Service - Manual

BM 2000/60
S/N 821 836 13 ....

Cold Milling Machine

Catalogue number.
008 910 36 06/2006
Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 11
1.4 Tightening torques 13
Technical data 15
2.1 Technical data 17
2.2 Maintenance chart 22
2.3 Table of fuels and lubricants 25
2.4 Fuels and lubricants 26
Fundamental electrics 29
3.1 Understanding circuit diagrams 31
3.2 Terminal designations 35
3.3 Current and voltage 39
3.4 Resistance 43
3.5 Series / parallel connection 45
3.6 Ohm's law 46
3.7 Electrical energy 47
3.8 Formula diagram 48
3.9 Logical base gates 49
3.10 Metrology 50
3.11 Diodes, relays, fuses 53
3.12 Batteries 55
3.13 Three-phase generator 58
3.14 Electric starter 63
Special tools, electrics 67
4.1 Special tools, electrics 68
Machine related electrics 75
5.1 Component overview 77
5.2 Driver's stand 78
5.3 Control console, rear right 80
5.4 Control console, rear left 81
5.5 Control console, front right 82
5.6 Control console, front left 83
5.7 Control console for auxiliary control 84
5.8 Engine hood control console 85
5.9 Loading conveyor belt 86
5.10 Steering limitation, front 88
5.11 Middle position, rear steering 90
5.12 Operating conditions for rear steering 92
5.13 Height limitation, rear 100
5.14 Operating conditions for rear posts 101
5.15 High pressure sensors for travel/conveyor belt pump 103
5.16 Pressure sensor for steering / working hydraulics 104
5.17 Pressure sensor for clutch pressure 106
5.18 Pressure sensor for fan circuit 107

008 910 36 BOMAG 3

Table of Contents

5.19 Differential pressure switch for hydraulic oil filter 108

5.20 Pressure switch for water sprinkling system 109
5.21 Operating condition for sprinkling system 110
5.22 Limit switch on scraper 111
5.23 Operating conditions for scraper 113
5.24 Rope sensors, height regulation 116
5.25 Inclination sensor for height regulation 119
5.26 Operating conditions for height regulation 120
5.27 Levelling control panel 128
5.28 Speed sensor 130
5.29 Operating conditions for travel drive 131
5.30 Terminal box 141
5.31 Pin assignment, ID4.....ID6 149
5.32 Battery compartment 161
5.33 Battery maintenance 162
5.34 Multi-function display, inputs/outputs 163
5.35 TUNING PID Parameter 164
5.36 Digital inputs and outputs in the electric circuit diagram 166
5.37 Switching states, COMPACT (ID4) 167
5.38 Switching states, COMPACT (ID5) 169
5.39 Switching states, COMPACT (ID6) 171
5.40 Switching states, CGC MATRIX 173
5.41 Operating conditions for conveyor belt 175
5.42 Operating conditions for gathering foot 177
5.43 Operating conditions for grade shoes 179
5.44 Operating condition for milling rotor operation 180
Engine 181
6.1 General information on diesel engine 183
6.2 Engine attachment parts 185
6.3 Lubrication oil schematic 187
6.4 Electronic engine control EMR 188
6.5 Sensor data EMR 202
6.6 Plug assignment EMR 203
6.7 Connection diagram EMR engine control 205
6.8 Engine 207
6.9 Fault lamp 209
6.10 Diagnostics button 210
6.11 Overview of fault flashing codes 212
6.12 Possible diagnostics with the SERIDA software 220
6.13 Checking the engine speed 221
6.14 Disassembling and assembling the injection valves 222
6.15 Checking and adjusting the start of commencement 224
6.16 Replacement of radial seal on flywheel side 227
6.17 Replacement of radial seal on pump carrier 229
6.18 Replacing the thermostats 230
6.19 Replacing the coolant pump 231
6.20 Sealing / replacing the oil cooler 232
6.21 Replacing the cylinder head gasket 233

4 BOMAG 008 910 36

Table of Contents

6.22 Check, adjust the valve clearance 238

6.23 Checking, replacing the generator V-belt 240
6.24 Service the combustion air filter 241
6.25 Check the coolant level 243
6.26 Change the coolant 244
6.27 Check the engine oil level 244
6.28 Changing engine oil and oil filter cartridges 245
6.29 Check fastening of engine / turbocharger / combustion air hoses 246
6.30 Engine conservation 247
6.31 Cleaning the engine 247
6.32 Fuel pre-filter / water separator (SEPAR filter) 248
6.33 Checking, cleaning the water separator 251
6.34 Changing the fuel prefilter element 251
6.35 Change the fuel filter cartridge 252
6.36 Special tools, Deutz engine (BF8M 1015C) 253
6.37 Explanation of symbols 256
Milling drive, mechanics 261
7.1 Milling drive 263
7.2 Checking, replacing the milling drum V-belt 277
7.3 Change the oil in the milling drum reduction gear 278
7.4 Oil change in milling drum bearing 278
7.5 Checking/replacing cutting tools, scraper 279
7.6 Replacing bases/holders 282
7.7 Lubricating the milling drum 283
7.8 Lubricating the dry clutch 283
7.9 Checking the wear of the friction lining 284
7.10 Friction lining / replacing the outer discs 284
Conveyor belts, mechanics 289
8.1 Conveyor belts 291
8.2 Checking, tightening the conveyor belts 295
8.3 Checking the safety ropes 296
8.4 Lubricating the conveyor belts 296
8.5 Folding / unfolding the loading conveyor belt 298
Travel drive, mechanics 299
9.1 Travel drive 301
9.2 Checking the track plates 305
9.3 Retightening the track shoe fastening screws 305
9.4 Checking the track drive 306
9.5 Lubricating the travel drive 308
9.6 Lubricating the steering system 308
9.7 Oil change in track drive gear 309
Pump transfer case 311
10.1 Transfer case 313
10.2 Check the oil level in the pump drive gear 316
10.3 Change the oil in the pump drive gear 316
Hydraulics 319
11.1 Service Training Hydraulics 321

008 910 36 BOMAG 5

Table of Contents

Hydraulic cylinder 413

12.1 Repairing hydraulic cylinders 415
Suppliers documentation 417
13.1 Steering and working pump A10V ...... 419
13.2 Travel pump A4VG 71 ... 180 449
13.3 Conveyor belt pump A10VG 28 ... 56 511
13.4 Travel motor A6VM/VE 569
13.5 Travel gear 705C3H10C80 623
13.6 Conveyor belt motor OMT 693
13.7 Sprinkling pump 711
Circuit diagrams 735
14.1 Wiring diagram 737
14.2 Hydraulic diagram 787

6 BOMAG 008 910 36

1 General

008 910 36 BOMAG 7

1.1 Introduction

1.1 Introduction This training manual has not only been written as a
support for the professional work of the trainer, but
This manual contain all necessary information for also for the trainees attending these training courses.
training and repair work.
The different levels of product training demand, that
The repair instructions describe the removal or dis- the training performed by BOMAG, its Profit Centres
mantling and assembly of components and assembly or its dealers reflects the high quality of the training
groups. conducted at the Training Centre at BOMAG in Bopp-
The repair of disassembled assembly groups is de- ard. For this reason we invested a lot of time in the
scribed as far as this makes sense with respect to preparation of these materials.
available tools and spare parts supply and as far as it
Documentation
can be understood by a skilled mechanic.
For the BOMAG machines described in this training
manual the following documentation is additionally
Danger
! available:
Danger of injury 1 Operating and maintenance instructions
Please observe strictly the safety regulations in 2 Spare parts catalogue
this manual, in the operating instructions as well 3 Wiring diagram*
as the applicable accident prevention regulations.
4 Hydraulic diagram*
Spare parts needed for repairs can be taken from the 5 Service Information
spare parts catalogue for the machine.
Reliable construction equipment is of benefit for all You should only use genuine BOMAG spare parts.
parties involved: This manual is not subject of any updating service; we
l
they enable the customer/user to exactly calculate would therefore like to draw your
the running times and the completion of projects attention to the additionally published "technical serv-
within the specified time. ice information".
In case of a new release all necessary changes will be
l in the rental business machines can be reliably
included.
used and planned, so that the number of stock ma-
chines can be kept at a low level. In the course of technical development we reserve the
right for technical modifications without prior notifica-
l for the manufacturer satisfied customers provide a
tion.
good image and give a feeling of confidence.
Information and illustrations in this manual must not
It is BOMAG's philosophy to design and produce the be reproduced and distributed, nor must they be used
machines with highest possible reliability. This aspect for the purpose of competition. All rights according to
of simple and easy maintenance was one of the key the copyright law remain expressly reserved.
issues when developing and designing the machine:
BOMAG GmbH
l the location of components in the machine eases
maintenance work, Printed in Germany
Copyright by BOMAG
l the high quality standard of BOMAG is the basis for
the considerable extension of the service and main- * The applicable documents valid at the date of print-
tenance intervals. ing are part of this manual.
l
the After Sales Service of BOMAG, including excel-
lent operating and maintenance instruction manu-
als, high quality training courses and on-site
machine demonstrations helps the customer to
maintain their machines in good condition over a
long period of time.
Permanent training of BOMAG’s own service person-
nel as well as the service personnel of BOMAG Profit
Centres and dealers is therefore a general prerequi-
site for BOMAG’s excellent world-wide service.
This program of permanent training is only possible
with appropriate and up-to-date training material for
trainers as well as persons attending the training
courses.

8 BOMAG 008 910 36

Safety regulations 1.2
Important notes Tools, lifting gear, lifting tackle, supports and other
1.2 Safety regulations
l

auxiliary equipment must be fully functional and in

These safety regulations must be read and ap- safe condition.
plied by every person involved in the repair of this l Use only safe and approved lifting gear of sifficient
machine. The applicable accident prevention in-
load bearing capacity to remove and install parts or
structions and the safety regulations in the oper-
components from and to the machine.
ating and maintenance instructions must be
additionally observed. l Be careful with cleansing agents. Do not use easily
inflammable or harmful substances, such as gaso-
Repair work shall only performed by appropriately line or paint thinners for cleaning.
trained personnel or by the after sales service of
BOMAG.
l Cleaning or repair work on the fuel tank is very dan-
gerous. Do not smoke or allow any ignitable sparks
This manual contain headers like "Note", "Attention",
or open fire in the vicinity when cleaning or repairing
"Danger" and "Environment", which must be strictly
a tank. .
complied with in order to avoid dangers for health and
for the environment. l When performing welding work strictly comply with
the respective welding instructions.

! Danger
Special safety regulations
Paragraphs marked like this highlight possible
dangers for persons. l Use only genuine BOMAG spare parts for repair
purposes. Original parts and accessories have
been specially designed for this machine.
Caution
!
l
We wish to make explicitly clear that we have not
Paragraphs marked like this highlight possible
tested or approved any parts or accessories not
dangers for machines or parts of the machine.
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
i Note the specific characteristics of the machine and
Paragraphs marked like this contain technical infor- thereby impair the active and/or passive driving
mation for the optimal economical use of the machine. safety. The manufacturer explicitly excludes any li-
ability for damage caused by the use of non-original
parts or accessories.
Environment l Unauthorized changes to the machine are prohibit-
Paragraphs marked like this point out practices ed for safety reasons.
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
l If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
Observe the regulations for the protection of the lation area of the machine, danger of injury!
environment.
l Do not perform cleaning work while the engine is
running.
General
l
If tests must be performed with the engine running
l Before starting repair work stand the machine on do not touch rotating parts of the engine, danger of
level and solid ground. injury.
l Always secure the machine against unintended roll- l
Exhaust gases are highly dangerous. Always en-
ing. sure an adequate supply of fresh air when starting
l
Secure the engine reliably against unintentional the engine in closed rooms.
starting. l Refuel only with the engine shut down. Ensure strict
l
Mark a machine that is defective or being repaired cleanliness and do not spill any fuel.
by attaching a clearly visible warning tag to the l Keep used filters in a separate waste container and
steering wheel. dispose of environmentally.
l On machines with articulated joint keep the articu- l Dispose of oils and fuel environmentally when per-
lated joint locked during work. forming repair or maintenance work.
l
Use protective clothes like hard hat, safety boots l Do not refuel in closed rooms.
and gloves.
l
Do not heat up oil higher than 160 °C because it
l Keep unauthorized persons away from the machine may ignite.
during repair work.
l Wipe off spilled oil and fuel.

008 910 36 BOMAG 9

1.2 Safety regulations

l Do not smoke when refuelling or when checking the

acid level in the battery.
l Do not check the acid level of the battery with a na-
ked flame, danger of explosion!
l Old batteries contain lead and must be properly dis-
posed of.
l
There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature.
l on machines with rubber tires a tire may busr if in-
correctly assembled. This can cause severe injury.
l Do not exceed the specified highest permissible tire
pressure.

Hydraulics
l Hydraulic oil escaping under pressure can pene-
trate the skin and cause severe injury. You should
therefore relieve the pressure in the system before
disconnecting any lines.
l Before applying pressure to the system make sure
that all line connections and ports have been prop-
erly tightened and are in perfect condition.
l Hydraulic oil leaking out of a small opening can
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When
being injured by hydraulic oil consult a physician im-
mediately, as otherwise this may cause severe in-
fections.
l Do not step in front of or behind the drums/wheels/
crawler tracks when performing adjustment work in
the hydraulic system while the engine is running.
Block drums and/or wheels / crawler tracks with
wedges.

Reattach all guards and safety installations after

all work has been completed.

10 BOMAG 008 910 36

General repair instructions 1.3
General Fill new hydraulic units with hydraulic oil before
1.3 Gener al repair instructions
l

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

008 910 36 BOMAG 11

1.3 General repair instructions

Electrics the immediate vicinity of the welding location. Strict-

ly disconnect the cables from the generator before
starting work.
The electric and electronic systems in construction l Do not disconnect or connect battery or generator
equipment are becoming more and more extensive. while the engine is running. Do not operate the main
Electronic elements are increasingly gaining impor- battery switch under load. Do not use jump leads af-
tance in hydraulic and mechanical vehicle systems. ter the battery has been removed.
Diagnostics according to plan l Sensors and electric actuators on control units must
A structured approach in trouble shooting saves time never be connected individually or between exter-
and helps to avoid mistakes and expenses, especially nal power sources for the purpose of testing, but
in the fields of electrics and electronics. Understand- only in connection with the control unit in question,
ing electronic controls requires the knowledge of as otherwise there may be a risk of destruction
some basic terms concerning their general perform- (damage)!
ance. In many cases error logs are just simply read l Even with an existing polarity reversal protection in-
out and control units are replaced without any further correct polarity must be strictly avoided. Incorrect
trouble shooting. This is in most cases unnecessary polarity can cause damage to control units!
and, even more important, very expensive. l Plug-in connectors on control units are only dust
Random tests have revealed that purely electronic and water tight if the mating connector is plugged
components or control units only very rarely are the on! Control units must be protected against spray
actual cause of failures: water, until the mating connector is finally plugged
l
In approx. 10 % of the examined cases the prob- on!
lems were caused by control units. l Disconnecting the control unit plug connectors with
l
In approx. 15 % sensors and actuators were the the control unit switched on, i.e. with the power sup-
cause of the problems. ply (terminal 15 "On"), is not permitted. Switch the
voltage supply "off" first - then pull out the plug.
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. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
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 Perform trouble shooting in a systematic way. Do
not become confused by the high number and vari-
ety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
l Surge voltages in the electric system must be strict-
ly avoided: For electric and inert gas welding all
electric components, battery and generator must be
electrically isolated. When performing welding work
always fasten the earth clamp of the welding unit in

12 BOMAG 008 910 36

Tightening torques 1.4
Tightening torques
1.4 Tightening tor ques

l Tighten fastening screws and nuts according to the table of tightening torques.
l Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.

Caution
!

Self-locking nuts must be generally renewed.

Tightening torques for screws with metric unified thread

Tightening torque Nm* (ft-lb)

Screw dimension
8.8 10.9 12.9
M4 3 (2) 5 (4) 5 (4)
M5 6 (4) 9 (7) 10 (7)
M6 10 (7) 15 (11) 18 (13)
M8 25 (18) 35 (26) 45 (33)
M10 50 (37) 75 (55) 83 (61)
M12 88 (65) 123 (91) 147 (108)
M14 137 (101) 196 (145) 235 (173)
M16 211 (156) 300 (221) 358 (264)
M18 290 (213) 412 (303) 490 (361)
M20 412 (304) 578 (426) 696 (513)
M22 560 (413) 785 (559) 942 (695)
M24 711 (524) 1000 (738) 1200 (885)
M27 1050 (774) 1480 (1092) 1774 (1308)
M30 1420 (1047) 2010 (1482) 2400 (1770)
Tightening torques for screws with metric fine thread

Tightening torques Nm1 (ft-lb)

Screw dimension
8.8 10.9 12.9
M8 x 1 26 (19) 37 (27) 48 (35)
M10 x 1.25 52 (38) 76 (56) 88 (65)
M12 x 1.25 98 (72) 137 (101) 126 (119)
M12 x 1.5 93 (69) 127 (94) 152 (112)
M14 x 1.5 152 (112) 216 (159) 255 (188)
M16 x 1.5 225 (166) 318 (235) 383 (282)
M18 x 1.5 324 (239) 466 (344) 554 (409)
M20 x 1.5 461 (340) 628 (463) 775 (572)
M22 x 1.5 618 (456) 863 (636) 1058 (780)
M24 x 2 780 (575) 1098 (808) 1294 (1416)
M27 x2 1147 (846) 1578 (1164) 1920 (1416)
M30 x 2 1568 (1156) 2254 (1662) 2695 (1988)
1 Strength classes for screws with untreated, non-lubricated surface.
The values result in a 90% utilization of the screw’s yield point at a coefficient of friction μ total = 0,14.
Compliance with the tightening torques is checked with torque wrenches.
Tightening torques deviating from the ones mentioned in the table are specially mentioned in these descriptions.
The values specified in the table apply for screws black, oiled and with surface protection A4C.
The quality designation of the screws is stamped on the screw heads.

008 910 36 BOMAG 13

1.4 Tightening torques

14 BOMAG 008 910 36

2 Technical data

008 910 36 BOMAG 15

16 BOMAG 008 910 36
2.1 Technical data

17 BOMAG 008 910 36

Technical data 2.1

008 910 36 BOMAG 18

2.1 Technical data

19 BOMAG 008 910 36

Technical data 2.1

Fig. 1

Dimensions in A B B1 H H1 H2 L L1 L2
mm
BM 2000/60 4720 2500 300 4485 3990 2980 14050 7275 12050

1
BM 2000/60

Weights
Operating weight (CECE) kg 32650
Front axle load kg 17000
Rear axle load kg 15650

Rotor
Max. working depth mm 320
Max. working width mm 2100
Diameter mm 1070
Max. slope ° 5
Number of teeth 168

Travel characteristics
Working speed m/min 0 - 30
Speed km/h 0-5
Max perm. inclination % 18
Max perm. slope % 5

Drive
Engine manufacturer Deutz
Type BF8M 1015CP-EMR
Cooling Water
Number of cylinders 8V
Rated power ISO 3046 kW(HP) 440 (598)
Rated speed rpm 2100

008 910 36 BOMAG 20

2.1 Technical data

1
BM 2000/60
Fuel Diesel

Crawler tracks
Dimensions LxWxH front mm 1725x300x635
Dimensions LxWxH rear mm 1725x300x635

Electrical system
Voltage V 24
Batteries (2) Ah 2x155
Generator A 80

Conveyor system
Belt width, gathering belt mm 800x2400
Belt width, loading belt mm 800x7600

Filling capacities
Diesel fuel l 1200
Hydraulic oil l 230
Water l 3300
1 The right for technical modifications remains reserved

21 BOMAG 008 910 36

Maintenance chart 2.2
2.2 Maintenance chart

every 50 operating hours, every week

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 4000 operating hours

every 250 operating hours
after 50 operating hours
Running-in instructions
No. Maintenance work Remark

as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check water level, spray nozzles Inspection glass X
5.11 Checking/replacing cutting tools, scrap- several times X
er
5.12 Checking the track plates X
5.13 Checking, tightening the conveyor belts X
5.14 Checking the safety ropes X
5.15 Lubricating the machine X
5.16 Check the coolant level Inspection glass X
5.17 Check the oil level in the transfer box X
5.18 Retightening the floor plate fastening X
screws
5.19 Lubricating the machine X
5.20 Clean the cooling fins on engine and hy- X
draulic oil cooler
5.21 Cleaning the engine X
5.22 Change engine oil and oil filter car- min. 1x per year X X
tridge1
5.23 Checking, replacing the generator V- X
belt
5.24 Checking, replacing the milling drum V- X
belt
5.25 Checking the track drive X
5.26 Lubricating the machine X
5.27 Change the fuel pre-filter element X

008 910 36 BOMAG 22

2.2 Maintenance chart

every 50 operating hours, every week

every 10 operating hours, daily

every 1000 operating hours

every 2000 operating hours

every 4000 operating hours

every 250 operating hours
after 50 operating hours
Running-in instructions
No. Maintenance work Remark

as required
5.28 Change the fuel filter cartridge X
5.29 Check fastening of engine / turbocharg- Pole grease X
er / combustion air hoses
5.30 Change the hydraulic oil2 min. 1x per year X
5.31 Change the hydraulic oil filter** min. 1x per year X
5.32 Change the oil in the transfer box3 X X
5.33 Change the oil in the milling drum re- min. 1x per year X X
duction gear
5.34 Oil change in milling drum bearing min. 1x per year X
5.35 Oil change in track drive gear min. 1x per year X
5.36 Check, adjust the valve clearance min. 1x per year X
5.37 Drain the sludge from the fuel tank

5.38 Service the battery Pole grease X

5.39 Change the coolant at least every 2 X
years
5.40 Change the injection valves X
5.41 Check, clean turbo charger compressor X
outlet
5.42 Change the crankcase ventilation valve X
5.43 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2
years
5.44 Clean water tank and water filter X
5.45 Water spray system, maintenance in X
case of frost
5.46 Replacing the fuse in the control cabi- X
net.
5.47 Tightening torques X
5.48 Engine conservation X

23 BOMAG 008 910 36

Maintenance chart 2.2
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Also in case of repair in the hydraulic system.
3 Also after 500 operating hours

008 910 36 BOMAG 24

2.3 Table of fuels and lubricants

2.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil SAE 10 W-40 ACEA: E4-99/E6-04 or approx. 45 litres without
oil filter

Deutz DQC III-05

Fuel

Diesel Winter diesel fuel approx. 1200 litres

Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 230 litres

Milling drum drive reduc- Gear oil on basis of POLY-ETHYLEN-GLYCOL acc. approx. 18 litres
tion gear to DIN 51502 or gear oil on basis of POLY-ALPHA-
OLEFIN (PAO) acc. to DIN 51517-3G of viscosity
class ISO VG 220.

Milling drum bearings Gear oil on basis of POLY-ETHYLEN-GLYCOL acc. approx. litres
to DIN 51502 or gear oil on basis of POLY-ALPHA-
OLEFIN (PAO) acc. to DIN 51517-3G of viscosity
class ISO VG 220.

