BEFORE DISASSEMBLY 4AKE CARE
TO AVOID CONTAMINATION OF THE SYSTEM PORTS #LEANING PARTS BY USING A CLEAN SOLVENT WASH
AND AIR DRYING IS USUALLY ADEQUATE

!S WITH ANY PRECISION EQUIPMENT KEEP ALL PARTS FREE OF FOREIGN MATERIALS AND CHEMICALS
0ROTECT ALL EXPOSED SEALING SURFACES AND OPEN CAVITIES FROM DAMAGE AND FOREIGN MATERIAL
)F LEFT UNATTENDED COVER THE PUMP WITH A PROTECTIVE LAYER OF PLASTIC

d Replace all O-rings and gaskets

5SE NEW / RINGS AND GASKETS DURING REASSEMBLY ,IGHTLY LUBRICATE ALL / RINGS WITH CLEAN
PETROLEUM JELLY PRIOR TO ASSEMBLY

t Secure the unit

&OR REPAIR PLACE THE UNIT IN A STABLE POSITION WITH THE SHAFT POINTING DOWNWARD )T WILL BE
NECESSARY TO SECURE THE PUMP WHILE REMOVING AND TORQUING END COVERS CONTROLS AND
valves.

6 520L0818 s 2EV !# s December 2011

544 BOMAG 008 918 12

Travel pump 18.1
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

SAFETY PRECAUTIONS !LWAYS CONSIDER SAFETY PRECAUTIONS BEFORE BEGINNING A SERVICE PROCEDURE 0ROTECT

YOURSELF AND OTHERS FROM INJURY 4AKE THE FOLLOWING GENERAL PRECAUTIONS WHENEVER SERVICING A
HYDRAULIC SYSTEM

Unintended machine movement

W Warning
5NINTENDED MOVEMENT OF THE MACHINE OR MECHANISM MAY CAUSE INJURY TO THE TECHNICIAN
OR BYSTANDERS 4O PROTECT AGAINST UNINTENDED MOVEMENT SECURE THE MACHINE OR DISABLE
DISCONNECT THE MECHANISM WHILE SERVICING

Flammable cleaning solvents

W Warning
3OME CLEANING SOLVENTS ARE mAMMABLE 4O AVOID POSSIBLE lRE DO NOT USE CLEANING
SOLVENTS IN AN AREA WHERE A SOURCE OF IGNITION MAY BE PRESENT

Fluid under pressure

W Warning
%SCAPING HYDRAULIC mUID UNDER PRESSURE CAN HAVE SUFlCIENT FORCE TO PENETRATE YOUR SKIN
CAUSING SERIOUS INJURY ANDOR INFECTION 4HIS mUID MAY ALSO BE HOT ENOUGH TO CAUSE BURNS
5SE CAUTION WHEN DEALING WITH HYDRAULIC mUID UNDER PRESSURE 2ELIEVE PRESSURE IN THE
SYSTEM BEFORE REMOVING HOSES lTTINGS GAUGES OR COMPONENTS .EVER USE YOUR HAND
OR ANY OTHER BODY PART TO CHECK FOR LEAKS IN A PRESSURIZED LINE 3EEK MEDICAL ATTENTION
IMMEDIATELY IF YOU ARE CUT BY HYDRAULIC mUID

Personal safety
W Warning
0ROTECT YOURSELF FROM INJURY 5SE PROPER SAFETY EQUIPMENT INCLUDING SAFETY GLASSES AT ALL
TIMES

520L0818 s 2EV !# s December 2011 7
008 918 12 BOMAG 545
18.1 Travel pump
3ERIES !XIAL 0ISTON #LOSED #IRCUIT 0UMPS
Service Manual
)NTRODUCTION

SYMBOLS USED IN  7!2.).'