Transfer case Gear oil SAE 90, API GL5 approx. 3,5 litres

Crawler track drive gear Gear oil SAE 90, API GL5 approx. 4 x 1.3 litres

Engine cooling system Water and cooling system protection agent approx. 100 litres

Milling drum Water and cooling system protection agent approx. 355 litres

Lubrication points: High pressure, lithium saponified EP NLGI 2) as required

Loading belt, supporting
rollers, swinging fork
Gathering belt, supporting
rollers
Steering linkage front and
rear
Steering linkage, front and
rear crawler tracks
Bushings of the 4 posts
Milling drum bearing

Lubrication points: High pressure, lithium saponified EP NLGI 3) as required

Clutch, milling drive

Water tank, spray system Water approx. 3300 litres

25 BOMAG 008 910 36

Fuels and lubricants 2.4
2.4 Fuels and lubricants When using fuels with a sulphur content of more
than 0.5% to 1% or under ambient temperatures
below -10 °C the oil change intervals specified in
Engine oil the table must be halved. For fuels with a sulphur
content of more than 1% you should consult the
Quality
responsible service agency.
Use oil according to ACEA-classification E4-99 (Deutz
oil quality TLX-10W-40FE). This allows the utilisation
of the longest oil change intervals.
Fuels
Lubrication oils are classified according to their per- Quality
formance and quality class. Oils according to other You should only use commercially available brand
comparable specifications may be used. diesel fuel with a sulphur content below 0.5% and en-
sure strict cleanliness when filling in. A higher sulphur
Approved engine oils content has a negative effect on the oil change inter-
ACAE* E4-99/E6-04 vals. Use only winter-grade diesel fuel under low am-
Deutz bient temperatures. The fuel level should always be
DQC III-05/DQC IV-05 topped up in due time so that the fuel tank is never run
dry, as otherwise filter and injection lines need to be
The exact assignment of the approved oil qualities
bled.
and oil change intervals can be taken from the follow-
ing section "Lubrication oil change intervals". When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in particu-
Consult your local service station if in doubt.
lar in connection with low ambient temperatures.
Oil viscosity The following fuel specifications are permitted:
You should generally use multi-purpose oils of quality l
DIN/EN 590
SAE 10W/40.
l
BS 2869: A1 and A2
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo- l ASTM D 975-88: 1-D and 2-D.
cation of the engine is of utmost importance when l Nato Codes: F-54, F-75;
choosing the viscosity class (SAE-class) (see dia-
gram). Winter fuel
Occasional falling short of the temperature limit (e.g.
use of SAE 10W/40 down to -20 °C) may effect the ! Danger
cold starting ability of the engine, but will not cause Fire hazard!
any engine damage.
Diesel fuels must never be mixed with gasoline.
Temperature related lubrication oil changes can be
avoided by using multi-purpose oils. The following oil For winter operation use only winter diesel fuel, to
change intervals apply also when using multi-purpose avoid clogging because of paraffin separation. At very
oils. low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
Oil change intervals
In most cases a sufficient cold resistance can also be
The longest permissible time a lubrication oil should achieved by adding flow enhancing fuel additives (fuel
remain in an engine is 1 year. If the following oil additive / petroleum). Consult the engine manufactur-
change intervals are not reached over a period of 1 er.
year, the oil change should be performed at least once
per year, irrespective of the operating hours reached.
Coolant, anti-freeze agent
ACEA1 High performance diesel engines require a well bal-
E4-99/E6-04 = 250 operating hours anced coolant mixture of water, anti-freeze and sup-
plementary coolant additives.

!Caution For coolant mixtures use only soft tap water with a wa-
ter hardness between 3 and 20 °dGH. The water
These intervals apply only when using a diesel
should not contain more than 100 mg/dm3 of chlorine
fuel with maximum 0.5 % sulphur by weight and
and sulphate. The ph-value should be between 6.5
for ambient temperatures higher than
and 8.5.
-10 °C.
Prepare and check coolant with highest care, since
otherwise the engine may be damaged by corrosion,
cavitation and freezing.
1 Association des Constructeurs European d’Automobiles

008 910 36 BOMAG 26

2.4 Fuels and lubricants

As a protection against frost and boiling point anti- ! Caution

freeze agents must be used under any climatic condi-
tions. These two lubricants are not suitable for mixing!

Mixing of coolant water and cooling system protection

agent must be performed at a concentration level of
Oil for track drive gear and hydraulic
the cooling system protection agent of minimum 35% pump drive transfer box
and maximum 45%. For the drive gear use only multi-purpose transmis-
sion oil of API-class GL5, viscosity class SAE 90 EP.
! Caution
Do not mix different coolants and additives of any Lubrication grease
other kind. For lubrication of the milling drive clutch use only EP-
high pressure grease, lithium saponified NLGI 2 or
NLGI 3.
Environment
Cooling system protection agents must be dis-
posed of environmentally.

Hydraulic oil
The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of
46 mm2/s at 40°C. For topping up or for oil changes
use only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV ac-
cording to ISO 6743/3. The viscosity index (VI) should
be at least 150 (observe information of manufacturer).

Bio-degradable hydraulic oil

On request the hydraulic system can also be filled with
ester based biodegradable hydraulic oil (Panolin HLP
Synth. 46). The biologically quickly degradable hy-
draulic oil meets all demands of a mineral oil based
hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth. 46
always use the same oil to top up. When changing
from mineral oil based hydraulic oil to an ester based
biologically degradable oil, you should consult the lu-
brication oil service of the oil manufacturer for details.
Check the filter more frequently after this change.

! Caution
Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for content of water
and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.

Oil for milling drum gear and milling drum

bearings
For the milling drum drive use only synthetic gear oil
on basis of POLY-
ETHYLEN-GLYCOL acc. to DIN 51502 or gear oil on
basis of POLY-ALPHA-OLEFIN (PAO) acc. to DIN
51517-3 of viscosity class ISO VG 220.

27 BOMAG 008 910 36

Fuels and lubricants 2.4

008 910 36 BOMAG 28

3 Fundamental electrics

008 910 36 BOMAG 29

30 BOMAG 008 910 36
Understanding circuit diagrams 3.1
3.1 Understanding circuit dia- Table of contents
grams The table of contents lists all function groups.

Wiring diagrams are graphical representations of cir-

List of components
cuitry conditions, related to the electrical system. They
do not contain any information about the actual type of Here you find all components used in alphabetical or-
wiring, they only serve the purpose of visualizing the der, related to the name of the component.
circuitry logics.
The wiring diagram is indispensable for effective and Function groups
systematic trouble shooting in the vehicle wiring sys- On the individual pages the electric circuits are com-
tem. This plan provides the following information: bined to function groups.
l Number and type of individual elements in the ex- The individual current paths must be read as follows:
amined electric circuit, such as plug connectors, l From top (plus potential) to bottom (minus poten-
fuses, switches, consumers, relays, ...
tial).
l The sequence in which current flows through the in- l From left to right.
dividual elements in the electric circuit.
l From function group to function group.
l Connections between the examined, faulty electric
circuit and other circuits in the vehicle wiring sys-
l Via cross references for potentials and relays.
tem.
l Pin assignment of plug-and-socket connections.

Fig. 1 Potential cross references Example:

Potential cross references Potential "0V" on pag.2 continues to the left on pag.1A
in current path "8" and to the right on pag.17 in current
Potential cross references (Fig. 1) serve the purpose
path "5".
of tracking signals, which are transmitted from one
function group to another.

008 910 36 BOMAG 31

3.1 Understanding circuit diagrams

Current paths
The pages of a circuit diagram are sub-divided into
current paths (Fig. 2) (0 ..... 9).

Fig. 2 Current paths

Relay cross reference

Relay cross references (Fig. 3) serve the tracking of
signals, which need to be tracked for components with
outgoing contacts.

Fig. 3 Relay cross reference

A mimic diagram with information about the contact
types of a relay and their positions in the wiring dia-
gram is additionally attached to the bottom of each
contactor coil.

Example:
The coil of relay (K2) is located on pag.2 in current
path "2".
The contact pictogram under the relay specifies that a
normally open contact with terminals 5 and 9 in cur-
rent path 3 is triggered.

32 BOMAG 008 910 36

Understanding circuit diagrams 3.1
Digital controls in a circuit diagram l C = CPU side
l
4 = control ID4
Example (49C4)
l I = I/O side.
l 49 = Pin 49 to control

Fig. 4

i Note
24Y2 = Solenoid valve, grade shoe right (PWM - sig-
nal)) on page 24

008 910 36 BOMAG 33

3.1 Understanding circuit diagrams

Graphic symbol
serves the purpose of global understanding and fault
Graphic symbol

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

Fig. 5 Graphic symbol

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

Fig. 6 Graphic symbol

1 Diode
2 Transistor
3 NPN-Transistor
4 changeable resistance
5 Condenser
6 Working current relay

34 BOMAG 008 910 36

Terminal designations 3.2
3.2 Terminal designations the individual connection terminals is determined by
the standard DIN 72552. The following table repre-
For easier connection work almost every connection sents a section with the most important terminals from
on a consumer or switch used in a motor vehicle has this standard.
a terminal designation. In Germany the designation of

Terminal designa- Meaning

tion
1 Ignition coil, ignition distributor low voltage
1a Ignition distributor with 2 separate electric circuits, to ignition timer 1
1b Ignition distributor with 2 separate electric circuits, to ignition timer 2

2 Short circuit terminal (magneto ignition)

4 Ignition coil, ignition distributor high voltage

4a Ignition distributor with 2 separate electric circuits, from ignition coil 1, terminal 4
4b Ignition distributor with 2 separate electric circuits, from ignition coil 2, terminal 4

15 Switch plus (after battery) : Output of ignition-travel switch

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

30a Battery changeover relay 12V / 24V, input from battery 2 plus

31 Battery minus direct or ground

31a Battery changeover relay 12V / 24V return line to battery 2 minus
31b Return line to battery minus or ground via switch or relay (switched minus)
31c Battery changeover relay 12V / 24V return line to battery 1 minus

32 Electric motors, return line

33 Electric motors, main connection

33a Electric motors, limit shut down
33b Electric motors, shunt field
33f Electric motors, for 2nd lower speed range
33g Electric motors, for 3rd lower speed range
33h Electric motors, for 4th lower speed range
33L Electric motors, counter-clockwise rotation
33R Electric motors, clockwise rotation

45 Starter, separate starter relay output; starter: Input (main current)

45a 2-starter parallel operation, start relay for engagement current, output starter 1
45b 2-starter parallel operation, start relay for engagement current, output starter 2

48 Terminal on starter and on start repeat relay, monitoring of starting process

49 Input flasher relay

49a Output flasher relay
49b Flasher relay output 2nd flasher circuit
49c Flasher relay output 3rd flasher circuit

50 Starter, starter control

50a Battery changeover relay, output for starter control
50b Starter control, parallel operation of 2 starters with sequence control

008 910 36 BOMAG 35

3.2 Terminal designations

Terminal designa- Meaning

tion
50c Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 1
Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 2
50d Start locking relay, input
50f Start locking relay, output
50g Start repetition relay, input
50h Start repetition relay, output

51 A.C.-generator, direct voltage on rectifier

51a A.C.-generator, direct voltage on rectifier with reactance coil for day travel

52 Trailer signals: further signals from trailer to towing vehicle

53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding
53c Electric windscreen washer pump
53e Wiper, braking effect
53i Wiper motor with permanent magnet and 3rd brush for higher speed

54 Trailer signals, trailer plug device and lamp combination, brake light
54g Trailer signals, compressed air valve for permanent brake in trailer, electromag-
netically operated

55 Fog light

56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light

57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right

58 Side lights, tail light, number plate light, dashboard light

58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right

59 A.C.-generator (magneto generator), alternating voltage output or rectifier input

59a A.C.-generator, charging armature output
59b A.C.-generator, tail light armature output
59c A.C.-generator, brake light armature output

61 Generator control

71 Intermittent tone control unit, input

71a Intermittent tone control unit, output to horn 1 + 2 (low)
71b Intermittent tone control unit, output to horn 3 + 4 (high)

72 Alarm switch (flashing beacon)

36 BOMAG 008 910 36

Terminal designations 3.2
Terminal designa- Meaning
tion
75 Radio, cigarette lighter

76 Loudspeaker

77 Door valve control

81 Switch (breaker and two-way contact), input

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

82 Switch (maker), input

82a Switch (maker), output 1
82b Switch (maker), output 2
82z Switch (maker), input 1
82y Switch (maker), input 2

83 Switch (multi-position switch), input

83a Switch (multi-position switch), output position 1
83b Switch (multi-position switch), output position 2
83L Switch (multi-position switch), output position left
83R Switch (multi-position switch), output position right

84 Current relay, input drive and relay contact

84a Current relay, output drive
84b Current relay, output relay contact

85 Switching relay, output drive winding end (minus or ground)

86 Switching relay, input drive winding start

86a Switching relay, input drive winding start 1st winding
86b Switching relay, input drive winding start 2nd winding

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

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

88 Relay contact for maker

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

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

008 910 36 BOMAG 37

3.2 Terminal designations

Terminal designa- Meaning

tion
DF2 Dynamo field 2 (generator excitation current)

U Three-phase generator, three-phase terminal

V Three-phase generator, three-phase terminal
W Three-phase generator, three-phase terminal

C Travel direction indicator (flasher relay) control light 1

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

38 BOMAG 008 910 36

Current and voltage 3.3
3.3 Current and voltage The following statements concerning electric volt-
age can be made
l
electric voltage is the pressure or force applied to
General
free electrons.
If one wants to describe electric current, this can most l the electric voltage is the cause of electric current
simply be accomplished by means of a comparison:
l
electric voltage is a result of the equalization at-
One simply compares electric current with water. tempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt

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

Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.

Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons

008 910 36 BOMAG 39

3.3 Current and voltage

Current Types of current

Electric current generally describes the directed Direct current (D.C.)
movement of charge carriers.
l
The charge carriers may either be electrons or ions.
l Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
l
The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.

Unit, Ampere Fig. 1 Direct current (D.C.)

The electric amperage (I) is measured in Ampere Direct current flows with steady voltage and amper-
(A). age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
The technical flow direction is specified from
tors or batteries.
PLUS to MINUS.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
i Note the consumers switched on, the voltage is not con-
Current actually flows from minus to plus, because the stant, but drops gradually according to the battery
current flow is made up of negatively charged elec- charge condition.
trons.
The internal resistance of the battery also causes per-
But since this was only discovered after the poles of a manent changes in the vehicle voltage, as soon as
current source had already been designated, the as- consumers are switched on or off.
sumption that current flows from plus to minus was
maintained for historic reasons. Alternating current (A.C.)

Circuit

Fig. 2 Alternating current (A.C.)

Fig. 3 Circuit Alternating current not only changes its direction, but
also its amperage.
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring. Pulsating direct current
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).

Fig. 3 Pulsating direct current

Converting alternating current into a direct current sig-
nal by means of a rectifier results in an pulsating direct
current.

40 BOMAG 008 910 36

Current and voltage 3.3
Pulse width modulation (PWM)

Fig. 4 PWM
The PWM signal is in most cases generated by a con-
trol and can be used to trigger proportional valves.
The signal (square wave signal) is changed in its
pulse control factor, the period, however, remains un-
changed.
The following applies:
l
The signal voltage cannot be measured.
l The current can be measured.

Caution
!

Solenoid valves must not be interference sup-

pressed with suppressor diodes.

008 910 36 BOMAG 41

3.3 Current and voltage

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

Fig. 5 CAN Characteristics of CAN

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

42 BOMAG 008 910 36

Resistance 3.4
3.4 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.
Resistance and voltage drop
While current flows through a conductor the current
Unnecessary resistances
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance. Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.

Bad

Fig. 1 Various size resistors

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

Fig. 2 Spring clamps

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

Symbol, R

Unit, Ohm

The electric resistance (R) is measured in Ohm.

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

008 910 36 BOMAG 43

3.4 Resistance

Sometimes the flanks of flat plugs bend open. If these

are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.

Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.

Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.

Fig. 4 Balistol oil

44 BOMAG 008 910 36

Series / parallel connection 3.5
3.5 Series / parallel connection Parallel connection
In parallel connection all resistances (consumers) are
Series connection connected between feed and return line.
In a series circuit the resistors (consumers) are lined l All resistances (consumers) are supplied with the
up one after the other and the same current (I) passes same voltage.
through each of the consumers However, series con- l Each of the resistances (consumers) draws as
nection of consumers is not suitable in practice, as
much current as required.
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
Fig. 2 Parallel connection
In series connection the current is identical at every
point. Current
Itotal = I1 = I2 = I3 The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The sum of all partial voltages is identical with the total Voltage
voltage. The voltage values are identical at every resistance
Utotal = U1 + U2 + U3 (consumer).
Utotal = U1 = U2 = U3
Resistance
The sum of all partial resistances is identical with the Resistance
total resistance. The total resistance is less than the lowest individual
Rtotal = R1 + R2 + R3 resistance.

Series connection of batteries Parallel connection of batteries

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.
l
In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
ond battery.
l The sum of all individual voltages is applied to the
free poles.
l
The total capacity (Ah) is identical with the capacity
of the individual battery.

Fig. 3
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.

008 910 36 BOMAG 45

3.6 Ohm's law

l In parallel connection the plus pole of the first bat- 3.6 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).

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

46 BOMAG 008 910 36

Electrical energy 3.7
3.7 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

008 910 36 BOMAG 47

3.8 Formula diagram

3.8 Formula diagram Example:

P = 150 Watt
Description:
U = 24 Volt
l Select the desired value from the inner circle.
Sought for = Current in Ampere
l Determine the formula variables in the quarter circle
l Calculate I = P : U = 150 W : 24 Volt = 6.25 Ampere

Fig. 1

Resistance, R Ohm

Voltage, U Volt

Current, I Ampere

Power, P Watt

48 BOMAG 008 910 36

Logical base gates 3.9
3.9 Logical base gates
A B Q
General 0 0 0
0 1 0
In modern electronics links (logic base gates) are
1 0 0
used for data processing and digitizing.
1 1 1
They arrange the vast variety of entered signals ac-
cording to certain established mathematical rules. This logic gate is also known as AND gate. Any circuit
They thereby "set the points" for all incoming signals. corresponding with the truth table is an AND gate.
Links enable certain computing operations, such as The following rules apply:
addition, subtraction, multiplication, etc. Output Q is only 1, if all inputs are 1.
In digital technology circuits are today generally built Output Q is 0, if at least one input is 0.
up with electronic components: resistors, diodes, tran-
sistors, capacitors, etc. Substitute circuit with relay
This enables clear circuits with all components. As-
semblies are also replaced by simplified circuit sym-
bols.

Truth table
The truth table is a tabular representation of events for
logic links, as used in Boolean algebra. Truth tables
are created for the logic links AND gate, OR gate,
NOT gate etc., for flip-flops and for extensive logic cir-
cuits, under due consideration of logic states at all in-
puts and outputs. In truth tables the logic states are
called "0" and "1".

AND / Conjunction
AND is called a conjunction.
AND is a basic gate working on the principle that the
result is true, if two states or statements are true:
If A and B, then...

Fig. 2 AND relay circuit

OR / Disjunction
OR is called a disjunction.
OR is a base gate working on the principle that the re-
sult is true, if one or the other condition or one or the
other statement is true:
If A or B, then...
Fig. 1 AND gate

Truth table AND gate

Output Q is always 1, if the inputs A and B are equal 1.

008 910 36 BOMAG 49

3.10 Metrology

3.10 Metrology

Test lamps
Test lamp

Fig. 3 OR gate

Truth table OR gate

Output Q is always 1, if the inputs A or B are equal 1.

A B Q
0 0 0
0 1 1
1 0 1 Fig. 1 Test lamp
1 1 1
! Caution
This logic gate is also known as OR gate. Any circuit
corresponding with the truth table is an OR gate. This type of tester must not be used for testing on
electronic components. The high power con-
The following rules apply:
sumption of the test lamp may destroy electronic
Output Q is 1, if at least one input is 1. components in the control units.
Output Q is only 0, if all inputs are 0.
Diode test lamp
Substitute circuit with relay This instrument is used for simple voltage measure-
ments. The test lamp consists of two test points. The
negative measuring cable is connected to ground and
the positive measuring cable to the corresponding
measuring location.

Fig. 4 OR relay circuit Fig. 2 Diode test lamp

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

50 BOMAG 008 910 36

Metrology 3.10
Multimeter Voltage and voltage drop measurement with mul-
timeter
This tester is a multimeter and can be used to meas-
ure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
frequency.

Fig. 2
l The meter is always connected parallel to consum-
Fig. 1 Multimeter
er, component or power source.
In order to avoid damage: l Measurement at the voltage source measures the
l
the range selector switch must be correctly set for currently available Voltage.
the corresponding measurement. l
A measurement at the consumer measures the volt-
l the test cable must be plugged into the correct age drop at this component.
socket.
l
the voltage type (AC/DC) must be set. Current measurement with the multimeter
l In case of direct voltage the correct polarity must be
assured.
l
the measuring range should be chosen higher at
the beginning of the test.
l In order to avoid any influence on the circuitry to be
measured, the internal resistance of the voltage
tester should be as high as possible.

Resistance and continuity measurement with mul-

timeter
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
l The component to be measured must not be con-
nected to the power supply during the measure-
ment. Fig. 3
l At least one side of the component to be measured l
During the measurement the current must be able
must be disconnected from the circuitry, as other- to flow through the meter, i.e. the electric circuit
wise the measuring result may be influenced by must be opened. The meter is connected in series
parallel components. with the consumer.
l Polarity is of no significance.
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.

008 910 36 BOMAG 51

3.10 Metrology

Clip-on measuring instrument Magnet tester

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

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. 1 Clip-on measuring instrument

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

52 BOMAG 008 910 36

Diodes, relays, fuses 3.11
3.11 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 with electric current,
when switch S34 is switched to position "1" or "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.

008 910 36 BOMAG 53

3.11 Diodes, relays, fuses

Relays 85 = Ground supply for coil

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

Fuses

Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
A free-wheeling diode prevents induction voltage from
flowing back from the coil into the vehicle wiring sys-
tem, which would cause interference with electronic
components (control units).
With the possibility of using breaker - maker contacts
the effect of an information can be reversed.

Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.

Caution
!

Fuses must not be repaired or bridged.

The melting time at 23 °C is:
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

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

54 BOMAG 008 910 36

Batteries 3.12
3.12 Batteries for tools. If the poles are connected e.g. by a spanner,
the battery will become an electric welder.
Battery – accumulator As a measure to avoid short circuits you should first
disconnect the negative pole during disassembly and
reconnect the negative pole last during assembly.
Terminal clamps should be assembled with as little
force as possible.
Poles and terminal clamps should always be kept
clean to avoid transition resistances during starting
and the related development of heat.
You should obviously also pay attention to secure fas-
tening of the battery in the vehicle.
Safety precautions:
l Wear goggles and face protection (acid).
l Wear suitable clothes to protect face, hands and
Fig. 1
body (acid).
In vehicles batteries are used to start the engine. The l Work and store accumulators only well ventilated
ability to start the engine depends on the charge con-
rooms. (Development of oxyhydrogen gas).
dition of the batteries.
l Do not lean over the battery while it is under load,
Lead collectors or accumulators are secondary ele- being charged or tested. (Danger of explosion).
ments, i.e they can be recharged after discharging
electric current.
l
Burning cigarettes, flames or sparks can cause ex-
plosion of the accumulator
The basic element of a lead accumulator is the cell. It l Keep ignition sources away from the battery.
contains the plate blocks consisting of positive and
negative plates. These plates are separated from l
Always shield eyes and face towards the battery.
each other by separators. l Do not use battery chargers or jump leads without
All positive plates are arranged parallel to the plus following the operating instructions.
pole, the negative plates parallel to the minus pole of l
Keep the cell plugs closed.
the cells. l After an accident with acid flush the skin with 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.

Battery maintenance

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
Fig. 2 longer period of time, the battery will slowly discharge
All cells are filled with a conductive fluid, the electro- by itself.
lyte. For a 12 Volt battery 6 cells are connected in se- The accumulator may only be discharged down to a fi-
ries. nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
Capacity
sulphate forms increasingly coarser crystals, which
is a synonym for the amount of current taken up and will finally not react at all or only very sluggishly during
discharged by a battery over a specified period of a subsequent charging process.
time.
In the worst case the accumulator can only be dis-
Rules for the handling of batteries posed of after such an exhaustive discharge.
Even though it may be conveniently installed in the The following therefore applies for longer downtimes:
engine compartment, it should never be used as a rest

008 910 36 BOMAG 55

3.12 Batteries

l Remove the battery and store it in a cool, dry and

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 Fig. 3 Reading the acid level

l
Is the battery leaking? Can traces of impact, shock l
Maximum permissible tolerance between highest
or compression be found in the leaking area? and lowest measuring value of the 6 cells: 0.03 kg/
l Check for e.g. incorrect fastening, foreign bodies on dm3.
the battery mounting surface and similar.
Testing batteries without screw plugs
Testing batteries with screw plugs On closed batteries the acid density cannot be meas-
Checking the acid density: ured, we therefore recommend testing with the follow-
l The cells are filled with diluted sulphuric acid as ing mobile tester:
electrolyte (approx. 25 Vol% sulphuric acid in dis-
tilled water), also referred to as accumulator acid,
which has a density of 1.285 kg/dm3 at a tempera-
ture of +27° Celsius. This means that one litre of
electrolyte has a weight of 1.285 kg. As the cell is
being discharged lead sulphate (PbSO4) will form
on both electrodes and the electrolyte will increas-
ingly change to water. Since water has a lower spe-
cific weight than diluted sulphuric acid the density of
the electrolyte will also drop during the discharge
and with a fully discharged cell and a temperature
of 27°C it will only be 1.18 kg/dm3.
l
With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is Fig. 4 Battery and generator tester
used to determine the charge condition of a lead
battery. The so-called acid tester (hydrometer) is The battery and generator tester comes with an 8-line
used for this purpose. In a battery of good condition LC display with background illumination and is able to
the acid density should be the same in all cells. print out test results via an (optional) integrated ther-
mal printer.
Acid density at 27 °C in kg/dm3
l 1.25 -1.28, open-circuit voltage approx. 12.7 Volt. i Note
Battery is charged.
Before testing clean the poles and ensure good con-
l 1.20 -1.24, open circuit voltage approx.12.4 to 12.5 nection between clamps and poles.
Volt, is 50% discharged. Charging is necessary.
The test program calculates the text messages "good"
l 1.19 and less, open circuit voltage less than 12.3
or "replace" on the basis of the charge condition (de-
Volt. Battery is insufficiently charged. Battery needs
rived from the battery voltage) and the currently avail-
to be recharged immediately.
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
i Note one with 75% starting power as poor ("replace").
If the current consumption during charging is not 1/20 The starting power represents the ratio of detected
of the nominal capacity (example 100 Ah battery: cold testing current to the entered cold testing current
100Ah x 1/20 = 5 A) or full charging of the battery re- of the battery.
sults in a final acid density of only 1.24 kg/dm3 or less, The starting power can exceed 100%.
the battery shows normal wear by aging. The battery
was insufficient charging or exhaustive discharge.

56 BOMAG 008 910 36

Batteries 3.12
Charge condition with hydrometer

Fig. 5 Charge condition

Green = Charge condition >65%
Dark = Charge condition <65%
Light = Electrolyte level too low

! Danger

Danger of explosion!!! If the electrolyte level is too

low, the battery must no longer be charged.

008 910 36 BOMAG 57

3.13 Three-phase generator

3.13 Three-phase generator

General
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.

! Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
Reason: In case of an inductance electric current has
the tendency to continue flowing when it is switched
off. For this to take place, a voltage of several thou-
Fig. 7 Stator with 3 windings
sand Volt builds up (caused by the collapsing magnet-
ic field), which can be noticed by an arc appearing at
the point of damage. With direct current this can have
severe consequences, because there is no zero
crossover at which the arc could tear off.
In the generator the armature windings are located in-
side the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).

Fig. 8 3-phase current

Fig. 6 Rotor with claw poles The generator first of all produces three-phase volt-
The three stator windings (Fig. 7) are electrically offset age / three-phase current.
to each other by 120°. The excitation of the magnetic The wiring diagram (Fig. 8) shows the 3 windings in Y-
field requires direct current, which is fed to the rotor connection and the 6 associated rectifier diodes.
via two carbon brushes and slip rings.
The diodes D1, D2, D3 are also referred to as minus
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

58 BOMAG 008 910 36

Three-phase generator 3.13
of the wave is allowed to pass, resulting in a pulsating Voltage regulator
D.C. voltage.

Reverse current protection

The rectifier diodes also prevent discharging of the
battery via the stator windings. The current can only
flow from the generator to the battery.

Why does three-phase current need to be rectified

and how does this work?
There are a few components for which can either be
operated with alternating current or direct current, be-
cause they work independently from the current flow
direction.
This includes :
l Incandescent lamps
l Fluorescent lamps
l Glow lamps
l Electric heating elements.
There are also a few components that could be oper-
ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly. Fig. 9 Governor with diode plate and rectifier diodes
This includes : In most cases voltage regulators (Fig. 9) with carbon
l Electric motors brushes form a compact component. The voltage reg-
l
Relays ulator is maintenance free and the wear of carbon
brushes is only so little, that they hardly ever need to
Finally, a variety of important components solely re-
be replaced during the lifetime of a machine.
quire direct current. These will under no circumstanc-
es work with alternating or three-phase current. The regulator has the following function:
This includes :
l
To maintain the vehicle voltage under any operating
conditions below 14.4 V.
l
Accumulators
l To match the regulator voltage to the temperature.
l Control units
l
Smooth rising of generator current when switching
l
All electronics
loads (convenience function to avoid jerking of the
l Communication equipment. engine).

008 910 36 BOMAG 59

3.13 Three-phase generator

Checking the generator

First one must check whether the generator is actually
defective.
l
This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
l When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
l Cable connections on the generator OK? Fig. 10 Rotor
l V-belt OK? l
Remove the regulator with carbon brush.
l Generator ground (engine ground) OK? l Contact the rotor slip ring with the tester points.
l Pre-excitation from vehicle electronics OK? l
The resistance should be between 3 and 6 OHM.
Only if all criteria mentioned above are OK, the fault l The rotor coils should not have continuity to ground.
must be in the generator itself. In this case it must be
Checking the stator
replaced or the following trouble shooting procedure
must be performed.

Measuring the charge current

l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l
The generator ground connection must be OK.
l During the measurement switch on as many con-
sumers as possible.
49 Attach the clip-on ammeter around the B+
line.
50 Gradually increase the engine speed.
51 The generator current must be at least as
high as the total current of all consumers.

Checking the rotor

i Note
The rotor coils can only be measured in disassembled
state.

Fig. 11 Stator

i Note
The stator coils can only be measured in disassem-
bled state.
l Measure the resistance of all three coils.
l
The coils should not have contact among each oth-
er.

60 BOMAG 008 910 36

Three-phase generator 3.13
Checking the regulator voltage with the generator l Perform the measurement at raised engine speed.
tester l
The voltage (B+) should adjust itself at 13 to 14 Volt.
The battery and generator tester comes with an 8-line
Checking the regulator in disassembled state
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
i Note
When testing the regulator one should be aware that
there are 2 different types of regulators:
l
If the carbon brush is not connected to ground the
regulator is a so-called minus controlled regulator.
The exciter winding is positioned between D+ and
DF, the regulator therefore regulates the exciter
winding on the ground side. The other carbon brush
is connected with the cathodes of the exciter di-
odes, terminal D+. This leaves one further terminal,
this is DF.
D+ (vehicle wiring system)
D- (ground contact, mostly located on one of the fas-
Fig. 12 tening screws)
The generator test assesses the regulator voltage and DF (Dynamo Field)
the ripple factor of the generator voltage.
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l
The generator ground connection must be OK.
l The battery should be in good condition – the idle
speed 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.

Checking the regulator voltage with the multime-

ter

Fig. 14
l If the carbon brush is connected to ground the reg-
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).

Fig. 13
l
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l The generator ground connection must be OK.
l The battery should be in good condition – the idle
speed voltage of the battery should be at least 12.6
Volt.
l If possible switch off all consumers.

008 910 36 BOMAG 61

3.13 Three-phase generator

Fig. 15
E.g minus controlled regulator
One connects the regulator (Fig. 15) with D+ and D- to
the power source, as shown in the illustration, and the
lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
will first become brighter, because the regulator al-
lows all lamp current (= exciter current) to flow at volt-
age values up to 14.4V. Once the regulator voltage is
reached, the regulator switches the lamp current off.
When returning the voltage back below the control
voltage, the regulator will switch the lamp back on.
With this test the major difficulty is the problem to re-
move the regulator an identify terminals D+, DF and
D-.

Fig. 16

Fig. 17
The illustrations (Fig. 16) and (Fig. 17) show two dif-
ferent regulator types.

62 BOMAG 008 910 36

Electric starter 3.14
3.14 Electric starter l to maintain this connection.
l
to switch on the starter current.
Duties of the starter:
After starting the engine:
l to accelerate the combustion engine to start speed
with lowest possible current consumption.
l to return the starter pinion to initial position.
l establish the gear connection between starter and
l to switch off the starter current.
combustion engine.

Fig. 1 Electric starter

1 Pinion
2 Roller free-wheeling
3 Steep thread
4 Guide ring
5 Spring winding
6 Armature
7 Pole shoe
8 Carbon brushes
9 Armature brake
10 Collector
11 Magnetic switch
12 Engagement lever

008 910 36 BOMAG 63

3.14 Electric starter

Magnetic switch Trouble shooting "Starter"

The magnetic switch is normally arranged directly The most frequent fault is definitely a fully discharged
above the starter. battery.
With the starter switch switched on, both the pickup In some cases oxidized electric contacts or a soiled
winding and the holding winding are energized and ground connection causing extremely high voltage
shift the iron core in axial direction. With a lever this losses in the overall starter system are the cause of
iron core pulls the starter pinion towards the engine problems.
flywheel. Frequently a jammed return mechanism is the reason
Once the gears are engaged the starter current is ap- for a starter failure.
plied to the back through a large cross-section. At the Occasionally worn contacts are found on the magnetic
same time the pickup winding is shorted via the starter return switch
current and thus switched off as a measure to reduce
the load on the energy household. Defects on the actual starter motor including pinion
and carbon brushes are very rare.
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system
can only work when many conditions are fulfilled at
the same time.
l Immobilizer deactivated?
l Ignition switch OK?
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?
Fig. 2 Switching position during engagement l
Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l
Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l the experience of the specialist
l
the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.

Fig. 3 Switching position during starting

1 Ground
2 Battery
3 Starter switch
4 Pull-in winding
5 Holding winding
6 Exciter winding
7 Restoring spring
8 Driver
9 Pinion
10 Flywheel

64 BOMAG 008 910 36

Electric starter 3.14
Testing and measuring the electric starter

i Note
The highest current flows when the starter is blocked!
(Short circuit current in starter). This is the case when
the pinion is engaged and the starter has the duty to
accelerate the flywheel to starting speed.

Function test with starter installed

l
Initiate the starting process and measure the volt-
age on the pickup solenoid switch (50a). At least
10.8 Volt should be applied.
l When operating the starter switch the magnetic
switch must engage in the flywheel ring gear (no-
ticeable clicking sound) and release the starting
current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
this does not happen even though voltage is ap-
plied, replace the magnetic switch.

Function tests with disassembled starter

!Caution
Before removing the starter you must disconnect
the ground cable from the minus pole of the bat-
tery while the ignition is switched off.
l Check the wear on the carbon brushes and their
contact pressure.
l Check the collector, it must not have electrical con-
tact with the rotor shaft.
l Check the drive pinion for excessive wear.
l The return mechanism should not be tight, if neces-
sary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
l Measure the resistance of the magnetic switch main
contact in disengaged condition. Maximum value
0.2 OHM.

008 910 36 BOMAG 65

3.14 Electric starter

66 BOMAG 008 910 36

4 Special tools, electrics

008 910 36 BOMAG 67

4.1 Special tools, electrics

4.1 Special tools, electrics

1. Electric test case

BOMAG part-no.: 057 505 70

Fig. 1
2. Multimeter

BOMAG part-no.: 057 509 91

Fig. 2
3. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

BOMAG part-no.: 079 900 53

4. Test prod red, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

BOMAG part-no.: 079 900 54

Fig. 3
5. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

BOMAG part-no.: 079 900 51

6. Test prod red, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.

BOMAG part-no.: 079 900 52

Fig. 4

68 BOMAG 008 910 36

Special tools, electrics 4.1
7. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.

BOMAG part-no.: 079 900 58

8. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 1 m.

BOMAG part-no.: 079 900 59

9. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 2 m.

BOMAG part-no.: 079 900 60

10. Measuring and connecting lines with 4mm plug,
Fig. 5 high flexible design, red, length 0.5 m.

BOMAG part-no.: 079 900 55

11. Measuring and connecting lines with 4mm plug,
high flexible design, red, length 1 m.

BOMAG part-no.: 079 900 56

12. Measuring and connecting lines with 4mm plug,
high flexible design, red, length 2 m.

BOMAG part-no.: 079 900 57

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

BOMAG part-no.: 079 900 63

14. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, black, length 600 mm.

BOMAG part-no.: 079 900 64

15. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 300 mm.
Fig. 6
BOMAG part-no.: 079 900 61
16. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 600 mm.

BOMAG part-no.: 079 900 62

17. Transition plug connector, with 4 mm plug on one
side and 2 mm socket on the other, insulated de-
sign

BOMAG part-no.: 079 900 65

Fig. 7

008 910 36 BOMAG 69

4.1 Special tools, electrics

18. Magnetic coil tester

BOMAG part-no.: 057 555 54

Fig. 8
19. Clip-on measuring instrument

BOMAG part-no.: 079 900 50

Fig. 9
20. Battery - generator tester

BOMAG part-no.: 079 900 91

Fig. 10
Spring clamps (Wago or Weidmüller)
21. Cranked screwdriver (Fig. 11) to open spring
clamps (Fig. 12).

BOMAG part-no.: 972 024 68

Fig. 11

70 BOMAG 008 910 36

Special tools, electrics 4.1
22. Testing adapter to measure the signals from the
series spring clamps (Wago).

BOMAG part-no.: 057 564 26

Fig. 12
Deutsch contacts
23. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).

BOMAG part-no.: 079 900 84

Fig. 13
24. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.

AWG 20 = 0.5 mm² cable cross-section

AWG 16 = 1.5 mm² cable cross-section

AWG 12 = 4.0 mm² cable cross-section

BOMAG part-no.: 079 900 79

Fig. 14
25. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.

AWG 8 = 10 mm² cable cross-section

AWG 6 = 16 mm² cable cross-section

BOMAG part-no.: 079 900 69

Fig. 15

008 910 36 BOMAG 71

4.1 Special tools, electrics

26. Disassembly tool for Deutsch contacts of series

HDP.

AWG 20, BOMAG part-no.: 079 900 78

AWG 16, BOMAG part-no.: 079 900 71

AWG 12, BOMAG part-no.: 079 900 72

AWG 8, BOMAG part-no.: 079 900 73

Fig. 16
ITT contacts
27. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 80

Fig. 17
28. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 81

Fig. 18
29. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 82

Fig. 19

72 BOMAG 008 910 36

Special tools, electrics 4.1
Schaltbau contacts
30. Disassembly tool for Schaltbau contacts of series
M1, M2.

BOMAG part-no.: 057 509 95

Fig. 20
31. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 mm²
to 6 mm².

BOMAG part-no.: 057 509 94

Fig. 21
FCI Burndy contacts
32. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO

BOMAG part-no.: 079 900 00

Fig. 22
33. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 mm² to 1 mm².

BOMAG part-no.: 972 038 47

Fig. 23

008 910 36 BOMAG 73

4.1 Special tools, electrics

34. Precision pressing pliers for non-insulated flat

male and female connectors 0.50 mm² to 6 mm².

BOMAG part-no.: 079 900 70

Fig. 24
35. Current measurement adapter for Hirschmann
plugs.

BOMAG part-no.: 057 503 83

Fig. 25
36. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).

BOMAG part-no.: 079 900 68

Fig. 26
37. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.

BOMAG part-no.: 079 900 83

Fig. 27

74 BOMAG 008 910 36

5 Machine related electrics

008 910 36 BOMAG 75

76 BOMAG 008 910 36
Component overview 5.1
5.1 Component overview

Fig. 1

Fig. 2

Pos. Designation in circuit diagram Description

1 Control panel with switches, warning lights, potentiometers,
travel lever and multi-function display
2 Electric terminal box or control box with various components
3 36S1 / 36S2 Proximity switches for height limitation of the rear lifting cylinders
4 Battery compartment with batteries and fuses
5 36S4 / 36S5 Proximity switches for automatic middle position of rear crawler
assemblies
6 24S1 / 24S2 Limit switch on scraper
7 34R1 / 34R2 Rope sensors
8 39S4 / 39S3 Proximity switches for front steering limits
9 39S2 / 39S1 Proximity switches for height limitation of the front lifting cylin-
ders
10 26R1 / 26R2 Control block with valves and pressure sensors
11 23R1 / 26R3 Hydraulic pumps with pressure sensors
12 26R4 Pressure sensors for hydraulic fan circuit
13 24S5 / 30S5 / 30S2 Limit switch for conveyor belt folding mechanism
14 30S1 / 33Y1 Pressure switch and shut-off valve for water sprinkling system
15 28S3 RPM-sensor on hydraulic motor for travel speed

008 910 36 BOMAG 77

5.2 Driver's stand

5.2 Driver's stand

Fig. 3

Example:

In the circuit diagram 5S1 can be found on page 5.

Pos. Designation in circuit diagram Designation

1 5S1; 16S1; 16S2; 28R2 Travel lever
2 16S3; 16S4 Safety button
3 13S5; 13S6 Control lever, rear steering
4 14S2; 14S5 Selector switch, rear steering mode
5 18H7; 18H8 Steering limitation control lamp
6 10S6 Selector switch for grade shoes
7 3S4 Rotary button for protection roof
8 12S2 Selector switch for height adjustment automatic front
9 12S3 Selector lever for height adjustment
10 13S4 Rotary button for height adjustment at rear
11 13S2 Rotary button for height adjustment front left, manual
12 13S3 Rotary button for height adjustment front right, manual
13 CGC Multi-function display
14 18H3 General fault warning lamp
15 18H1 Engine warning light
16 18H2 Fault warning lamp, hydraulic system
17 18H4 Low fuel level warning lamp
18 6S1 Rotary switch for flashing beacon
19 15S1 Rotary switch for steering and working hydraulics
20 14S3; 14S4 Rotary button, work on/off (pause)
21 1s2; 1S3 Push button for warning horn
22 10S4; 10S5 Control lever, loader conveyor belt
23 10S3 Rotary button for right hand grade shoe
24 2S1 Rotary switch, engine ignition
25 5S3 Engine shut-down button

78 BOMAG 008 910 36

Driver's stand 5.2
26 5S2 Engine start button
27 47R1 Potentiometer for engine speed
28 15S3 Potentiometer for speed limitation control
29 15S4 Rotary switch for engine anti-stall control
30 28R1 Potentiometer for working speed under load limit control
31 4S1 Emergency stop push button
32 11S3 Rotary button, water spray system
33 15S2 Rotary button, milling drum
34 10S1 Rotary button for breaker (mouldboard) gathering belt
35 11S2 Rotary button, conveyor belts
36 22R1 Potentiometer for conveyor belt speed
37 12S1 Rotary button for scraper
38 10S2 Rotary button for left hand grade shoe

008 910 36 BOMAG 79

5.3 Control console, rear right

5.3 Control console, rear right

Fig. 4

Example:

In the circuit diagram 41S5 can be found on page

41.

Pos. Designation in circuit diagram Designation

1 Plug, levelling display unit
2 41S5 Rotary button to raise the scraper shield
3 41S4 Rotary momentary contact switch to fold back the scraper
shield
4 41S3 Rotary button for right hand grade shoe
5 W41 Plug, external sensor for 3-point average levelling system
6 41S2 Rotary button for height adjustment at rear
7 41S1 Emergency stop push button

80 BOMAG 008 910 36

Control console, rear left 5.4
5.4 Control console, rear left

Fig. 5

Example:

In the circuit diagram 40S5 can be found on page

40.

Pos. Designation in circuit diagram Designation

1 40S5 Emergency stop push button
2 40S4 Rotary button to raise the scraper shield
3 40S3 Rotary momentary contact switch to fold back the scraper
shield
4 W40 Plug, external sensor (for 3-point average levelling sys-
tem)1
5 40S2 Rotary button for left hand grade shoe
6 40S1 Rotary button for height adjustment at rear
1 Optional equipment

008 910 36 BOMAG 81

5.5 Control console, front right

5.5 Control console, front right

Fig. 6

Example:

In the circuit diagram 43S4 can be found on page

43.

Pos. Designation in circuit diagram Designation

1 43S4 Emergency stop push button
2 43S3 Rotary button for gathering conveyor foot
3 W43 Plug, external sensor (for 3-point average levelling sys-
tem)1
4 43S2 Rotary button to fold in the loader conveyor belt
5 43S1 Warning horn
6 24H2 Signal lamp (right hand grade shoe)
1 Optional equipment

82 BOMAG 008 910 36

Control console, front left 5.6
5.6 Control console, front left

Fig. 7

Example:

In the circuit diagram 24S1 can be found on page

24.

Pos. Designation in circuit diagram Designation

1 Plug for Yo -Yo sensor1
2 Plug, control of external levelling
3 24H1 Signal lamp (left hand grade shoe)
4 42S4 Warning horn
5 W42 Plug, external sensor (for 3-point average levelling sys-
tem)*
6 42S3 Rotary button for water pump control
7 42S2 Rotary button for gathering conveyor foot
8 42S1 Emergency stop push button
1 Optional equipment

008 910 36 BOMAG 83

5.7 Control console for auxiliary control

5.7 Control console for auxiliary

control

Fig. 8

Example:

In the circuit diagram 3S3 can be found on page 3.

Pos. Designation in circuit diagram Designation

1 Pressure gauge for brake release pressure
2 3S3 Rotary button for protection roof
3 3S2 Rotary button to release the parking brake (towing)
4 3S1 Rotary button for emergency working hydraulics

84 BOMAG 008 910 36

Engine hood control console 5.8
5.8 Engine hood control console

Fig. 9

Example:

In the circuit diagram 44S1 can be found on page

44.

Pos. Designation in circuit diagram Designation

1 Rotary button for scraper contact pressure
2 Pressure gauge for contact pressure of gathering conveyor
foot
3 Rotary button for contact pressure of gathering conveyor
foot
4 44S1 Engine hood key switch
5 Pressure gauge for scraper contact pressure

008 910 36 BOMAG 85

5.9 Loading conveyor belt

5.9 Loading conveyor belt

Folding control for loading conveyor belt

i Note
Conveyor belt folding operation is only possible with
the travel lever in "neutral" position.

Fig. 10 Limit switch

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 24S5 Limit switch conveyor belt in working position CPU4:44C4 0 / 24V
2 30S3 Limit switch conveyor belt folded for 180° CPU5:41C5 0 / 24V
3 30S2 Limit switch conveyor belt folded for 90° CPU5:40C5 0 / 24V
33Y2 / 33Y4 Solenoid valve for opening / closing the conveyor belt by CPU5:50I5 0 / 24V
90° CPU5:54I5
33Y3 / 33Y5 Solenoid valve for opening / closing the conveyor belt by CPU5:51I5 0 / 24V
180° CPU5:55I5

86 BOMAG 008 910 36

Loading conveyor belt 5.9
i Note
Operation of the conveyor belt (transport of milling
material) is not possible, unless the limit switch (1)
(24S5) has been closed or switched.

Fig. 13 Display indicates that the loading conveyor belt is folded in

(16)

Fig. 11 Hydraulic cylinder

Fig. 12 Control switch 43S2

Folding in
l Turning the rotary switch (Fig. 12) (43S2) anti-
clockwise triggers the solenoid valve (33Y4) and
the cylinder (4) moves OUT, until the limit switch (3)
is actuated. After this the solenoid valve (33Y5) is
triggered and the cylinder (5) moves OUT.

Folding out
l Turning the rotary switch clockwise triggers the so-
lenoid valve (33Y3) and the cylinder (5) moves IN,
until the limit switch (2) is actuated. Then the sole-
noid valve (33Y2) is triggered and the cylinder (4)
moves IN, until the limit switch (1) is actuated.

008 910 36 BOMAG 87

5.10 Steering limitation, front

5.10 Steering limitation, front

Proximity switches for steering limitation

Fig. 1 Proximity switches for steering limitation on front left lifting cylinder

Fig. 2 Proximity switch for height limitation front left

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 39S4 Proximity switch for steering limitation to them left I/O6:24I6 0 / 24V
2 39S3 Proximity switch for steering limitation to them right I/O6:41I6 0 / 24V
3 39S2 Proximity switch for height limitation left front I/O6:40I6 0 / 24V
4 39S1 Proximity switch for height limitation right front I/O6:39I6 0 / 24V

The proximity switches have the function of limiting l If one of the proximity switches for height limitation
the steering. (3) or (4) responds, steering is only possible to the
switching point of the proximity switches (1) or (2).
l If one of the proximity switches for steering (1) or (4)
responds, lowering is only possible to the switching
point of the proximity switches (3 or 4).

88 BOMAG 008 910 36

Steering limitation, front 5.10
i Note
The proximity switches are fitted with a red and a
green LED.
Green = not switched, contact open
Red = switched, contact closed

Fig. 4 Control lamp (steering limitation)

i Note
The steering limitation control lamp lights up when the
front of the machine has reached the steering limita-
tion.

008 910 36 BOMAG 89

5.11 Middle position, rear steering

5.11 Middle position, rear steering

Proximity switches for middle position

Fig. 1 Proximity switches on left rear lift cylinder

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 36S4 Proximity switch for steering limitation to them left CPU6:42C6 0 / 24V
2 36S5 Proximity switch for steering limitation to them right CPU6:43C6 0 / 24V

i Note
The proximity switches are fitted with a red and a
green LED.
Green = not switched, contact open
Red = switched, contact closed
If the crawler assemblies are in middle position, the
green LEDs on both proximity switches will light

Replacing the steering sensor

i Note
After replacing a steering sensor the zero position
Fig. 2 Rotary switch, rear steering mode must be adjusted as follows:
l When turning the momentary contact switch (14S2) l Align the crawler tracks to the longitudinal axis of
4(Fig. 2) to the right while the control lever (3) is in the machine.
middle position, the solenoid valve (36Y5) or (36Y6)
is energized, until both proximity switches 1 and 2
(Fig. 1) show green (LED).

90 BOMAG 008 910 36

Middle position, rear steering 5.11

Fig. 3
l Adjust the rope sensor (Fig. 3) so that the stroke is
identical on both sides.

Fig. 4
l For zeroizing press key "F1" in this menu (Fig. 4).

008 910 36 BOMAG 91

5.12 Operating conditions for rear steering

5.12 Operating conditions for rear

steering

Manual to left

Fig. 1

13S5 -B- or 13S5 -A- 24S1 14S2 -1- 14S2 -2- 15S1-2- 36Y6
13S6 -B- or or or
13S6 -A- 14S5 -1- 14S5 -2-
0 1 1 1 0 1 1

92 BOMAG 008 910 36

Operating conditions for rear steering 5.12
Manual to right

Fig. 1

13S5 -A- 13S5 -B- or 24S1 14S2 -1- 14S2 -2- 15S1-2- 36Y5
or 13S6 -B- or or
13S6 -A- 14S5 -1- 14S5 -2-
0 1 1 1 0 1 1

008 910 36 BOMAG 93

5.12 Operating conditions for rear steering

Steering to left in copying mode1

1 Optional equipment

Fig. 1

37R2 < 13S5 -A- 13S5 -B- 16S5 16S5 24S1 14S2 -2- 14S2 -1- 15S1-2- 36Y6
37R1 or or CRAB COPY or or
13S6 -A- 13S6 -B- 14S5 -2- 14S5 -1-
1 1 0 0 1 1 1 0 1 1
0 1 0 0 1 1 1 0 1 1
1 0 0 0 1 1 1 0 1 1

94 BOMAG 008 910 36

Operating conditions for rear steering 5.12
Steering to right in copying mode1

1 Optional equipment

Fig. 1

37R2 > 13S5 -B- 13S5 -A- 16S5 16S5 24S1 14S2 -2- 14S2 -1- 15S1-2- 36Y5
37R1 or or CRAB COPY or or
13S6 -B- 13S6 -A- 14S5 -2- 14S5 -1-
1 1 0 0 1 1 1 0 1 1
0 1 0 0 1 1 1 0 1 1
1 0 0 0 1 1 1 0 1 1

008 910 36 BOMAG 95

5.12 Operating conditions for rear steering

Steering to left in auto center mode

Fig. 1

36S4 13S5 -A- 13S5 -B- 16S5 16S5 24S1 14S2 -2- 14S2 -1- 15S1-2- 36Y6
or or CRAB COPY or or
13S6 -A- 13S6 -B- 14S5 -2- 14S5 -1-
1 1 0 0 0 1 1 0 1 1
0 1 0 0 0 1 1 0 1 1
1 0 0 0 0 1 1 0 1 1

96 BOMAG 008 910 36

Operating conditions for rear steering 5.12
Steering to right in auto center mode

Fig. 1

36S5 13S5 -B- 13S5 -A- 16S5 16S5 24S1 14S2 -2- 14S2 -1- 15S1-2- 36Y5
or or CRAB COPY or or
13S6 -B- 13S6 -A- 14S5 -2- 14S5 -1-
1 1 0 0 0 1 1 0 1 1
0 1 0 0 0 1 1 0 1 1
1 0 0 0 0 1 1 0 1 1

008 910 36 BOMAG 97

5.12 Operating conditions for rear steering

Steering to left in asynchronous mode1

1 Optional equipment

Fig. 1

37R2 > 13S5 -A- 13S5 -B- 16S5 16S5 24S1 14S2 -2- 14S2 -1- 15S1-2- 36Y6
37R1 or or CRAB COPY or or
13S6 -A- 13S6 -B- 14S5 -2- 14S5 -1-
1 1 0 1 1 1 1 0 1 1
0 1 0 1 1 1 1 0 1 1
1 0 0 1 1 1 1 0 1 1

98 BOMAG 008 910 36

Operating conditions for rear steering 5.12
Steering to right in asynchronous mode1

1 Optional equipment

Fig. 1

37R2 < 13S5 -B- 13S5 -A- 16S5 16S5 24S1 14S2 -2- 14S2 -1- 15S1-2- 36Y5
37R1 or or CRAB COPY or or
13S6 -B- 13S6 -A- 14S5 -2- 14S5 -1-
1 1 0 1 1 1 1 0 1 1
0 1 0 1 1 1 1 0 1 1
1 0 0 1 1 1 1 0 1 1

008 910 36 BOMAG 99

5.13 Height limitation, rear

5.13 Height limitation, rear

Proximity switches, height limitation

Fig. 1 Proximity switches on right rear lift cylinder

Fig. 2 Proximity switches on left rear lift cylinder

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 36S1 Proximity switch for height limitation left rear CPU6:39C6 0 / 24V
2 36S2 Proximity switch for height limitation right rear CPU6:40C6 0 / 24V

l
The machine can only be raised up to the switching
point of one of the proximity switches.

i Note
The proximity switches are fitted with a red and a
green LED.
Green = not switched, contact open
Red = switched, contact closed

100 BOMAG 008 910 36

Operating conditions for rear posts 5.14
5.14 Operating conditions for rear
posts

Manual lowering

Fig. 1

13S4 -1- 40S -1- 41S -1- 15S1-2- 36Y4

1 1 1 1 1
0 1 1 1 1
1 0 1 1 1
0 0 1 1 1
1 1 0 1 1
0 1 0 1 1
1 0 0 1 1

008 910 36 BOMAG 101

5.14 Operating conditions for rear posts

Manual lifting

Fig. 1

12S3 up 13S4 -2- 40S1 -2- 41S2 -2- 12S3 up 36S1 36S2 15S1-2- 36Y3
+ STOP
1 1 1 1 1 1 1 1 1
0 1 1 1 1 1 1 1 1
1 0 1 1 1 1 1 1 1
0 0 1 1 1 1 1 1 1
1 1 0 1 1 1 1 1 1
0 1 0 1 1 1 1 1 1
1 0 0 1 1 1 1 1 1
0 0 0 1 1 1 1 1 1
1 1 1 0 1 1 1 1 1
0 1 1 0 1 1 1 1 1
1 0 1 0 1 1 1 1 1
0 0 1 0 1 1 1 1 1
1 1 0 0 1 1 1 1 1
0 1 0 0 1 1 1 1 1
1 0 0 0 1 1 1 1 1
0 0 0 0 1 1 1 1 1

102 BOMAG 008 910 36

High pressure sensors for travel/conveyor belt pump 5.15
5.15 High pressure sensors for
travel/conveyor belt pump

Fig. 1 Pressure sensors for hydraulic pressure

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 23R1 High pressure sensor, travel system CPU4:25C4 4-20 mA /
0 -450 bar
4 26R3 High pressure sensor, conveyor belt drive I/O4:24I4 4-20 mA /
0 -320 bar

Fig. 2 Display in multi-function display Fig. 3 Fault message (9), pressure in travel drive above 600 bar.
Fault message (8), pressure in conveyor belt drive above 220 bar.

i Note
In case of a fault the corresponding symbol will be dis-
played on screen. The bell symbol accompanies the
warning buzzer. Press the ENTER-key to switch off
the warning buzzer.

008 910 36 BOMAG 103

5.16 Pressure sensor for steering / working hydraulics

5.16 Pressure sensor for steering /

working hydraulics

Fig. 1 Sensor on control block under valve (1)

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
2 26R1 High pressure sensor for steering / working hydraulics I/O4:22I4 4-20 mA
0 -240 bar

Fig. 2 Display in multi-function display Fig. 3 Warning lamp (16), pressure in steering / working hydraulics
too low

i Note
In case of a fault the corresponding symbol will be dis-
played on screen (Fig. 4). The bell symbol accompa-
nies the warning buzzer. Press the ENTER-key to
switch off the warning buzzer.

104 BOMAG 008 910 36

Pressure sensor for steering / working hydraulics 5.16

Fig. 4 Fault message (7), pressure under 150bar

008 910 36 BOMAG 105

5.17 Pressure sensor for clutch pressure

5.17 Pressure sensor for clutch

pressure

Fig. 1 Sensor on the side of valve block (9)

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
3 26R2 High pressure sensor for clutch pressure I/O4:23I4 4-20 mA
0 -45 bar

Fig. 2 Display in multi-function display Fig. 3 Fault message (6), clutch pressure under 39 bar or over 50
bar.

i Note
In case of a fault the corresponding symbol will be dis-
played on screen. The bell symbol accompanies the
warning buzzer. Press the ENTER-key to switch off
the warning buzzer.

106 BOMAG 008 910 36

Pressure sensor for fan circuit 5.18
5.18 Pressure sensor for fan circuit

Fig. 1 Sensor on pressure relief valve

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
5 26R4 High pressure sensor, fan circuit I/O4:25I4 4-20 mA
0 -200 bar

Fig. 2 Display in multi-function display Fig. 3 Fault message (10), pressure in fan circuit above 250 bar.

i Note
In case of a fault the corresponding symbol will be dis-
played on screen. The bell symbol accompanies the
warning buzzer. Press the ENTER-key to switch off
the warning buzzer.

008 910 36 BOMAG 107

5.19 Differential pressure switch for hydraulic oil filter

5.19 Differential pressure switch

for hydraulic oil filter

Fig. 1 Differential pressure switch on the corresponding hydraulic oil filter

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
3 23S7 Differential pressure switch for travel circuit CPU4:46C4 0 / 24 V
4 23S1 Differential pressure switch for conveyor belt cir- CPU4:27C4 0 / 24 V
cuit
5 23S2 Differential pressure switch for steering/working CPU4:28C4 0 / 24 V
circuit

played on screen. The bell symbol accompanies the

warning buzzer. Press the ENTER-key to switch off
the warning buzzer.

Fig. 2 Display (3, 4 and 5) differential pressure fault

i Note
In case of a fault the corresponding symbol will be dis-

108 BOMAG 008 910 36

Pressure switch for water sprinkling system 5.20
5.20 Pressure switch for water
sprinkling system

Fig. 1 When the rotary button 11S5 is actuated the solenoid

The pressure switch 2(Fig. 1) serves the purpose of valve 33Y1 is energized and opens the water flow. At
monitoring the water reservoir. This monitoring en- the same time the solenoid valve 33Y6 is also ener-
sures that the water pump will not run dry and thus be gized and the water spray pump delivers water.
damaged. When no water is left, i.e. the water pressure drops to
Pressure switch and solenoid valve are located at the below 1.5 bar for longer than 5 seconds, the solenoid
right under the machine frame in front of the milling valves 33Y1 and 33Y6 will be de-energized, i.e. the
drum housing. water flow will be shut off and the water spray pump
will stop.

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 33Y1 Solenoid valve for water sprinkler system I/O5:48I5 0 / 24 V
2 30S1 Pressure switch for water sprinkling system CPU5:39C5 0 / 24 V

Fig. 2 Lack of water indicator (4)

i Note
In case of a fault the corresponding symbol will be dis-
played on screen. The bell symbol accompanies the
warning buzzer. Press the ENTER-key to switch off
the warning buzzer.

008 910 36 BOMAG 109

5.21 Operating condition for sprinkling system

5.21 Operating condition for sprin-

kling system

Fig. 1

14S3 -2- or 14S3 -1- or 11S3 -2- 30S1 11S3 -1- 12S3 up + 15S1-2- 33Y1
14S4 -2- 14S4 -1- STOP
1 0 1 1 0 0 1 1

14S3 -2- or 14S3 -1- or 11S3 -2- 30S1 11S3 -1- 12S3 up + 15S1-2- 33Y6
14S4 -2- 14S4 -1- STOP
1 0 1 1 0 0 1 1

110 BOMAG 008 910 36

Limit switch on scraper 5.22
5.22 Limit switch on scraper

Fig. 1 Limit switch, scraper raised

Fig. 2 Limit switch, scraper opened

008 910 36 BOMAG 111

5.22 Limit switch on scraper

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 24S2 Limit switch, scraper raised CPU4:41C4 0 / 24 V
2 24S1 Limit switch, scraper opened CPU4:39C4 0 / 24 V

Scraper raised
l The limit switch 1 (Fig. 1) opens, when the scraper
shield is raised.

i Note
Opening the scraper door is only possible, when the
limit switch (1) is actuated.

Scraper completely opened

l When the scraper shield is completely open, e.g. for
replacement of tools or tool holders, the limit switch
2 (Fig. 2) is no longer actuated and is thus open.

i Note
Once the scraper is opened, it is no longer possible to
drive the machine or to switch on the milling drum.

Fig. 3 Fault message (2), scraper shield raised

i Note
In case of a fault the corresponding symbol will be dis-
played on screen. The bell symbol accompanies the
warning buzzer. Press the ENTER-key to switch off
the warning buzzer.

112 BOMAG 008 910 36

Operating conditions for scraper 5.23
5.23 Operating conditions for
scraper

Scraper in floating position

Fig. 1

15S1-2- 12S1 -1- or 12S1 -2- or 41S4 -1- or 41S4 -2- or 24S1 24S2 39Y1
40S4 - 2- or 40S4 - 1- or 40S3 -1- 40S3 -2-
41S5 -2- 41S5 -1-
1 1 0 0 0 0 0 0

15S1-2- 12S1 -1- or 12S1 -2- or 41S4 -1- or 41S4 -2- or 24S1 24S2 39Y2
40S4 -2- or 40S4 - 1- or 40S3 -1- 40S3 -2-
41S5 -2- 41S5 -1-
1 1 0 0 0 0 0 0

15S1-2- 12S1 -1- or 12S1 -2- or 41S4 -1- or 41S4 -2- or 24S1 24S2 39Y3
40S4 - 2- or 40S4 - 1- or 40S3 -1- 40S3 -2-
41S5 -2- 41S5 -1-
1 1 0 0 0 0 0 0

008 910 36 BOMAG 113

5.23 Operating conditions for scraper

Scraper up / open

Fig. 1

15S1-2- 14S4 -1- or 12S1 -2- or 24S2 41S4 - 2- or 12S1 -1- or 39Y1
40S3 -1- 40S4 -1- or 40S3 -2- 40S4 -2- or
41S5 -1- 41S5 -2-
1 1 1 1 0 0 1
1 1 0 1 0 0 1
1 0 1 1 0 0 1

15S1-2- 14S4 -1- or 12S1 -2- or 24S2 41S4 - 2- or 12S1 -1- or 39Y3
40S3 -1- 40S4 -1- or 40S3 -2- 40S4 -2- or
41S5 -1- 41S5 -2-
1 1 1 1 0 0 1
1 1 0 1 0 0 1
1 0 1 1 0 0 1

114 BOMAG 008 910 36

Operating conditions for scraper 5.23
Closing the scraper

Fig. 1

41S4 -2- or 40S3 -2- 15S1-2- 41S2 -1- or 40S3 -1- 39Y2
1 1 0 1

41S4 -2- or 40S3 -2- 15S1-2- 41S2 -1- or 40S3 -1- 39Y3
1 1 0 1

008 910 36 BOMAG 115

5.24 Rope sensors, height regulation

5.24 Rope sensors, height regula-

tion

Fig. 1 Rope sensor right

Fig. 2 Rope sensor left

116 BOMAG 008 910 36

Rope sensors, height regulation 5.24

Pos. Designation in Description Terminal in Measuring

circuit diagram electrical value
junction box
1 34R2 Rope sensor right CPU6:5C6 0-10 V
2 34R1 Rope sensor left CPU6:4C6 0-10 V

i Note
Function If the machine processes an uneven pattern, or if the
machine moves up/down on one side by itself, one of
In the rope sensor a potentiometer (adjustable resis- the rope sensors may be defective
tor) is adjusted. The further the steel rope is pulled, the
higher the voltage at the potentiometer output and
thus on terminal CPU6:4C6 or on terminal CPU6:5C6.

Fig. 3 Rope sensor

1 = toothed belt
2 = winding roller
3 = potentiometer
4 = plug connection
5 = wire rope
l
Pulling the wire rope 5(Fig. 3) (pulling force > reset-
ting force of spring) or releasing (resetting force of
spring > pulling force) the wire rope (5) rotates the
winding roller (2). The toothed belt (1) has the func-
tion of a mechanical link to the potentiometer (3).
l When setting the winding roller (2) into motion, the
Fig. 4 Pin assignment
resistance of the potentiometer will change.
A = voltage supply
l
The further the wire rope (5) is pulled out, the high
the voltage on the potentiometer output. B = output voltage
C = analog ground (AGND)

008 910 36 BOMAG 117

5.24 Rope sensors, height regulation

l There is a constant resistance between terminals A

and C (Fig. 4).
l The resistance changing in dependence on the
rope length can be measured between the termi-
nals (A and B).

Sensor connections
The junction box is located near the front left and right
control panels.

Fig. 7 Selector switch for height regulation (9)

Fig. 5 Connection of rope sensor, via adapter cable

Fig. 6 Connection of an external levelling control

i Note
When the height regulation is controlled via an exter-
nal levelling control, the levelling control selector lever
9 (Fig. 7) (12S3) must be set to manual control.
The rope sensor does not have to be disconnected.

118 BOMAG 008 910 36

Inclination sensor for height regulation 5.25
5.25 Inclination sensor for height
regulation

Fig. 1 Inclinometer in control cabinet, left

Designation in circuit diagram Description Terminal in electrical junction Measuring

box value
34S1 Inclination sensor CPU6:6C6 0,5 - 4,5 V

The voltage applied to the output pin (6) varies in de-

pendence on the inclination of the machine.
l -15° degree = 0,5 Volt
l 0° degree = 2,5 Volt
l +15° degree = 4,5 Volt

Pin assignment
1 = power supply 24 Volt
2 = vehicle ground (GND)
6 = voltage output 0,5 - 4,5 Volt

008 910 36 BOMAG 119

5.26 Operating conditions for height regulation

5.26 Operating conditions for

height regulation

Manual lowering of front right hand post

Fig. 1

12S3 13S3 -1- 13S3 -2- 12S3 up 12S3 up 12S3 24S1 15S1-2- 36Y2
manual + STOP AUTO down
1 1 0 0 0 0 0 1 1

120 BOMAG 008 910 36

Operating conditions for height regulation 5.26
Manual lifting of front right hand post

Fig. 1

12S3 13S3 -1- 13S3 -2- 12S3 up 12S3 up 12S3 24S1 15S1-2- 36Y2 up
manual + STOP AUTO
1 1 0 0 0 0 0 1 1

008 910 36 BOMAG 121

5.26 Operating conditions for height regulation

Manual lowering of front left hand post

Fig. 1

12S3 13S2 -1- 13S2 -2- 12S3 up 12S3 up 12S3 24S1 15S1-2- 36Y1
manual + STOP AUTO down
1 1 0 0 0 0 0 1 1

122 BOMAG 008 910 36

Operating conditions for height regulation 5.26
Manual lifting of front left hand post

Fig. 1

12S3 13S2 -1- 13S2 -2- 12S3 up 12S3 up 12S3 24S1 15S1-2- 36Y1 up
manual + STOP AUTO
1 0 1 0 0 0 0 1 1

008 910 36 BOMAG 123

5.26 Operating conditions for height regulation

Automatic height regulation, left, via rope

sensor

Fig. 1 2 Levelling control panel VG1100, left, depth control

1 Levelling control panel VG1100, left Auto

Lowering of post

Actual depth < adjusted depth

15S1-2- 12S3 12S3 up 12S3 12S3 VG1100 VG1100 12S2-2- 14S3 -1- 24S1 36Y1
AUTO up + manual left left, or down
STOP AUTO depth 14S4 -1-
control
1 1 0 0 0 1 1 1 0 0 1

Lifting the post

Actual depth > adjusted depth

15S1-2- 12S3 12S3 up 12S3 12S3 VG1100 VG1100 12S2-2- 14S3 -1- 24S1 36Y1 up
AUTO up + manual left left, or
STOP AUTO depth 14S4 -1-
control
1 1 0 0 0 1 1 1 0 0 1

124 BOMAG 008 910 36

Operating conditions for height regulation 5.26
Automatic height regulation, right, via
rope sensor

Fig. 1 2 Levelling control panel VG1100, right depth con-

1 Levelling control panel VG1100, right AUTO trol

Lowering of post

Actual depth < adjusted depth

15S1-2- 12S3 12S3 up 12S3 12S3 VG1100 VG1100 12S2-2- 14S3 -1- 24S1 36Y2
AUTO up + manual right right or down
STOP AUTO depth 14S4 -1-
control
1 1 0 0 0 1 1 1 0 0 1

Lifting the post

Actual depth > adjusted depth

15S1-2- 12S3 12S3 up 12S3 12S3 VG1100 VG1100 12S2-2- 14S3 -1- 24S1 36Y2 up
AUTO up + manual right right or
STOP AUTO depth 14S4 -1-
control
1 1 0 0 0 1 1 1 0 0 1

008 910 36 BOMAG 125

5.26 Operating conditions for height regulation

Automatic height regulation, left, via incli-

nation sensor

Fig. 1 2 Levelling control panel VG1100, left inclination

1 Levelling control panel VG1100, left Auto control

Lowering of post

Actual depth < adjusted depth

15S1-2- 12S3 12S3 up 12S3 12S3 VG1100 VG1100 12S2-2- 14S3 -1- 24S1 36Y1
AUTO up + manual left left incli- or down
STOP AUTO nation 14S4 -1-
control
1 1 0 0 0 1 1 1 0 0 1

Lifting the post

Actual depth > adjusted depth

15S1-2- 12S3 12S3 up 12S3 12S3 VG1100 VG1100 12S2-2- 14S3 -1- 24S1 36Y1 up
AUTO up + manual left left incli- or
STOP AUTO nation 14S4 -1-
control
1 1 0 0 0 1 1 1 0 0 1

126 BOMAG 008 910 36

Operating conditions for height regulation 5.26
Automatic height regulation, right, via in-
clination sensor

Fig. 1 2 Levelling control panel VG1100, right inclination

1 Levelling control panel VG1100, right AUTO control

Lowering of post

Actual depth < adjusted depth

15S1-2- 12S3 12S3 up 12S3 12S3 VG1100 VG1100 12S2-2- 14S3 -1- 24S1 36Y2
AUTO up + manual right right in- or down
STOP AUTO clina- 14S4 -1-
tion
control
1 1 0 0 0 1 1 1 0 0 1

Lifting the post

Actual depth > adjusted depth

15S1-2- 12S3 12S3 up 12S3 12S3 VG1100 VG1100 12S2-2- 14S3 -1- 24S1 36Y2 up
AUTO up + manual right right in- or
STOP AUTO clina- 14S4 -1-
tion
control
1 1 0 0 0 1 1 1 0 0 1

008 910 36 BOMAG 127

5.27 Levelling control panel

5.27 Levelling control panel

Fig. 1 Control panel

The levelling control panels do not regulate the height
of the machine, they only serve the purpose of a pe-
riphery for inputs and outputs.
l Input means , that the height is specified by press-
ing keys.
l Output means, that the current levelling values are
shown in the display.

Fig. 2 Terminal box with adapter cable

i Note
The actual control is accomplished by the D4 control.
i Note
This machine offers the possibility to unplug a control
panel on the one side and plug it in on the other side,
as long as at least one control panel remains connect-
ed.
In order to be able to work with two, three or four con-
trol panels, each of the panels must have a different
initial position A, B, C or D.
Adjustment procedure, see operating and mainte-
nance instructions.

128 BOMAG 008 910 36

Levelling control panel 5.27

Fig. 3 Section from circuit diagram

i Note
When connecting the levelling control panel, ground is
switched to pin F and the control recognizes that at
least one control panel is connected.

008 910 36 BOMAG 129

5.28 Speed sensor

5.28 Speed sensor

Fig. 1 Sensor on rear right travel motor

Designation in circuit diagram Description Terminal in electrical junction Measuring

box value
38S3 Speed sensor CPU5:10C5 2366 puls-
es per me-
ter

Pin assignment
i Note
A = frequency output (0 - 3 kHz) Switching gap = 0.5 mm:
B = vehicle ground (GND) Back out for approx. min. 85°
C = power supply (24 Volt) back out max. 120°
l
Secure the sensor with the hexagon nut.

Sensor installation i Note

l With the travel motor at standstill carefully screw the A defective rpm-sensor has no effect on the travel
sensor into the mounting hole, until it touches the in- control. The rpm-sensor solely serves the purpose of
ternal ring gear. detecting the speed, which is shown in the display.
l
In accordance with the thread pitch (1.5 mm) back
the sensor out for approx. 1/3 of a revolution.

130 BOMAG 008 910 36

Operating conditions for travel drive 5.29
5.29 Operating conditions for trav-
el drive

Transport speed forward

Fig. 1 PWM voltage cannot be measured.

Travel forward, 30Y1 PWM current can be measured.

i Note
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2).

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 30Y1

16S4 14S4 -1-
1 1 1 0 0 1 0 1

Speed changeover, 30Y3

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 30Y3

16S4 14S4 -1-
1 1 1 0 0 1 0 1

Brake, 30Y5

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 30Y5

16S4 14S4 -1-
1 1 1 0 0 1 0 1

008 910 36 BOMAG 131

5.29 Operating conditions for travel drive

Transport speed reverse

Fig. 1 PWM voltage cannot be measured.

Travel reverse, 30Y1 PWM current can be measured.

i Note
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2).

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 30Y1

16S4 14S4 -1-
1 1 1 0 0 1 0 1

Speed changeover, 30Y3

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 30Y3

16S4 14S4 -1-
1 1 1 0 0 1 0 1

Brake, 30Y5

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 30Y5

16S4 14S4 -1-
1 1 1 0 0 1 0 1

132 BOMAG 008 910 36

Operating conditions for travel drive 5.29
Working speed forward

Fig. 1 PWM voltage cannot be measured.

Travel forward, 30Y1 PWM current can be measured.

i Note
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2).

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y1
16S4 14S4 -1-
1 1 1 0 0 0 0 1 1

Brake, 30Y5

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y5
16S4 14S4 -1-
1 1 1 0 0 0 0 1 1

008 910 36 BOMAG 133

5.29 Operating conditions for travel drive

Working speed reverse

Fig. 1 PWM voltage cannot be measured.

Travel reverse, 30Y1 PWM current can be measured.

i Note
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2).

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y1
16S4 14S4 -1-
1 1 1 0 0 0 0 1 1

Brake, 30Y5

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y5
16S4 14S4 -1-
1 1 1 0 0 0 0 1 1

134 BOMAG 008 910 36

Operating conditions for travel drive 5.29
Working speed forward with differential
lock

Fig. 1 PWM voltage cannot be measured.

Travel forward, 30Y1 PWM current can be measured.

i Note
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2).

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y1
16S4 14S4 -1-
1 1 1 0 0 0 1 1 1

Differential, 30Y4

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y4
16S4 14S4 -1-
1 1 1 0 0 0 1 1 1

Brake, 30Y5

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y5
16S4 14S4 -1-
1 1 1 0 0 0 1 1 1

008 910 36 BOMAG 135

5.29 Operating conditions for travel drive

Working speed reverse with differential

lock

Fig. 1 PWM voltage cannot be measured.

Travel reverse, 30Y1 PWM current can be measured.

i Note
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2).

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y1
16S4 14S4 -1-
1 1 1 0 0 0 1 1 1

Differential, 30Y4

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y4
16S4 14S4 -1-
1 1 1 0 0 0 1 1 1

Brake, 30Y5

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y5
16S4 14S4 -1-
1 1 1 0 0 0 1 1 1

136 BOMAG 008 910 36

Operating conditions for travel drive 5.29
Working speed forward with engine load
control

Fig. 1 PWM voltage cannot be measured.

Travel forward, 30Y1 PWM current can be measured.

i Note
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2) minus delta engine
speed.

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S4-1- 15S4-2- 30Y1
16S4 14S4 -1-
1 1 1 0 0 0 0 0 1

Brake, 30Y5

16S3 or 16S1 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y5
16S4 14S4 -1-
1 1 1 0 0 0 0 0 1

008 910 36 BOMAG 137

5.29 Operating conditions for travel drive

Working speed reverse with engine load

control

Fig. 1 PWM voltage cannot be measured.

Travel reverse, 30Y1 PWM current can be measured.

i Note
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2) minus delta engine
speed.

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S4-1- 15S4-2- 30Y1
16S4 14S4 -1-
1 1 1 0 0 0 0 0 1

Brake, 30Y5

16S3 or 16S2 28R2 14S3 -1- or 24S1 15S3-2- 15S3-1- 15S4-2- 30Y5
16S4 14S4 -1-
1 1 1 0 0 0 0 0 1

138 BOMAG 008 910 36

Operating conditions for travel drive 5.29
Working speed forward with engine load
control and high sensitivity

Fig. 1 speed, minus potentiometer for high sensitivity

(28R1).
Travel forward, 30Y1
PWM voltage cannot be measured.
i Note PWM current can be measured.
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2) minus delta engine

28R1 16S3 or 16S1 28R2 14S3 -1- 24S1 15S3-2- 15S4-1- 15S4-2- 30Y1
16S4 or
14S4 -1-
1 1 1 1 0 0 0 1 0 1

Brake, 30Y5

28R1 16S3 or 16S1 28R2 14S3 -1- 24S1 15S3-2- 15S4-1- 15S4-2- 30Y5
16S4 or
14S4 -1-
1 1 1 1 0 0 0 1 0 1

008 910 36 BOMAG 139

5.29 Operating conditions for travel drive

Working speed reverse with engine load

control and high sensitivity

Fig. 1 speed, minus potentiometer for high sensitivity

(28R1).
Travel reverse, 30Y1
PWM voltage cannot be measured.
i Note PWM current can be measured.
The PWM-current (30Y1) behaves proportional to the
travel lever potentiometer (28R2) minus delta engine

28R1 16S3 or 16S2 28R2 14S3 -1- 24S1 15S3-2- 15S4-1- 15S4-2- 30Y1
16S4 or
14S4 -1-
1 1 1 1 0 0 0 1 0 1

Brake, 30Y5

28R1 16S3 or 16S2 28R2 14S3 -1- 24S1 15S3-2- 15S4-1- 15S4-2- 30Y5
16S4 or
14S4 -1-
1 1 1 1 0 0 0 1 0 1

140 BOMAG 008 910 36

Terminal box 5.30
5.30 Terminal box All actuators and sensors are connected in the termi-
nal box.
The terminal box contains the individual terminal
strips, relays, fuses, controls, sensors and diagnostic
sockets.

Fig. 1 Terminal box

Pos. Designation in Description Page in circuit

circuit diagram diagram
1 48U1 DC/DC transformer (voltage transformer 24V/10V) for sensors 48
2 10V Terminal strip for 10V voltage for sensors 22; 28; 34; 37;
40; 41; 42; 43;
48
3 CPU4 Terminal strip for control ID4 CPU-end 22; 23; 24
4 I/O4 Terminal strip for control ID4 I/O-end 25; 26; 27
5 2K3; 4K1; 4K2 Power relay (see circuit diagram) 2; 4; 6
6 11x automatic circuit breaker 3; 4; 5; 6; 48
7 47K1 Timer relay for engine speed acceleration after engaging the 47
clutch (5 sec.)
8 2K2; 4.1K1; Relay (see circuit diagram) 2; 4; 1;5
4.1K2; 4.1K3;
4.1K4; 5K1

008 910 36 BOMAG 141

5.30 Terminal box

Fig. 3 Blocked test button

i Note
Blocked test button (Fig. 3) = switch.
For this purpose rotate the test button by 90°, so that
the reminder points towards the outside. For this pur-
pose the locking pin above the test button must be cut
off. After the test the blocked test button must be re-
turned to "Button" position.

Fig. 2 finder relay Pos. 8

i Note
By pressing the test button the contacts remain closed
Fig. 4 Relay base
until the test button is released.

Pos. Designation in Description Page in circuit

circuit diagram diagram
9 CPU5 Terminal strip for control ID5 CPU-end 28; 29; 30
10 I/O5 Terminal strip for control ID5 I/O-end 31; 32; 33
11 X1 Terminal strip, general
12 X1 Fuse with LED-display 4.1; 5; 35; 39;
48;

i Note
If a fuse has blown, the corresponding control lamp
will light up.

! Danger

Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.

142 BOMAG 008 910 36

Terminal box 5.30

Fig. 5
l Fold the housing down, open the cover and remove
the fuse (Fig. 5).
l Insert a fuse of the same amperage.

Pos. Designation in Description Page in circuit

circuit diagram diagram
13 XC Terminal strip
14 CPU6 Terminal strip for control ID6 CPU-end 34; 35; 36
15 I/O6 Terminal strip for control ID6 I/O-end 37; 38; 39
16 34S1 Inclination sensor 34

008 910 36 BOMAG 143

5.30 Terminal box

Fig. 6 Terminal box

Pos. Designation in Description Page in circuit

circuit diagram diagram
17 27S5 Cross-slope sensor 27
18 3PCB1 Terminal strip with diodes for various circuits for emergency op- 3
eration
19 36U1 Terminal strip with resistors for various circuits 36; 39
20 XPSX Terminal strip for control panel rear left 40
21 XPDX Terminal strip for control panel rear right 41
22 XASX Terminal strip for control panel front left 42
23 XADX Terminal strip for control panel front right 43
24 Deutz Terminal strip for DEUTZ-EMR 47

144 BOMAG 008 910 36

Terminal box 5.30

Fig. 7 Terminal box

Pos. Designation in Description Page in circuit

circuit diagram diagram
25 ID6 I/O Control for steering limitation front and scraper 37; 38; 39
26 ID5 I/O Control for folded conveyor belt and sprinkling system 31; 32; 33
27 ID4 I/O Control for cross-slope control sensor, various level switches, 25; 26; 27
conveyor belt control and gathering belt control

008 910 36 BOMAG 145

5.30 Terminal box

Fig. 8 Terminal box

Pos. Designation in Description Page in circuit

circuit diagram diagram
28 ID6 CPU Control for rear steering and front/rear lift cylinders up/down 34; 35; 36
29 ID5 CPU Control for limit switches on conveyor belt, travel drive control, 28; 29; 30
working hydraulics, clutch, belt tensioner
30 ID4 CPU Control for scraper shield, various pressure switches, engine 22; 23; 24
hood, grade shoes, conveyor belt forw./reverse

146 BOMAG 008 910 36

Terminal box 5.30

Fig. 9 SERDIA connection

These connections are located inside the terminal box
and are bundled on the floor of the terminal box.
l 31 – 33 Connecting plugs for program transmission
from PC to control (this function is reserved for the
manufacturer or the central after sales service).
l
34 Diagnostics interface for connection of the diag-
nostics unit SERDIA. For this purpose the PC or
laptop is connected to the diagnostic interface by
means of an interface cable.

008 910 36 BOMAG 147

5.30 Terminal box

Fig. 10 Terminal box

Pos. Designation in Description Page in circuit

circuit diagram diagram
35 5S1; 16S1; 16S2; Travel lever left with potentiometer, limit switch and safety push 5; 16; 28
16S3; 28R1; button
28R2;
36 55U1 Converter RS232 / RS485 for levelling control panels 55
37 X3.3; X3.4; X3.5; CGC display (multi function display) 10; 11; 12; 13;
X3.6; X3.7; X3.8; 14; 15; 16; 17;
X3.9; X3.1; X3.10; 18; 19; 20; 21
X3.11; X1.7; X1.8;

148 BOMAG 008 910 36

Pin assignment, ID4.....ID6 5.31
5.31 Pin assignment, ID4.....ID6
Pin assignment ID6 I/O

Fig. 1 Pin assignment

Pin Terminal in ter- Description Measuring val-

minal box ue
1 I/O6:1I6 Supply voltage 24 V
2 I/O6:2I6 Supply voltage 24 V
3 I/O6:3I6 Ground for analog inputs AGND
4 I/O6:4I6 Signal input from rope sensor 37R1 0 - 10 V
5 I/O6:5I6 Signal input from rope sensor 37R2 0 - 10 V
6 I/O6:6I6 Connection from control panel RR 0 - 10 V
7 I/O6:7I6 not used
8 I/O6:8I6 Ground for analog inputs AGND
9 I/O6:9I6 not used
10 I/O6:10I6 not used
11 I/O6:11I6 Vehicle ground GND
12 I/O6:12I6 not used
13 I/O6:13I6 not used
14 I/O6:14I6 not used
15 I/O6:15I6 not used
16 I/O6:16I6 not used
17 I/O6:17I6 not used
18 I/O6:18I6 not used
19 I/O6:19I6 not used
20 I/O6:20I6 not used
21 I/O6:21I6 not used
22 I/O6:22I6 not used
23 I/O6:23I6 not used
24 I/O6:24I6 not used
25 I/O6:25I6 not used
26 I/O6:26I6 not used
27 I/O6:27I6 not used
28 I/O6:28I6 not used
29 I/O6:29I6 not used
30 I/O6:30I6 not used
31 I/O6:31I6 not used
32 I/O6:32I6 not used
33 I/O6:33I6 not used
34 I/O6:34I6 not used
35 I/O6:35I6 not used
36 I/O6:36I6 not used
37 I/O6:37I6 not used
38 I/O6:38I6 not used
39 I/O6:39I6 Proximity switch (39S1) lift cylinder FR 0 / 24 V

008 910 36 BOMAG 149

5.31 Pin assignment, ID4.....ID6

Pin Terminal in ter- Description Measuring val-

minal box ue
40 I/O6:40I6 Proximity switch (39S2) lift cylinder FL 0 / 24 V
41 I/O6:41I6 Proximity switch (39S3) steering front to the right 0 / 24 V
42 I/O6:42I6 Proximity switch (39S4) steering front to the left 0 / 24 V
43 I/O6:43I6 External button (W39SX) for rear lift cylinder down 0 / 24 V
44 I/O6:44I6 External button (W39SX) for rear lift cylinder up 0 / 24 V
45 I/O6:45I6 External button (W39DX) for rear lift cylinder down 0 / 24 V
46 I/O6:46I6 External button (W39DX) for rear lift cylinder up 0 / 24 V
47 I/O6:47I6 Vehicle ground GND
48 I/O6:48I6 Solenoid valve (39Y1) scraper up 0 / 24 V
49 I/O6:49I6 Solenoid valve (39Y2) scraper down 0 / 24 V
50 I/O6:50I6 Solenoid valve (39Y3) scraper float position 0 / 24 V
51 I/O6:51I6 Solenoid valve (39Y4) steering limitation right 0 / 24 V
52 I/O6:52I6 Solenoid valve (39Y5) steering limitation left 0 / 24 V
53 I/O6:53I6 not used
54 I/O6:54I6 not used
55 I/O6:54I6 not used

150 BOMAG 008 910 36

Pin assignment, ID4.....ID6 5.31
Pin assignment ID5 I/O

Fig. 2 Pin assignment

Pin Terminal in ter- Description Measuring val-

minal box ue
1 I/O5:1I5 Supply voltage 24 V
2 I/O5:2I5 Supply voltage 24 V
3 I/O5:3I5 not used
4 I/O5:4I5 not used
5 I/O5:5I5 not used
6 I/O5:6I5 not used
7 I/O5:7I5 not used
8 I/O5:8I5 not used
9 I/O5:9I5 not used
10 I/O5:10I5 not used
11 I/O5:11I5 not used
12 I/O5:12I5 not used
13 I/O5:13I5 not used
14 I/O5:14I5 not used
15 I/O5:15I5 not used
16 I/O5:16I5 not used
17 I/O5:17I5 not used
18 I/O5:18I5 not used
19 I/O5:19I5 not used
20 I/O5:20I5 not used
21 I/O5:21I5 not used
22 I/O5:22I5 not used
23 I/O5:23I5 not used
24 I/O5:24I5 not used
25 I/O5:25I5 not used
26 I/O5:26I5 not used
27 I/O5:27I5 not used
28 I/O5:28I5 not used
29 I/O5:29I5 not used
30 I/O5:30I5 not used
31 I/O5:31I5 not used
32 I/O5:32I5 not used
33 I/O5:33I5 not used
34 I/O5:34I5 not used
35 I/O5:35I5 not used
36 I/O5:36I5 not used
37 I/O5:37I5 not used
38 I/O5:38I5 not used
39 I/O5:39I5 not used
40 I/O5:40I5 not used
41 I/O5:41I5 not used

008 910 36 BOMAG 151

5.31 Pin assignment, ID4.....ID6

Pin Terminal in ter- Description Measuring val-

minal box ue
42 I/O5:42I5 not used
43 I/O5:43I5 not used
44 I/O5:44I5 not used
45 I/O5:45I5 not used
46 I/O5:46I5 not used
47 I/O5:47I5 Vehicle ground GND
48 I/O5:48I5 Solenoid valve (33Y1) sprinkling system 0 / 24 V
49 I/O5:49I5 Solenoid valve (33Y6) sprinkling pump 0 / 24 V
50 I/O5:50I5 Solenoid valve (33Y2) conveyor belt open 90° 0 / 24 V
51 I/O5:51I5 Solenoid valve (33Y3) conveyor belt open 180° 0 / 24 V
52 I/O5:52I5 Signal lamp (33H2) load limit control 0 / 24 V
53 I/O5:53I5 Warning horn (33HU1) backup alarm 0 / 24 V
54 I/O5:54I5 Solenoid valve (33Y4) conveyor belt close 90° 0 / 24 V
55 I/O5:54I5 Solenoid valve (33Y4) conveyor belt close 180° 0 / 24 V

152 BOMAG 008 910 36

Pin assignment, ID4.....ID6 5.31
Pin assignment ID4 I/O

Fig. 3 Pin assignment

Pin Terminal in ter- Description Measuring val-

minal box ue
1 I/O4:1I4 Supply voltage 24 V
2 I/O4:2I4 Supply voltage 24 V
3 I/O4:3I4 not used
4 I/O4:4I4 not used
5 I/O4:5I4 not used
6 I/O4:6I4 not used
7 I/O4:7I4 not used
8 I/O4:8I4 not used
9 I/O4:9I4 not used
10 I/O4:10I4 not used
11 I/O4:11I4 CAN-GND 2 to EMR CAN-Bus
12 I/O4:12I4 CAN-LOW 2 to EMR CAN-Bus
13 I/O4:13I4 CAN-HIGH 2 to EMR CAN-Bus
14 I/O4:14I4 not used
15 I/O4:15I4 Power outlet for hydraulic oil temperature sensor (22R2) 20 mA
16 I/O4:16I4 Power outlet for fuel level sensor (22R3) 20 mA
17 I/O4:17I4 not used
18 I/O4:18I4 not used
19 I/O4:19I4 not used
20 I/O4:20I4 not used
21 I/O4:21I4 not used
22 I/O4:22I4 Signal input from pressure sensor for steering / working hydrau- 4-20 mA
lics (26R1)
23 I/O4:23I4 Signal input from hydraulic pressure sensor for clutch (26R2) 4-20 mA
24 I/O4:24I4 Signal input from hydraulic pressure sensor in conveyor belt 4-20 mA
drive circuit
25 I/O4:25I4 Signal input from hydraulic pressure sensor in fan drive circuit 4-20 mA
26 I/O4:26I4 not used
27 I/O4:27I4 not used
28 I/O4:28I4 not used
29 I/O4:29I4 not used
30 I/O4:30I4 not used
31 I/O4:31I4 bridged with I/O4:32I4 CAN-Bus
32 I/O4:32I4 bridged with I/O4:31I4 CAN-Bus
33 I/O4:33I4 not used
34 I/O4:34I4 not used
35 I/O4:35I4 not used
36 I/O4:36I4 not used
37 I/O4:37I4 not used
38 I/O4:38I4 not used
39 I/O4:39I4 Inclined position control switch (27S5) 0 / 24 V

008 910 36 BOMAG 153

5.31 Pin assignment, ID4.....ID6

Pin Terminal in ter- Description Measuring val-

minal box ue
40 I/O4:40I4 Coolant level switch (27S1) 0 / 24 V
41 I/O4:41I4 not used
42 I/O4:42I4 Hydraulic oil level switch (27S2) 0 / 24 V
43 I/O4:43I4 not used
44 I/O4:44I4 not used
45 I/O4:45I4 not used
46 I/O4:46I4 not used
47 I/O4:47I4 Vehicle ground GND
48 I/O4:48I4 Solenoid valve (27Y1) conveyor belt up 0 / 24 V
49 I/O4:49I4 Solenoid valve (27Y2) conveyor belt down 0 / 24 V
50 I/O4:50I4 Solenoid valve (27Y3) conveyor belt to the left 0 / 24 V
51 I/O4:51I4 Solenoid valve (27Y4) conveyor belt to the right 0 / 24 V
52 I/O4:52I4 not used
53 I/O4:53I4 Signal lamp (27H1) gathering belt foot in floating position 0 / 24 V
54 I/O4:54I4 Solenoid valve (27Y7) gathering belt foot up 0 / 24 V
55 I/O4:54I4 Solenoid valve (27Y8) gathering belt foot down 0 / 24 V

154 BOMAG 008 910 36

Pin assignment, ID4.....ID6 5.31
Pin assignment ID6 CPU

Fig. 4 Pin assignment

Pin Terminal in ter- Description Measuring val-

minal box ue
1 CPU6:1C6 Supply voltage 24 V
2 CPU6:2C6 Supply voltage 24 V
3 CPU6:3C6 Ground for analog inputs AGND
4 CPU6:4C6 Signal input from rope sensor (34R1) 0 - 10 V
5 CPU6:5C6 Signal input from rope sensor (34R2) 0 - 10 V
6 CPU6:6C6 Signal input from inclination sensor (34S1) 0,5 - 4,5 V
7 CPU6:7C6 Connection from control panel FL 0 - 10 V
8 CPU6:8C6 Ground for analog inputs AGND
9 CPU6:9C6 not used
10 CPU6:10C6 not used
11 CPU6:11C6 not used
12 CPU6:12C6 CAN-LOW 1 to ID4:CPU; ID5:CPU; CGC:X1.7 CAN-Bus
13 CPU6:13C6 CAN-HIGH 1 to ID4:CPU; ID5:CPU; CGC:X1.7 CAN-Bus
14 CPU6:14C6 not used
15 CPU6:15C6 not used
16 CPU6:16C6 not used
17 CPU6:17C6 not used
18 CPU6:18C6 Input RS232 from (W34) to load program
19 CPU6:19C6 Ground for (W34) to load program GND
20 CPU6:20C6 Supply voltage after E-STOP 24 V
21 CPU6:21C6 not used
22 CPU6:22C6 not used
23 CPU6:23C6 not used
24 CPU6:24C6 not used
25 CPU6:25C6 not used
26 CPU6:26C6 not used
27 CPU6:27C6 not used
28 CPU6:28C6 not used
29 CPU6:29C6 Vehicle ground GND
30 CPU6:30C6 not used
31 CPU6:31C6 not used
32 CPU6:32C6 not used
33 CPU6:33C6 not used
34 CPU6:34C6 not used
35 CPU6:35C6 not used
36 CPU6:36C6 Output RS232 from (W34) to load program
37 CPU6:37C6 not used
38 CPU6:38C6 Supply voltage after E-STOP 24 V
39 CPU6:39C6 Proximity switch (36S1) lift cylinder RR 0 / 24 V
40 CPU6:40C6 Proximity switch (36S2) lift cylinder RL 0 / 24 V
41 CPU6:41C6 Levelling control panel connected 0 / 24 V

008 910 36 BOMAG 155

5.31 Pin assignment, ID4.....ID6

Pin Terminal in ter- Description Measuring val-

minal box ue
42 CPU6:42C6 Proximity switch (36S4) steering rear to right 0 / 24 V
43 CPU6:43C6 Proximity switch (36S5) steering rear to left 0 / 24 V
44 CPU6:44C6 Switch (56S1) on ultrasonic sensor 56V1 0 / 24 V
45 CPU6:45C6 Switch (56S1) on ultrasonic sensor 56V2 0 / 24 V
46 CPU6:46C6 not used
47 CPU6:47C6 Vehicle ground GND
48 CPU6:48C6 Solenoid valve (36Y1) lift cylinder FL up (PWM) 0 - 1000 mA
49 CPU6:49C6 Solenoid valve (36Y1) lift cylinder FL down (PWM) 0 - 1000 mA
50 CPU6:50C6 Solenoid valve (36Y2) lift cylinder FR down (PWM) 0 - 1000 mA
51 CPU6:51C6 Solenoid valve (36Y2) lift cylinder FR up (PWM) 0 / 24 V
52 CPU6:52C6 Solenoid valve (36Y3) lift cylinder rear up 0 / 24 V
53 CPU6:53C6 Solenoid valve (36Y3) lift cylinder rear down 0 / 24 V
54 CPU6:54C6 Solenoid valve (36Y5) steering rear to right 0 / 24 V
55 CPU6:55C6 Solenoid valve (36Y6) steering rear to left 0 / 24 V

156 BOMAG 008 910 36

Pin assignment, ID4.....ID6 5.31
Pin assignment ID5 CPU

Fig. 5 Pin assignment

Pin Terminal in ter- Description Measuring val-

minal box ue
1 CPU5:1C5 Supply voltage 24 V
2 CPU5:2C5 Supply voltage 24 V
3 CPU5:3C5 Ground for analog inputs AGND
4 CPU5:4C5 Signal input from potentiometer (28R1) load limit control 0 - 10 V
5 CPU5:5C5 Signal input from potentiometer (28R2) travel lever 0 - 10 V
6 CPU5:6C5 not used
7 CPU5:7C5 not used
8 CPU5:8C5 not used
9 CPU5:9C5 Signal input from EMR (speed of engine) 0 - 410 kHz
10 CPU5:10C5 Signal input from speed sensor (28S3) 0 - 3 kHz
11 CPU5:11C5 not used
12 CPU5:12C5 CAN-LOW 1 to ID4:CPU; ID6:CPU; CGC:X1.7 CAN-Bus
13 CPU5:13C5 CAN-HIGH 1 to ID4:CPU; ID6:CPU; CGC:X1.7 CAN-Bus
14 CPU5:14C5 not used
15 CPU5:15C5 not used
16 CPU5:16C5 not used
17 CPU5:17C5 not used
18 CPU5:18C5 Input RS232 from (W28) to load program
19 CPU5:19C5 Ground for (W28) to load program GND
20 CPU5:20C5 Supply voltage after E-STOP 24 V
21 CPU5:21C5 not used
22 CPU5:22C5 not used
23 CPU5:23C5 not used
24 CPU5:24C5 not used
25 CPU5:25C5 not used
26 CPU5:26C5 not used
27 CPU5:27C5 not used
28 CPU5:28C5 not used
29 CPU5:29C5 Vehicle ground GND
30 CPU5:30C5 not used
31 CPU5:31C5 not used
32 CPU5:32C5 not used
33 CPU5:33C5 Vehicle ground GND
34 CPU5:34C5 not used
35 CPU5:35C5 not used
36 CPU5:36C5 Output RS232 from (W28) to load program
37 CPU5:37C5 not used
38 CPU5:38C5 Supply voltage after E-STOP 24 V
39 CPU5:39C5 Pressure switch (30S1) water sprinkling system 0 / 24 V
40 CPU5:40C5 Limit switch (30S2) conveyor belt 90° folded 0 / 24 V
41 CPU5:41C5 Limit switch (30S3) conveyor belt 180° folded 0 / 24 V

008 910 36 BOMAG 157

5.31 Pin assignment, ID4.....ID6

Pin Terminal in ter- Description Measuring val-

minal box ue
42 CPU5:42C5 not used
43 CPU5:43C5 not used
44 CPU5:44C5 not used
45 CPU5:45C5 not used
46 CPU5:46C5 not used
47 CPU5:47C5 Vehicle ground GND
48 CPU5:48C5 Solenoid valve (30Y1) travel drive forward (PWM) 200 - 600 mA
49 CPU5:49C5 Solenoid valve (30Y2) travel drive reverse (PWM) 200 - 600 mA
50 CPU5:50C5 Solenoid valve (30Y3) working or transport speed 0 / 24 V
51 CPU5:51C5 Solenoid valve (30Y4) differential lock 0 / 24 V
52 CPU5:52C5 Solenoid valve (30Y5) travel brake 0 / 24 V
53 CPU5:53C5 Solenoid valve (30Y6) steering and working hydraulics 0 / 24 V
54 CPU5:54C5 Solenoid valve (30Y7) clutch 0 / 24 V
55 CPU5:55C5 Solenoid valve (30Y8) belt tensioner 0 / 24 V

158 BOMAG 008 910 36

Pin assignment, ID4.....ID6 5.31
Pin assignment ID4 CPU

Fig. 6 Pin assignment

Pin Terminal in ter- Description Measuring val-

minal box ue
1 CPU4:1C4 Supply voltage 24 V
2 CPU4:2C4 Supply voltage 24 V
3 CPU4:3C4 Ground for analog inputs AGND
4 CPU4:4C4 Signal from potentiometer (22R1) conveyor belt speed 0 - 10 V
5 CPU4:5C4 Signal input from hydraulic oil temperature sensor (22R2) 0 - 10 V
6 CPU4:6C4 Signal input from fuel level sensor (22R3) 0 - 10 V
7 CPU4:7C4 not used
8 CPU4:8C4 Ground for analog inputs AGND
9 CPU4:9C4 Limit switch (22S1) for engine hood OPEN/CLOSE 24 V
10 CPU4:10C4 Limit switch (22S2) for engine hood safety rod 24 V
11 CPU4:11C4 Vehicle ground GND
12 CPU4:12C4 CAN-LOW 1 to ID5:CPU; ID6:CPU; CGC:X1.7 CAN-Bus
13 CPU4:13C4 CAN-HIGH 1 to ID5:CPU; ID6:CPU; CGC:X1.7 CAN-Bus
14 CPU4:14C4 not used
15 CPU4:15C4 not used
16 CPU4:16C4 not used
17 CPU4:17C4 not used
18 CPU4:18C4 Input RS232 from (W22) to load program
19 CPU4:19C4 Ground for (W22) to load program GND
20 CPU4:20C4 Supply voltage after E-STOP 24 V
21 CPU4:21C4 not used
22 CPU4:22C4 not used
23 CPU4:23C4 not used
24 CPU4:24C4 not used
25 CPU4:25C4 Signal input from hydraulic oil level sensor (23R1) hydraulic trav- 4 - 20 mA
el circuit
26 CPU4:26C4 not used
27 CPU4:27C4 Differential pressure switch (23S1) in hydraulic circuit for con- 0 / 24 V
veyor belt
28 CPU4:28C4 Differential pressure switch (23S2) in steering and working cir- 0 / 24 V
cuit
29 CPU4:29C4 Vehicle ground GND
30 CPU4:30C4 not used
31 CPU4:31C4 not used
32 CPU4:32C4 not used
33 CPU4:33C4 not used
34 CPU4:34C4 not used
35 CPU4:35C4 not used
36 CPU4:36C4 Output RS232 from (W22) to load program
37 CPU4:37C4 not used
38 CPU4:38C4 Supply voltage after E-STOP 24 V

008 910 36 BOMAG 159

5.31 Pin assignment, ID4.....ID6

Pin Terminal in ter- Description Measuring val-

minal box ue
39 CPU4:39C4 Limit switch (24S1), scraper shield open 0 / 24 V
40 CPU4:40C4 D+ from generator 0 / 24 V
41 CPU4:41C4 Limit switch (24S2), scraper shield lifted 0 / 24 V
42 CPU4:42C4 not used
43 CPU4:43C4 not used
44 CPU4:44C4 Limit switch (24S5) conveyor belt in working position 0 / 24 V
45 CPU4:45C4 Pressure switch (24S6) on air filter 0 / 24 V
46 CPU4:46C4 Differential pressure switch (24S7) in travel circuit 0 / 24 V
47 CPU4:47C4 Vehicle ground GND
48 CPU4:48C4 Solenoid valve (24Y1) grade shoe left (PWM) 0 - 1200 mA
49 CPU4:49C4 Solenoid valve (24Y2) grade shoe right (PWM) 0 - 1200 mA
50 CPU4:50C4 Warning light (24H1) grade shoe left lifted 0 / 24 V
51 CPU4:51C4 Warning light (24H2) grade shoe right lifted 0 / 24 V
52 CPU4:52C4 Warning buzzer (24H3) 0 / 24 V
53 CPU4:53C4 Signal lamp (24H3) conveyor belt ON 0 / 24 V
54 CPU4:54C4 Solenoid valve (24Y4) conveyor belt forward (PWM) 200 - 600 mA
55 CPU4:55C4 Solenoid valve (24Y4) conveyor belt reverse (PWM) 200 - 600 mA

160 BOMAG 008 910 36

Battery compartment 5.32
5.32 Battery compartment

Fig. 1

Pos. Designation in Description Page in circuit dia-

circuit diagram gram
1 1G1 Battery 12V 1A
2 1F2 Automatic circuit breaker 8 A 1A
3 1F1 Fuse 30 A 1A
4 1F3 Fuse 30 A 1A
5 2F1 Fuse 80 A 2
6 1Q1 Power disconnect switch 2
7 3F1 Automatic circuit breaker 8 A 3
8 1G2 Battery 12V 1A

008 910 36 BOMAG 161

5.33 Battery maintenance

5.33 Battery maintenance

! 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. 2
Environment l Remove the batteries (Fig. 2) 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).
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.
l
After each charging process allow the battery to rest Fig. 3
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 battery flap at the rear of the machine.

162 BOMAG 008 910 36

Multi-function display, inputs/outputs 5.34
5.34 Multi-function display, inputs/ Setting
outputs

General notes

i Note
The multi-function display has the following functions:
l Input of work parameters
l
Read out work parameters
l
Indication of faults
l
Indication of service intervals

Fig. 6
Switching on
l Press key F1 (setting) (Fig. 6).
l Switch on the ignition.
Inputs and outputs

Fig. 4
The initial screen is displayed (Fig. 4).
Fig. 7
The following information is displayed (Fig. 7):
i Note
l Contrast illumination
Always wait until the main menu appears on the
screen. l Time and date
l Inputs and outputs
l
Language selection

i Note
Use the cursor keys to select the setting "Inputs and
Outputs" and press ENTER to confirm.

i Note
Enter code 0000 and press ENTER to confirm

Fig. 5
l After approx. 30 seconds the main menu appears
(Fig. 5).

008 910 36 BOMAG 163

5.35 TUNING PID Parameter

5.35 TUNING PID Parameter

i Note
The parameter values shown here are only guide val-
ues and may vary from machine to machine.

Parameter for engine load control, travel

drive and height regulation

Fig. 8
The following information is displayed (Fig. 8):

i Note
Use the cursor keys to select the desired setting and
press ENTER to confirm.
l TUNING PID = Parameter for engine load control, Fig. 9
travel system, height regulation. The following information is displayed (Fig. 9):
l COMPACT (ID4) = Switching states of the digital in-
puts and outputs on the (ID4).
i Note
l COMPACT (ID5) = Switching states of the digital in- Select the desired setting with the cursor keys and
puts and outputs on the (ID5). change the values accordingly.
l COMPACT (ID6) = Switching states of the digital in- l
RPM GLR ON = (2090) RPM-value from which the
puts and outputs on the (ID6). motor load control will start to work
l
CGC MATRIX = Switching states of the digital in- l RPM = current speed of diesel engine (from EMR)
puts (Matrix) on the dashboard
l Kf = (1.04) multiplication factor for travel lever po-
tentiometer output
l Pot*Kf = (4132) potentiometer output value (28R2)
from travel lever multiplied with multiplication factor
of Kf
l
PotLimit = (4095) potentiometer output value
(28R1) for load control
l
Ki = (0,50) input value for sensibility of engine load
control
l Kp = (5.00) input value for sensibility of engine load
control
l Rn = (2) ramp value stored in the SW (there are 4
ramp values 1, 2, 3, 4. The response time for start-
ing and stopping is reduced by increasing the ramp
value.)

i Note
Press key F2 to open the next menu.

164 BOMAG 008 910 36

TUNING PID Parameter 5.35
l Ki Ralp Rgt = (0.20) input value for the sensibility of
the height control via the rope sensor on the right
hand side
l Kp Ralp Rgt = (12.00) input value for the sensibility
of the height control via the rope sensor on the right
hand side
l SPD UP Lft = (-430) input value for the lifting speed,
left
l SPD DW Lft = (380) input value for the lowering
Fig. 10 speed, left
The following information is displayed (Fig. 10): l SPD UP Rgt = (-430) input value for the lifting
speed, right

i Note l SPD DW Rgt = (380) input value for the lowering

speed, right
Select the desired setting with the cursor keys and
change the values accordingly.
l Ki Incl Lft = (1,00) input value for the sensibility of i Note
the height control via the inclination sensor on the The values for SPD UP Lft; SPD DW Lft; SPD UP Rgt;
left hand side SPD DW Rgt must be set as follows:
l
Kp Incl Lft = (15.00) input value for the sensibility of When lifting or lowering the machine, the front lift cyl-
the height control via the inclination sensor on the inders must move for 20 cm over a period of 8 sec-
left hand side onds. When increasing these values, the lifting
cylinders will move faster. When reducing these val-
l Ki Incl Rgt = (1.00) input value for the sensibility of
ues, the lifting cylinders will move slower.
the height control via the inclination sensor on the
right hand side
l Kp Incl Rgt = (15.00) input value for the sensibility
of the height control via the inclination sensor on the
right hand side

i Note
Press key F2 to open the next menu.

Fig. 12
The following information is displayed (Fig. 12):

i Note
Select the desired setting with the cursor keys and
change the values accordingly.
l Pre-Charge Side Plate Ropes = (8) pre-charging of
side plate ropes in percent of 100bar
Fig. 11
l Pot.Conveyor = (2003) potentiometer output value
The following information is displayed (Fig. 11): (22R1) for belt speed
l Clutch = (45) correction value for pressure sensor
i Note on clutch
Select the desired setting with the cursor keys and
change the values accordingly.
i Note
l Ki Ralp Lft = (0.20) input value for the sensibility of Press the QUIT key to return to the previous menu.
the height control via the rope sensor on the left
hand side
l
Kp Ralp Lft = (12.00) input value for the sensibility
of the height control via the rope sensor on the left
hand side

008 910 36 BOMAG 165

5.36 Digital inputs and outputs in the electric circuit diagram

5.36 Digital inputs and outputs in

the electric circuit diagram

Example (49C4)
l 49 = Pin 49 to control
l
C = CPU side
l 4 = control ID4
l I = I/O side.

i Note
24Y2 = Solenoid valve, grade shoe right (PWM - sig-
nal)) on page 24.

Fig. 13

166 BOMAG 008 910 36

Switching states, COMPACT (ID4) 5.37
5.37 Switching states, COMPACT l CAN-State: CAN-Bus connection status
(ID4) l DI´s = digital inputs on ID4
l DO´s = digital outputs on ID4
Switching states of the digital inputs and DI´s = digital inputs on ID4
outputs on the (ID4)

i Note
The switching states of the corresponding inputs or
outputs are shown as follows:
active = 1
inactive = 0

! Caution
Output signals to proportional valves (PWM-sig- Fig. 15
nals) are not shown at all, or appear falsified.
i Note
Press the QUIT key to return to the previous menu.

Fig. 14

i Note
Use the cursor keys to select the desired setting and
press ENTER to confirm.

Display Designation in Description Display status

circuit diagram
CAN- CAN-Bus connection status active
State
39C4 24S1 Limit switch, scraper shield open 0/1
40C4 D+ from generator 0/1
41C4 24S2 Limit switch, scraper shield lifted 0/1
42C4 not used
43C4 not used
44C4 24S5 Limit switch conveyor belt in working position 0/1
45C4 24S6 Differential pressure switch on air filter 0/1
46C4 24S7 Differential pressure switch in travel circuit 0/1
27C4 23S1 Differential pressure switch in hydraulic circuit for conveyor 0/1
belt
28C4 23S2 Hydraulic oil pressure switch in working hydraulics 0/1
09C4 22S1 Limit switch for engine hood OPEN/CLOSE 0/1
10C4 22S2 Limit switch for engine hood safety rod 0/1

008 910 36 BOMAG 167

5.37 Switching states, COMPACT (ID4)

Display Designation in Description Display status

circuit diagram
39I4 27S5 Cross-slope control switch 0/1
40I4 27S1 Coolant level switch 0/1
41I4 not used
42I4 27S2 Hydraulic oil level switch 0/1
43I4 not used
44I4 not used
45I4 not used
46I4 not used
27I4 not used
28I4 not used
09I4 not used
10I4 not used

DO´s = digital outputs on ID4

Fig. 16

i Note
Press the QUIT key to return to the previous menu.

Display Designation in Description Display status

circuit diagram
CAN- CAN-Bus connection status active
State
48C4 24Y1 Solenoid valve, grade shoe left (PWM-signal) cannot be shown
49C4 24Y2 Solenoid valve, grade shoe right (PWM-signal) cannot be shown
50C4 24S2 Warning light, grade shoe left 0/1
51C4 24H1 Warning light, grade shoe right 0/1
52C4 24H2 Warning buzzer 0/1
53C4 24H3 Signal lamp, conveyor belt ON 0/1
54C4 24Y4 Solenoid valve, conveyor belt forward (PWM-signal) cannot be shown
55C4 24Y4 Solenoid valve, conveyor belt reverse (PWM-signal) cannot be shown
48I4 23S1 Solenoid valve, conveyor belt up 0/1
49I4 27Y1 Solenoid valve, conveyor belt down 0/1
50I4 27Y2 Solenoid valve, conveyor belt to the left 0/1
51I4 27Y3 Solenoid valve, conveyor belt to the right 0/1
52I4 not used
53I4 27H1 Signal lamp, gathering belt foot in floating position 0/1
54I4 27Y7 Solenoid valve, gathering belt foot up 0/1
55I4 27Y8 Solenoid valve, gathering belt foot down 0/1

168 BOMAG 008 910 36

Switching states, COMPACT (ID5) 5.38
5.38 Switching states, COMPACT l CAN-State: CAN-Bus connection status
(ID5) l DI´s = digital inputs on ID5
l DO´s = digital outputs on ID5
Switching states of the digital inputs and DI´s = digital inputs on ID5
outputs on the (ID5)

i Note
The switching states of the corresponding inputs or
outputs are shown as follows:
active = 1
inactive = 0

! Caution
Output signals to proportional valves (PWM-sig- Fig. 18
nals) are not shown at all, or appear falsified.
i Note
Press the QUIT key to return to the previous menu.

Fig. 17

i Note
Use the cursor keys to select the desired setting and
press ENTER to confirm.

Display Designation in Description Display status

circuit diagram
CAN- CAN-Bus connection status active
State
39C5 30S1 Pressure switch for water sprinkling system 0/1
40C5 30S2 Limit switch, conveyor belt 90° folded 0/1
41C5 30S3 Limit switch, conveyor belt 180° folded 0/1
42C5 not used
43C5 not used
44C5 not used
45C5 not used
46C5 not used
27C5 not used
28C5 not used
09C5 RPM-signal from EMR (PWM-signal) cannot be shown
10C5 28S3 RPM-sensor, speed of travel motor cannot be shown

008 910 36 BOMAG 169

5.38 Switching states, COMPACT (ID5)

Display Designation in Description Display status

circuit diagram
39I5 not used
40I5 not used
41I5 not used
42I5 not used
43I5 not used
44I5 not used
45I5 not used
46I5 not used
27I5 not used
28I5 not used
09I5 not used
10I5 not used

DO´s = digital outputs on ID5

Fig. 19

i Note
Press the QUIT key to return to the previous menu.

Display Designation in Description Display status

circuit diagram
CAN- CAN-Bus connection status active
State
48C5 30Y1 Solenoid valve, travel drive forward (PWM-signal) cannot be shown
49C5 30Y2 Solenoid valve, travel drive reverse (PWM-signal) cannot be shown
50C5 30Y3 Solenoid valve working or transport speed 0/1
51C5 30Y4 Solenoid valve, differential lock 0/1
52C5 30Y5 Solenoid valve, travel system brake 0/1
53C5 30Y6 Solenoid valve for steering and working hydraulics 0/1
54C5 30Y7 Solenoid valve, clutch 0/1
55C5 30Y8 Solenoid valve, belt tensioner 0/1
48I5 33Y1 Solenoid valve, water sprinkling system 0/1
49I5 33Y6 Solenoid valve, water sprinkling pump 0/1
50I5 33Y2 Solenoid valve, conveyor belt open 90° 0/1
51I5 33Y3 Solenoid valve, conveyor belt open 180° 0/1
52I5 33H2 Signal lamp, load limit control 0/1
53I5 33HU1 Signal horn, backup alarm 0/1
54I5 33Y4 Solenoid valve, conveyor belt close 90° 0/1
55I5 33Y5 Solenoid valve, conveyor belt close 180° 0/1

170 BOMAG 008 910 36

Switching states, COMPACT (ID6) 5.39
5.39 Switching states, COMPACT l CAN-State: CAN-Bus connection status
(ID6) l DI´s = digital inputs on ID6
l DO´s = digital outputs on ID6
Switching states of the digital inputs and DI´s = digital inputs on ID6
outputs on the (ID6)

i Note
The switching states of the corresponding inputs or
outputs are shown as follows:
active = 1
inactive = 0

! Caution
Output signals to proportional valves (PWM-sig- Fig. 21
nals) are not shown at all, or appear falsified.
i Note
Press the QUIT key to return to the previous menu.

Fig. 20

i Note
Use the cursor keys to select the desired setting and
press ENTER to confirm.

Display Designation in Description Display status

circuit diagram
CAN- CAN-Bus connection status active
State
39C6 36S1 Proximity switch for height limitation on lift cylinder rear right 0/1
40C6 36S2 Proximity switch for height limitation on lift cylinder rear left 0/1
41C6 Levelling control panel connected 0/1
42C6 36S4 Proximity switch, rear steering to the right 0/1
43C6 36S5 Proximity switch, rear steering to the left 0/1
44C6 56S1 Switch on ultrasonic sensor 56V1 0/1
45C6 56S1 Switch on ultrasonic sensor 56V2 0/1
46C6 not used
27C6 not used
28C6 not used
09C6 not used
10C6 not used

008 910 36 BOMAG 171

5.39 Switching states, COMPACT (ID6)

Display Designation in Description Display status

circuit diagram
39I6 39S1 Proximity switch on lift cylinder front right 0/1
40I6 39S2 Proximity switch on lift cylinder front left 0/1
41I6 39S3 Proximity switch for steering limitation front to the right 0/1
42I6 39S4 Proximity switch for steering limitation front to the left 0/1
43I6 W39SX External switch for rear lift cylinder down 0/1
44I6 W39SX External switch for rear lift cylinder up 0/1
45I6 W39DX External switch for rear lift cylinder down 0/1
46I6 W39DX External switch for rear lift cylinder up 0/1
27I6 not used
28I6 not used
09I6 not used
10I6 not used

DO´s = digital outputs on ID6

Fig. 22

i Note
Press the QUIT key to return to the previous menu.

Display Designation in Description Display status

circuit diagram
CAN- CAN-Bus connection status active
State
48C6 36Y1 Solenoid valve, lift cylinder front left up (PWM-signal) cannot be shown
49C6 36Y1 Solenoid valve, lift cylinder front left down (PWM-signal) cannot be shown
50C6 36Y2 Solenoid valve, lift cylinder front right down (PWM-signal) cannot be shown
51C6 36Y2 Solenoid valve, lift cylinder front right up (PWM-signal) cannot be shown
52C6 36Y3 Solenoid valve, lift cylinder rear up 0/1
53C6 36Y4 Solenoid valve, lift cylinder rear down 0/1
54C6 36Y5 Solenoid valve, rear steering to the right 0/1
55C6 36Y6 Solenoid valve, rear steering to the left 0/1
48I6 39Y1 Solenoid valve, scraper up 0/1
49I6 39Y2 Solenoid valve, scraper down 0/1
50I6 39Y3 Solenoid valve, scraper floating position 0/1
51I6 39Y4 Solenoid valve, steering limitation to the right 0/1
52I6 39Y5 Solenoid valve, steering limitation to the left 0/1
53I6 not used
54I6 not used
55I6 not used

172 BOMAG 008 910 36

Switching states, CGC MATRIX 5.40
5.40 Switching states, CGC MA- l If the switch is closed, the pulse will pass through
and the display will show "1".
TRIX
l If the switch is open, no pulse will pass through and
the display will show "0".
Switching states of the digital inputs (Ma-
trix) on the dashboard

! Caution
The switching states on the CGC MATRIX are only
represented visually and cannot be measured
with a multimeter.

i Note
Function: Pulses are sent to the individual switches at
certain time intervals. Fig. 23

i Note
Press the QUIT key to return to the previous menu.

Display Designation in Description Display status

circuit diagram
QT09 10S1 Rotary button gathering foot up 0/1
QT10 10S1 Rotary button gathering foot floating position 0/1
QT11 10S6 Selector switch for milling drum off + grade shoe up 0/1
QT12 10S2 Rotary button for left hand grade shoe 0/1
QT13 10S3 Rotary button for right hand grade shoe 0/1
QT14 10S4+10S5 Control lever conveyor belt up 0/1
QT15 10S4+10S5 Control lever conveyor belt down 0/1
QT16 10S4+10S5 Control lever conveyor belt left 0/1
QT17 10S4+10S5 Control lever conveyor belt right 0/1
QT18 43S2 Rotary button conveyor belt open 0/1
QT19 43S2 Rotary button conveyor belt close 0/1
QT20 11S2 Rotary button conveyor belt forward 0/1
QT21 11S2 Rotary button, conveyor belt stop and reverse 0/1
QT22 11S3 Rotary button, water off 0/1
QT23 11S3 Rotary button, water on 0/1
QT24 12S1 Rotary button, scraper up 0/1
QT25 12S1 Rotary button scraper floating position 0/1
QT26 40S3 Rotary button, scraper close 0/1
QT27 40S3 Rotary button, scraper open 0/1
QT28 12S2 Selector switch, height regulation right Auto 0/1
QT29 12S2 Selector switch, height regulation left Auto 0/1
QT30 12S3 Selector lever, height regulation in automatic position 0/1
QT31 12S3 Selector lever, height regulation in manual position 0/1
QT32 12S3 Selector lever, height regulation in position for milling opera- 0/1
tion off + 4 lift cylinders up
QT33 12S3 Selector lever, height regulation in position 4 lift cylinders up 0/1
QT34 13S2 Rotary button, lift cylinder front left up 0/1
QT35 13S2 Rotary button, lift cylinder front left down 0/1
QT36 13S3 Rotary button, lift cylinder front right up 0/1
QT37 13S3 Rotary button, lift cylinder front right down 0/1
QT38 13S4 Rotary button, lift cylinder rear up 0/1
QT39 13S4 Rotary button, lift cylinder rear down 0/1
QT40 13S5+13S6 Control lever, rear steering to the right 0/1
QT41 13S5+13S6 Control lever, rear steering to the left 0/1
QT42 14S2+14S5 Selector switch, rear steering in automatic position 0/1
QT43 14S2+14S5 Selector switch, rear steering in manual position 0/1

008 910 36 BOMAG 173

5.40 Switching states, CGC MATRIX

Display Designation in Description Display status

circuit diagram
QT44 14S3+14S4 Rotary button milling drive + travel on (pause) 0/1
QT45 14S3+14S4 Rotary button milling drive + travel off (pause) 0/1
QT46 not used
QT47 not used
QT48 not used
QT49 15S1 Rotary button working hydraulics on 0/1
QT50 15S2 Rotary button milling drum on 0/1
QT51 15S2 Rotary button milling drum off 0/1
QT52 15S3 Rotary switch for transport speed 0/1
QT53 15S3 Rotary switch for working speed 0/1
QT54 15S4 Rotary switch, automatic load limit control with potentiometer 0/1
QT55 15S4 Rotary switch, manual load limit control 0/1
QT56 15S1 Switch, working hydraulics off 0/1
QT57 not used
QT58 not used
QT59 16S1 Micro-switch on travel lever forward 0/1
QT60 16S2 Micro-switch on travel lever reverse 0/1
QT61 16S3+16S4 Safety push button on travel lever 0/1
QT62 16S4 Selector switch, rear steering mode "crab-walk" 0/1
QT63 16S4 Selector switch, rear steering mode "asynchronous like front" 0/1
QT64 not used

174 BOMAG 008 910 36

Operating conditions for conveyor belt 5.41
5.41 Operating conditions for con-
veyor belt

Conveyor belt forward

Fig. 1

22R1 11S2 -2- 11S2 -1- 14S3 -1- 14S4 -1- 24S1 24S5 12S3 UP+ 24Y4
STOP
1 1 0 0 1 0 1 0 1
1 1 0 1 0 0 1 0 1
1 1 0 0 0 0 1 0 1

008 910 36 BOMAG 175

5.41 Operating conditions for conveyor belt

Conveyor belt reverse

Fig. 1

i Note
The button (11S2 -2-) must be held depressed for
longer than 7 seconds.

22R1 11S2 -2- 11S2 -1- 14S3 -1- 14S4 -1- 24S1 24S5 12S3 UP+ 24Y4
STOP
1 1 0 0 1 0 1 0 1
1 1 0 1 0 0 1 0 1
1 1 0 0 0 0 1 0 1

176 BOMAG 008 910 36

Operating conditions for gathering foot 5.42
5.42 Operating conditions for gath-
ering foot

Gathering foot in floating position

Fig. 1

15S1-2- 16S2 10S1-1- or 42S2-1- 10S1-2- or 42S2-2- 27Y8

or 43S3-1- or 43S3-2-
1 0 0 1 1

008 910 36 BOMAG 177

5.42 Operating conditions for gathering foot

Gathering foot up

Fig. 1

15S1-2- 10S1-1- or 42S2-1- or 10S1-2- or 42S2-2- or 27Y7

43S3-1- 43S3-2-
1 1 0 1

178 BOMAG 008 910 36

Operating conditions for grade shoes 5.43
5.43 Operating conditions for
grade shoes

Grade shoes right

Fig. 1

15S1-2- 10S3-1- or 24Y2

41S3-2-
1 1 1

Grade shoe left

Fig. 1

15S1-2- 10S3-1- or 24Y1

41S2-2-
1 1 1

008 910 36 BOMAG 179

5.44 Operating condition for milling rotor operation

5.44 Operating condition for mill-

ing rotor operation

Fig. 2

5S1 16S2 or 15S1-2- 15S2-2- 14S3 -1- 24S1 15S2-1- 15S1-1- 15S3-2- 30Y7
16S1 or
14S4 -1-
1 0 1 1 1 0 0 0 0 1

180 BOMAG 008 910 36

6 Engine

008 910 36 BOMAG 181

182 BOMAG 008 910 36
General information on diesel engine 6.1
6.1 General information on diesel l low exhaust emissions (EPA II)
engine l
and a high level of comfort
also speak in favour of this engine.
Road milling machines of series BM 2000/60 and BM
2000/ 50 are powered by a Deutz diesel engine of
product range BF8M 1015 C EMR.
The engine is an 8-cylinder V-type engine with water
cooling. The two rows of cylinders are arranged to
each other under an angle of 90°. Because of its well
known characteristics, such as
l high reliability
l long lifetime and
l low running costs,
this engine is particularly suitable for use in cold mill-
ing machines.
Further features, such as:
l compact design Fig. 1 Service access through large size engine hood
l low noise level

Fig. 2 Deutz diesel engine

008 910 36 BOMAG 183

6.1 General information on diesel engine

In the cylinders of a four-stroke engine one ignition holds two conrods, belonging to opposite cylinders.
and therefore one working cycle occurs every two rev- The ignition occurs alternately, every 360°.
olutions of the crankshaft (after 720°). The V-angle of 90° is ideal for 8-cylinder engines, on
On V-type engines two lines of cylinders are arranged 6-cylinder engines, however, it produces uneven firing
under a certain angle to each other. Each crank pin intervals and therefore erratic running of the engine.

Fig. 3 Deutz diesel engine

The cylinder heads are made of high quality grey cast
iron and assembled as single cylinder heads. The cyl-
inder heads are cross-flow cylinder heads with four
valves per cylinder and a centrally arranged injection
valve. In connection with the high pressure injection
system this results in an optimal combustion of the fu-
el. Valve guides and valve seat rings are replaceable.
To be able to meet the environmental requirements
also in the future, the engine is equipped with a low-
twist combustion system, in connection with the high
pressure injection system. An additional intercooler
ensures compliance with the exhaust emission stand-
ard EPA II.
The amply finned structure of the crankcase is an im-
portant contribution to a low noise level.
Water and oil channels are integrated in the crank-
case and in the front housing carrier. The oil cooler is
also part of the housing carrier.

184 BOMAG 008 910 36

Engine attachment parts 6.2
6.2 Engine attachment parts

Fig. 1 Starter side 13 Intake pipe, from turbo charger to intercooler

1 Exhaust turbo charger 14 Glow plug (left)
2 Exhaust manifold
3 Crankcase
4 Starter motor
5 Oil filler neck (at this location, not shown in this
drawing)
6 Oil sump
7 Lubrication oil filter
8 V-belt pulley with vibration damper
9 Coolant connection from heat exchanger to en-
gine
10 Lubrication oil cooler
11 Fan (not used)
12 Intake pipe, after intercooler

008 910 36 BOMAG 185

6.2 Engine attachment parts

Fig. 2 Generator side

15 Oil filler neck
16 Cylinder head
17 Generator
18 Oil dipstick
19 SAE-housing
20 Flywheel
21 Compressor, not used
22 Fuel supply line
23 Glow plug (left)
24 Compressor

186 BOMAG 008 910 36

Lubrication oil schematic 6.3
6.3 Lubrication oil schematic

Fig. 1 Lubrication oil schematic 20 Oil pressure sensor / oil pressure switch
1 Oil sump 21 Oil line to exhaust turbo charger
2 Suction line 22 Exhaust turbo charger
3 Lubrication oil pump 23 Oil line to compressor
4 Pressure relief valve 24 Compressor
5 Lubrication oil cooler 25 Hydraulic pump (not used)
6 Replaceable lubrication oil filter 26 Pressure retaining valve
7 Main oil channels 27 Return line from compressor to crankcase (not
8 Crankshaft bearings used)
9 Conrod bearings 28 Return line from exhaust turbo charger to crank-
10 Camshaft bearings case
11 Oil supply to injection pump
12 Injection pump
13 Return flow from injection pump to crankcase
14 Line to spray nozzle
15 Spray nozzle with pressure retaining valve for pis-
ton cooling
16 Plunger with rocker arm pulse lubrication
17 Push rod, oil supply for rocker arm lubrication
18 Rocker arm
19 Oil return bore in cylinder head leading to crank-
case

008 910 36 BOMAG 187

6.4 Electronic engine control EMR

6.4 Electronic engine control EMR possibly required spare control unit can be pro-
grammed with the actually required data set.

General The most important advantages of this system are:

l short response times in comparison to mechanically
The Deutz engines used in road milling machines of
governed engines, i.e. improved response times.
series BM 2000/60 and BM 2000/50 are equipped
This improvement is achieved without any increase
with an electronic rpm-control.
in acceleration fumes or in fuel consumption.
l electronic idle speed governor, leading to a higher
! Caution start-off torque
Sensors and electric actuators on control units l no mechanical throttle control (light moving, mainte-
must never be connected individually or between nance free, less susceptible for faults).
external power sources for the purpose of testing,
but only in connection with the EMR, as otherwise Limp Home
there may be a risk of destruction (damage)! The EMR offers extensive limp home functions, which
Even with an existing polarity reversal protection can be configured to match the application. The func-
incorrect polarity must be strictly avoided. Incor- tions are needed to be able to continue operation with
rect polarity can cause damage to control units! a substitute speed, if needed. In detail
Plug-in connectors on control units are only dust
l Specification of setpoint
and water tight if the mating connector is plugged l Charge air pressure
on! Control units must be protected against spray l Travel speed signal and/or
water, until the mating connector is finally l speed detected
plugged on!
can be activated. In case of a failure of the setpoint
Disconnecting the control unit plug connectors specification it is also possible to switch via CAN-Bus
with the control unit switched on, i.e. with the
power supply (terminal 15 "On"), is not permitted.
l over to substitute speed
Switch the voltage supply "off" first - then pull out . The respective fault type is logged in the fault log.
the plug.

Description of function
The engine mounted sensors supply the electronics in
the control unit with all relevant physical values. In ac-
cordance with the information concerning the actual
status of the engine and the specifications, the EMR
triggers an actuator which, in turn, operates the injec-
tion pump governor rod and thus doses the injected
fuel quantity, according to the power requirements.
The sensor for the governor rod travel, which is, to-
gether with the rotary magnet, located in a housing
(the "actuator"), reports the exact position of the gov-
ernor rod and corrects it, if this should be necessary.
The EMR is equipped with safety features in hardware
and software to ensure emergency functions.
To shut down the engine the EMR is deenergized via
the ignition switch. A sufficiently sized spring in the ac-
tuator presses the governor rod to zero position, when
the electric power is switched off. An additional mag-
net redundantly supports the shut-down process by
returning the governor rod to zero position in deener-
gized state, irrespective of the actuator.
After the programming, which is accomplished
through the ISO 9141 interface, the EMR receives an
engine specific data set and is thus firmly assigned to
the engine. It includes various applications, as well as
customer requirements, e.g. concerning a certain
scope of functions. This has the effect, that any future
changes must be reported to DEUTZ AG, so that a

188 BOMAG 008 910 36

Electronic engine control EMR 6.4
Installation location
F, vehicle plug
Installation loc ation and sys tem ov erview

The EMR control unit is located in the central electrics

M, engine plug
of the machine.

Fig. 1 Installation location, BM 2000/60

Fig. 2 Installation location, BM 2000/50

008 910 36 BOMAG 189

6.4 Electronic engine control EMR

SERDIA connection

Fig. 3 SERDIA connection, BM 2000/60

These connections are located inside the terminal box
and are bundled on the floor of the terminal box.
l
31 – 33 Connecting plugs for program transmission
from PC to control (this function is reserved for the
manufacturer or the central after sales service).
l
34 Diagnostics interface for connection of the diag-
nostics unit SERDIA. For this purpose the PC or
laptop is connected to the diagnostic interface by
means of an interface cable.

190 BOMAG 008 910 36

Electronic engine control EMR 6.4
System overview ed equipment is connected to the EMR control unit via
The EMR consists mainly of the sensors, the control separate wiring looms.
unit and the actuator. Engine, vehicle or system relat-

Fig. 4 System overview

1 Charge air pressure sensor (optional)
2 Actuator with governor rod travel sensor
3 Coolant temperature sensor
4 Cam shaft speed sensor (optional)
5 Crankshaft speed sensor
6 Shut-down magnet
7 Oil pressure sensor (optional)
8 Cold start aid (optional)
9 Fuel temperature sensor (optional)
10 Charge air temperature sensor (optional)
11 System and vehicle related equipment
12 Engine related equipment
13 EMR control unit

008 910 36 BOMAG 191

6.4 Electronic engine control EMR

Actuator control unit. At the same time the actual position of the
The actuator is directly connected with the injection actuator is fed back to the EMR control unit. The com-
pump governor rod and moves this rod due to the ex- ponent is basically a proportional solenoid with inte-
citement caused by the signal flows from the EMR grated travel measuring system.

Fig. 5 Actuator

Actuator monitoring
l
In case of a fault in the travel measuring system the
engine is shut down and the fault lamp flashes.

i Note
The fault lamp is not available as standard.

192 BOMAG 008 910 36

Electronic engine control EMR 6.4
Coolant temperature sensor ature has an effect on the injection quantity calculated
The coolant temperature sensor is located on the fan by the EMR.
side in the V-room of the engine. The coolant temper-

Fig. 6 Coolant temperature sensor

Coolant temperature monitoring

The operator is warned by the fault lamp, if
l the temperature exceeds the warning limit and/or
l
the power is reduced by the EMR after a pre-warn-
ing time, or
l
the temperature exceeds the shut-down limit and
the engine is shut down after a pre-warning time.

Fig. 7 Fault lamps in the display

i Note
In case of a sensor failure the engine will keep on run-
ning, the fault lamp 8 (Fig. 7)lights.
The coolant temperature (4) is also indicated in the
display.
The fault appears in the display (2) (Fig. 8)

008 910 36 BOMAG 193

6.4 Electronic engine control EMR

Fig. 8 Fault message in the display

i Note
In case of a fault the corresponding symbol will be dis-
played on screen. The bell symbol accompanies the
warning buzzer. Press the ENTER-key to switch off
the warning buzzer.

194 BOMAG 008 910 36

Electronic engine control EMR 6.4
Speed sensor for crankshaft speed
The crankshaft speed sensor is mounted to the SAE-
housing.

Fig. 9 Speed sensor on SAE-housing

Speed sensor monitoring

l In case of a too high engine speed the governor rod
is returned to zero position, until the speed has
reached the permissible range. The fault lamp lights
during this process.

i Note
In case of a sensor failure the engine is shut down, the
fault lamp flashes.

i Note
The fault lamp is not available as standard. Fig. 10 (2) engine speed in display

008 910 36 BOMAG 195

6.4 Electronic engine control EMR

Oil pressure sensor

The engine oil pressure sensor is located between the
front left hand cylinder and the control housing.

Fig. 11 Oil pressure sensor

Oil pressure monitoring

The operator is warned by the fault lamp, if
l the oil pressure falls short of the warning limit and/or
l the power is reduced by the EMR after a pre-warn-
ing time, or
l
the oil pressure falls short of the shut-down limit and
the engine is shut down after a pre-warning time.

Fig. 12 Fault lamps in the display

i Note
With a defective sensor the engine will keep on run-
ning, the fault lamps 8 and 17 (Fig. 12) light.
The oil pressure is also indicated in the display (3).
The fault appears in the display (1) (Fig. 13)

196 BOMAG 008 910 36

Electronic engine control EMR 6.4

Fig. 13 Fault message in the display

i Note
In case of a fault the corresponding symbol will be dis-
played on screen. The bell symbol accompanies the
warning buzzer. Press the ENTER-key to switch off
the warning buzzer.

008 910 36 BOMAG 197

6.4 Electronic engine control EMR

Charge air pressure sensor gine. The charge air pressure informs the EMR about
The sensor measures the pressure inside the intake the current load state of the engine. Under a high load
tube of the left hand cylinder bank (in direction of trav- a higher injection quantity is required to reach the
el). The sensor itself is located in the V-room of the en- speed determined by the throttle pedal position.

Fig. 14 Charge air pressure sensor

Charge air pressure monitoring

i Note
With a faulty sensor the engine continues to run with
a charge pressure simulation, the fault lamp lights.

i Note
The fault lamp is not available as standard.

198 BOMAG 008 910 36

Electronic engine control EMR 6.4
Combined charge air pressure / temperature sen- justs the injection quantity accordingly On the other
sor hand the EMR now detects the temperature of the
This sensor unites two function in one housing. On the passing air flow. This is used for smoke reduction.
one hand it detects the charge air pressure and ad-

Fig. 15 Combined charge air pressure / temperature sensor

Charge air pressure monitoring

i Note
With a faulty sensor the engine continues to run with
a charge pressure simulation, the fault lamp lights.

Charge air temperature monitoring

The operator is warned by the fault lamp, if
l the temperature exceeds the warning limit and/or
l the power is reduced by the EMR 2 after a pre-
warning time, or
l
the temperature exceeds the shut-down limit and
the engine is shut down after a pre-warning time.

i Note
In case of a temperature sensor failure the fault lamp
also light up and the engine keeps on running.

i Note
The fault lamp is not available as standard.

008 910 36 BOMAG 199

6.4 Electronic engine control EMR

Fuel temperature sensor fuel. Due to the detection of the fuel temperature this
The fuel temperature sensor is mounted to the injec- can be compensated by adding an extra amount of fu-
tion pump and detects the temperature in the fuel sup- el. This assures full engine power, even with warm fu-
ply. Fuel expands with increasing temperature and the el.
amount of fuel per volume unit is less than with cold

Fig. 16 Fuel temperature sensor

Fuel temperature monitoring

l
If the fuel is too hot,the fault lamp will light up as a
warning and a corresponding fault is logged.

i Note
In case of a sensor failure the fault lamp will light, but
the engine will keep on running.

i Note
The fault lamp is not available as standard.

200 BOMAG 008 910 36

Electronic engine control EMR 6.4
Diagnose
Replacement of system component
Diagnose

Fault lamp The individual system components like sensor, control

unit, actuator etc. can only be replaced, but not re-
i Note paired.
The fault lamp is not available as standard.
Replacement of control unit
The fault lamps enables a rough assessment of the
fault; meaning: Each control unit is firmly assigned to the engine (en-
gine serial number), according to its application. For
l
Lamp 2 s on: Self diagnose when switching the
replacement the control unit must therefore be com-
power supply on. Result: no fault is present.
pleted with
l Permanent light: There is a fault message present,
however, the system is still operable (possibly limit-
l a) its engine specific data set and
ed). l b) with a label [engine serial number ...]
l
Flashing: Severe fault - the engine is shut down, or .
cannot be started.
Programming with an engine specific data set is only
l Flashing code: Request results concerning the lo- possible with SERDIA (Level III and IIIa) and can be
cation of fault via the diagnostics button. performed in two different ways:
Diagnostics interface l When ordering a new control unit by stating the en-
The band end programming of the EMR takes place gine serial number and the part number.
via the serial diagnostics interface (acc. to ISO 9141). l Transfer of the data set 1 : 1 from the "old" control
Measuring values, fault messages and other parame- unit to the "new" control unit.
ters can be displayed and adjusted with the help of a
PC connected via an interface and the diagnostics Replacement of actuators
software SERDIA - depending on the access rights.
New control units can additionally be programmed. Series 1012/1013/2012/2013
Communication is only possible with the voltage sup- The actuators are fully exchangeable without addition-
ply switched on. al programming of the control unit.

CAN-Bus - interface Series 1015

The CAN-Bus interface (Controller-Area-Network) is Actuator (EDC actuator) and Bosch pump are
more and more used in vehicles and is most suitable matched (one TN). In case of a replacement the new
for the exchange of measuring values and data be- actuator (together with the pump) must be calibrated
tween one or several control units (hydraulics/trans- with the control unit. This calibration is necessary
mission control, etc.). Communication is based on the (with SERDIA Level IIIa), because the new character-
SAE J1939 protocol. istic curves must be stored in the control unit.

Plug assignment
The 25-pin plugs of the EMR control unit are mechan-
i Note

ically coded (different part numbers). Due to the vari- TN on control unit: Unprogrammed control unit (charg-
ety of pins the vehicle plugs (F) or system plug and the er). The engine cannot be started. The control unit
motor plug (M) only match the specific sockets, so that needs to be programmed.
mixing up by mistake is ruled out. TN in SERPIC: Programmed and completed control
unit (with engine serial number on label).

008 910 36 BOMAG 201

6.5 Sensor data EMR

6.5 Sensor data EMR

Sensors
Temperature sensor (NTC), coolant
l Pins:Signal Pin 9, GND Pin 8, engine plug
l
Measuring range: -40°C to 130°C

Fuel temperature sensor (NTC)

l Pins:Signal Pin 5, GND Pin 8, engine plug
l
Measuring range: -40°C to 130°C

Charge air temperature sensor (NTC)

l Pins:Signal Pin 4, GND Pin 8, engine plug
l Measuring range: -40°C to 130°C

Coolant level sensor

l Pins:Signal Pin 6, GND Pin 8, engine plug

Atmospheric pressure sensor

l
Depending on equipment configuration integrated
in control unit

Oil pressure sensor

l
Pins:Signal Pin 21, GND Pin 20, reference voltage
+5V Pin 22, engine plug
l
Measuring range: 0 to 10 bar
l
Output signal: 0.5 to 4.5 V DC

Charge air pressure sensor

l
Pins:Signal Pin 24, GND Pin 23, reference voltage
+5V Pin 25, engine plug
l
Measuring range: 0 to 4 bar
l Output signal: 0.5 to 4.5 V DC

Speed sensor
l
Measuring range: 30 to 4500 rpm

1. Rotary speed (optional)

l
Location: Camshaft, timing gear cover
l Pins: Signal Pin 13, GND Pin 12, engine plug
l 167 pulses/ camshaft revolution for series 1015
l 48 pulses/ camshaft revolution for series 1013/2013
l 44 pulses/ camshaft revolution for series 1012/2012

2. Rated speed
l Location: SAE-housing, crankshaft
l Pins: Signal Pin 11, GND Pin 10, engine plug
l
129 pulses/ crankshaft revolution for series 1012/
1013
l Terminal W (generator pulses)

202 BOMAG 008 910 36

Plug assignment EMR 6.6
6.6 Plug assignment EMR

Plug assignment (M) engine plug

Fig. 1 Plug assignment (M) engine plug

Pin - No. Designation Description

1 Spare Spare
2 Output: Digital 3 Digital output for engine solenoid, for permanent current <
4A
3 Output: Digital PWM 3 for heating flange (optional) / glow plug (optional)
4 Input (optional) Fuel temperature (optional)
5 Input (optional) Charge air temperature
6 Input (optional) Coolant level / oil level
7 Input (optional) output: Digital
7
8 GND Reference potential for analog signal on Pin 9
9 Input: Analog 3 Analog input for coolant temperature sensor (NTC)
10 GND Reference potential for analog signal on Pin 11
11 Multi-function input rotary Digital input of second engine speed (crankshaft) (option-
speed 2 al) and speed signal (optional)
12 GND Reference potential for analog signal on Pin 13
13 Input: Rotary speed 1 Digital input first engine speed (camshaft)
14 STG - PWM - output, signal for actuator coil)
15 STG + PWM - output, signal for actuator coil)
16 Screen Screening of governor rod travel sensor (for lines 17, 18
and 19)
17 RF - common connection for reference & measuring coil
18 RF REF Analog input, measuring signal for reference coil
19 RF MESS Analog input, measuring signal from measuring coil
20 GND Reference potential for analog signal on Pin 21
21 Input: Analog 4 / Digital 9 Analog input 4 (sensor signal oil pressure sensor) or digital
input 9
22 + 5 V REF + 5 Volt reference voltage for signal on Pin 21 (max. 15
mA)
23 GND Reference potential for analog signal on Pin 24
24 Input: Analog 2 / Digital 7 Analog input 2 (sensor signal charge air pressure) or digit-
al input 7
25 + 5 V LDA + 5 Volt reference voltage for signal on Pin 24 (max. 15
mA)

008 910 36 BOMAG 203

6.6 Plug assignment EMR

Plug assignment (F) vehicle plug

Fig. 1 Plug assignment (F) vehicle plug

Pin - No. Designation Description

1 U Batt Negative battery pole (terminal 31)
2 GND Reference potential for signals
3 Output: Digital / PWM 2 not used
4 Input / output: Digital 1 not used
5 Output: Digital / PWM 1 not used
6 Multi-function input not used
7 Input: Digital 10 not used
8 not used not used
9 not used not used
10 L- line Serial ISO 9141 interface
11 K - line Serial ISO 9141 interface
12 CAN high CAN-Bus - interface
13 CAN low CAN-Bus - interface
14 U Batt + 24 Volt power supply
15 Output: Digital 2 not used
16 Output: Digital / PWM / fre- PWM signal RMP
quency
17 Ground Relay contact 47K1
18 Input: Digital 1 / PWM 1 Relay contact 47K1, digital input
19 Multi-function input not used
20 Multi-function input: Digital 8 / not used
Analog 3
21 Input: Digital 2 / PWM 2 not used
22 Screen Screening for lines on Pin 1, 2 and 14
23 GND Potentiometer engine speed, reference potential for ana-
log signal on Pin 24
24 Input: Analog 1 / Digital 6 Potentiometer engine speed, analog input 1
25 + 5 V REF Potentiometer engine speed, + 5 Volt reference voltage for
signal on Pin 24 (max. 15 mA)

204 BOMAG 008 910 36

Connection diagram EMR engine control 6.7
6.7 Connection diagram EMR en-
gine control

008 910 36 BOMAG 205

6.7 Connection diagram EMR engine control

206 BOMAG 008 910 36

Engine 6.8
6.8 Engine

Faults Possible cause Remedy

The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank

Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.

Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.

Fuel lines leaking Check all line connections for leakages

and tighten the fittings.

Battery discharged or not connected Tighten the pole clamps, check the cable
connections

Injection valves or injection pump defec- Have examined by a specialist

tive

The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature

Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Injection lines leaking Check the lines for leakages

Turbo charger defective Have examined by a specialist

Dry air filter dirty clean, replace if necessary

Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary

Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance

Incorrect valve clearance Adjust the valve clearance

008 910 36 BOMAG 207

6.8 Engine

Faults Possible cause Remedy

Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Injection valve defective Have examined by a specialist

Engine oil level too low Top up engine oil to the upper dipstick
mark

Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted

Cooling air flow restricted Clean the cooling air duct

V-belt loos or broken Tension or replace the V-belt

Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark

Dry air filter dirty clean, change if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Charge air hose leaking Check fastening and connections

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)

Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.

The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective

208 BOMAG 008 910 36

Fault lamp 6.9
6.9 Fault lamp l Flashing: Severe fault - the engine is shut down, or
cannot be started.
l
Flashing code: Request results concerning the lo-
i Note cation of fault via the diagnostics button.
The fault lamp is not available as standard.
The fault lamps enables a rough assessment of the
fault.
EMR comes with a vast variety of protective functions
for the engine - depending on the available measuring
locations or sensors. Depending on the significance of
the detected fault the engine may keep on running,
however, with limitations (limp home), whereby the
fault lamp will continually light, or the engine will be
shut down and the fault lamp will flash.
A lighting fault lamp indicates a wiring fault (short cir-
cuit, cable breakage) or a defect on displays or the
corresponding sensors. Exceeding or falling short of
measuring value limits is another fault source.
Faults in the electronics are recorded / saved in the
control unit and indicated by the fault lamp. Once the
fault is eliminated the fault lamp will go out. The en-
gine must only be shut down with the ignition switch
for a moment to switch off the fault lamp, after the
electronics has been switched over to limp-home
(speed).
Even corrected or historic faults remain logged in the
control unit and can be read out or erased with the di-
agnostics software SERDIA.

Fig. 1 Fault lamp

l Lamp 2 s on: Self diagnose when switching the
power supply on. Result: no fault is present.
l Permanent light: There is a fault message present,
however, the system is still operable (possibly limit-
ed).

008 910 36 BOMAG 209

6.10 Diagnostics button

6.10 Diagnostics button 2 Diagnostics button

Reading out a current fault log - flashing code

i Note The fault lamp indicates an existing fault, i.e it flashes
Fault lamp 1(Fig. 1) and diagnostics button (2) are not or shows permanent light. The diagnostics button is
included in the standard scope of delivery. pressed for a period of 1 to 3 seconds. The EMR rec-
ognizes the read request and starts to display the er-
The diagnostics button provides the possibility to read rors. Reading out a fault code is only possible after the
out the existing faults in form of flashing codes and to fault lamp has gone out, or after the initialization
delete the fault log (one). phase of the operating program. This means that the
fault lamp may show permanent light after switching
on, if a fault has been detected after the initialization.
The EMR only emits active faults in form of a flashing
code.

Fig. 1 Pictogram: Diagnostics button and fault lamp

1 Fault lamp

Fig. 2 Diagnose with the diagnostics button The following describes the steps to read out the
l A = Off first fault flashing code:
l E = On (1) The fault lamp (F) indicates an existing fault, i.e
l D = Diagnostics button it flashes or shows permanent light.
l F = Fault lamp l
Press diagnostics button (D) 1 for 3 s: The flashing
l t = Time in seconds or permanent light of the fault lamp (F) goes out.

(2) After 2 s:
Detection of the EMR (2x short flashing).

210 BOMAG 008 910 36

Diagnostics button 6.10
l Output of the flashing sequence of the first logged l The next flashing code is emitted (3), (4).
fault. (3) After 2 s: 1xlong). l
After output of fault code: (5) 5 s pause, then display
(4) After 2 s: 1xshort). by flashing and permanent light.
l
After output of fault code: (5) 5 s pause, then display
by flashing and permanent light.
i Note
Steps for reading out the next fault code: These steps can be repeated until the last logged fault
code has been emitted. After this the system will re-
(1) The fault lamp (F) indicates an existing fault, i.e turn to the initially displayed fault.
it flashes or shows permanent light.
l Press diagnostics button (D) 1 for 3 s: The flashing Deleting fault log 1
or permanent light of the fault lamp (F) goes out. The EMR 2 has two fault logs (1 and 2). Each fault is
simultaneously saved in both logs. The diagnostics
(2) After 2 s:
button enables you to delete passive faults from fault
Detection of the EMR (2x short flashing). log 1. Fault log 2 can only be cleared with SERDIA.

Fig. 3 Deleting fault log 1 4 All passive faults in fault log 1 will be deleted.
l
A = Off 5 The deleting process is confirmed by three short
l E = On flashing pulses.
l
D = Diagnostics button
l F = Fault lamp
l
S = Ignition switch
l t = Time in seconds

The following describes the steps for clearing

fault log 1:
1 Press and hold the diagnostics button.
2 Switch on the ignition.
3 Release the diagnostics button, while the fault
lamp lights (duration 2 s).

008 910 36 BOMAG 211

6.11 Overview of fault flashing codes

6.11 Overview of fault flashing

codes

Fault Fault Location / Flashing Cause Remark Remedy

group No. in description code
SERDIA of fault

short 0.4 s

short 0.4 s
long 0.8 s
- No fault 2 - - No active fault present.
Zero fault display

01 Rotary speed 2 1 1 Sensor failed. Regulator in limp- Check distance.

sensor 1 Distance to gear home mode (if Check cable connec-
too big. Addition- sensor 2 is tion. Check sensor
al missing puls- present). Emer- and replace if neces-
es. Cable gency shut-down sary.
connection inter- (if sensor 2 not
rupted. present or has
failed).
02 Rotary speed 2 1 2 Regulator in limp-
sensor 2 home mode (with
sensor 1). Emer-
gency shut-down
(if sensor 1 not
present or has
failed).
03 Speed sen- 2 1 3 Speedometer Regulator in limp- Check wiring and
sor failed. Additional home mode. speedometer, re-
missing pulses. place if necessary.
Rotary speed / speed detection

Cable connec-
tion interrupted.
04 Overspeed 2 1 4 Rotary speed Engine shut-down Check parameter
shut-down was/is above (21). Check rotary
overspeed limit speed setting.
Check PID-setting. Check the link-
age Check the actuator, replace if
necessary. Check the cable to the
actuator. Check rotary speed sensor
(pulses for incorrect speed). Check
number of teeth. On vehicle check
for possible thrust operation.

212 BOMAG 008 910 36

Overview of fault flashing codes 6.11
Fault Fault Location / Flashing Cause Remark Remedy
group No. in description code
SERDIA of fault

short 0.4 s

short 0.4 s
long 0.8 s
05 Setpoint 2 2 1 Fault on corre- In case of a sen- Check the sensor ca-
transmitter 1 sponding sensor sor failure the re- ble. Check sensor
06 Setpoint 2 2 2 input (e.g. short lated monitoring and replace if neces-
transmitter 2 circuit or cable function is deacti- sary. Check fault lim-
07 Charge air 2 2 3 breakage). vated. its for the sensor.
pressure
08 Oil pressure 2 2 4
09 Coolant tem- 2 2 5
perature
10 Charge air 2 2 6
Sensors

temperature
11 Fuel temper- 2 2 7
ature

008 910 36 BOMAG 213

6.11 Overview of fault flashing codes

Fault Fault Location / Flashing Cause Remark Remedy

group No. in description code
SERDIA of fault

short 0.4 s

short 0.4 s
long 0.8 s
30 Oil pressure 2 3 1 Oil pressure be- Fault message Check engine (oil lev-
warning low engine (disappears, when el, oil pump). Check
speed depend- the oil pressure is oil pressure sensor
ent warning above the recov- and cable. Check the
characteristic. ery limit). After ex- oil pressure warning
piration of a characteristic.
certain delay time
- filling limitation.
31 Coolant tem- 2 3 2 Coolant temper- Fault message Check coolant.
perature ature exceeded (disappears when Check coolant tem-
warning warning level. coolant tempera- perature sensor and
ture has dropped cable.
below recovery
limit). After expira-
tion of a certain
delay time - filling
limitation.
32 Charge air 2 3 3 Charge air tem- Fault message Check charge air.
temperature perature ex- (disappears, when Check oil pressure
warning ceeded warning the charge air sensor and cable.
level. temperature has
dropped below the
recovery limit). Af-
ter expiration of a
certain delay time
- filling limitation.
34 Coolant level 2 3 5 Switch input Fault message. Check coolant level.
warning "coolant level Check coolant level
too low" is ac- sensor and cable.
tive.
35 Rotary speed 2 3 6 Rotary speed Overrevving pro- Check parameter
warning (in was/is above tection (21). Check rotary
thrust opera- overspeed limit speed setting.
tion) Function "thrust
operation" is ac-
tive.
Check PID-setting. Check the link-
age Check the actuator, replace if
necessary. Check the cable to the
actuator. Check rotary speed sensor
(pulses for incorrect speed). Check
number of teeth. On vehicle check
for possible thrust operation.
Functional faults

36 Fuel temper- 2 3 7 Fuel tempera- Fault message Check fuel. Check

ature warn- ture exceeded (disappears, when fuel temperature sen-
ing warning level. the fuel tempera- sor and cable.
ture has dropped
below the recov-
ery limit).

214 BOMAG 008 910 36

Overview of fault flashing codes 6.11
Fault Fault Location / Flashing Cause Remark Remedy
group No. in description code
SERDIA of fault

short 0.4 s

short 0.4 s
long 0.8 s
40 Oil pressure 2 3 1 Oil pressure be- Emergency shut- Check engine (oil lev-
shut-down low shut-down down el, oil pump). Check
limit oil pressure sensor
and cable. Check oil
pressure shut-down
limit.
41 Coolant tem- 2 3 2 Coolant temper- Check coolant.
perature ature exceeded Check coolant tem-
shut-down shut-down limit. perature sensor and
Functional fault, shut-down

cable. Check shut-

down limit.
42 Charge air 2 3 3 Charge air tem- Check charge air.
temperature perature ex- Check oil pressure
shut-down ceeded shut- sensor and cable.
down limit. Check shut-down lim-
it.
44 Coolant level 2 3 5 Switch input Emergency shut- Check coolant level.
shut-down "coolant level down Starting Check coolant level
too low" is ac- lock. sensor and cable.
tive.

008 910 36 BOMAG 215

6.11 Overview of fault flashing codes

Fault Fault Location / Flashing Cause Remark Remedy

group No. in description code
SERDIA of fault

short 0.4 s

short 0.4 s
long 0.8 s
50 Recirculation 2 5 1 Actuator not Emergency shut- Check actuator and
connected. Fault down Regulator replace if necessary.
in actuator feed- cannot be started. Check cable. Check
back. fault limits for the
"feedback".
52 Feedback Check actuator and
reference replace if necessary.
Check cable. Check
fault limits for the "ref-
erence feedback".
53 Difference Injection pump / Fault message Check actuator /actu-
control travel actuator jammed (disappears, if the ator linkage / injection
or not connect- different is < 10 pump, replace if nec-
ed. Difference %). essary. Check actua-
between nomi- tor cable.
nal/actual con-
trol travel > 10 %
of total control
travel.
59 Auto calibra- 2 5 2 Automatic actu- Engine shut-down Check actuator and
tion BOSCH- ator adjustment / starting lock. replace if necessary.
EDC pumps not possible. In- Regulator cannot Check feedback ca-
has failed correct input of be started. EDC- ble. Check voltage
actuator refer- actuator calibra- supply / cable. Check
ence values. tion required. fault limits and refer-
ence values of feed-
back. Program fault
limits for feedback,
save values, switch
ignition off and on
again. Check again.
In case of failure in-
form the DEUTZ
Service and perform
Hardware inputs / outputs Actuator

another automatic
adjustment. Reset
the fault limits.
60 Digital output 2 6 1 Fault (short cir- Driver stage Check cable of digital
3, Pin M2 cuit / cable switched off. output (cable break-
62 Digital output 2 6 2 breakage) on Fault message. age or short circuit).
6, Pin M7 digital output
63 Overcurrent 2 6 1
shut-off sole-
noid
67 Error Hand 2 6 2
Setp1
68 Error CAN
Sept1

216 BOMAG 008 910 36

Overview of fault flashing codes 6.11
Fault Fault Location / Flashing Cause Remark Remedy
group No. in description code
SERDIA of fault

short 0.4 s

short 0.4 s
long 0.8 s
70 CAN Bus 2 7 1 CAN-Controller Application de- Check CAN-connec-
Controller for CAN-Bus de- pendent tion, terminating re-
livers error. No sistor, check control
permanent fault unit.
rectification pos-
sible, despite
Communication

reinitialization.
71 CAN inter- Overflow in re-
face SAE J ceiving buffer or
1939 a delivery can-
not be applied to
the bus.

008 910 36 BOMAG 217

6.11 Overview of fault flashing codes

Fault Fault Location / Flashing Cause Remark Remedy

group No. in description code
SERDIA of fault

short 0.4 s

short 0.4 s
long 0.8 s
76 Parameter 2 8 1 Error in parame- Emergency shut- Switch the ignition off
program- ter programming down The engine and on again. Check
ming (writing in the read-only cannot be started. again. In case of a
to EEPROM) memory (ROM) fault inform the
of the regulator DEUTZ Service.
77 Cyclic pro- Continuous
gram test monitoring of the
program memo-
ry reveals errors
(so-called
"Flash-Test").
78 Cyclic RAM Continuous Write down the pa-
test monitoring of the rameter values (3895
random access and 3896). Switch the
memory (RAM) ignition off and on
reveals errors. again. Check again.
Memory

In case of a fault in-

form the DEUTZ
Service.
80 Power supply 2 9 1 Power supply for Fault message Switch the ignition off
(actuator) governor not (disappears when and on again. Check
within the per- current is back in again. In case of a
missible range. normal range). fault inform the
DEUTZ Service.
83 Reference 2 8 2 Reference volt- Fault message Check voltage sup-
voltage 1 age for governor (disappears when ply. Switch the igni-
84 Reference not within the voltage is back in tion off and on again.
voltage 2 permissible normal range). Check again. In case
85 Reference range. Substitute value 5 of a fault inform the
voltage 4 V DEUTZ Service.
86 Internal tem- 2 9 2 Internal temper- Fault message Switch the ignition off
perature ature for control (disappears when and on again. Check
unit not in per- temperature is again. In case of a
missible range. back in normal fault inform the
range). DEUTZ Service.
Control unit hardware

87 Atmospheric Atmospheric Fault message

pressure pressure not in (disappears when
permissible pressure is back
range. in normal range).
Atmospheric pres-
sure monitoring
function deactivat-
ed.

218 BOMAG 008 910 36

Overview of fault flashing codes 6.11
Fault Fault Location / Flashing Cause Remark Remedy
group No. in description code
SERDIA of fault

short 0.4 s

short 0.4 s
long 0.8 s
90 Parameter 2 10 1 No data found or The engine can- Check data for cor-
fault (read checksum for not be started. rect setting. Save the
EEPROM or data incorrect. parameters, switch
checksum er- (Note: Fault oc- the ignition off and on
ror) curs only when again. Check again.
setting / saving In case of a fault in-
or reset parame- form the DEUTZ
ters) Service.
93 Stack over- Internal comput- Emergency shut- Write down the pa-
flow ing error (so- down The engine rameter values (3897
called "Stack - cannot be started. and 3898). Switch the
Overflow" error). ignition off and on
Program logic

again. Check again.

In case of a fault in-
form the DEUTZ
Service.
94 Internal fault

008 910 36 BOMAG 219

6.12 Possible diagnostics with the SERIDA software

6.12 Possible diagnostics with the

SERIDA software
SERDIA (Service Diagnose) is a software program
enabling the user to monitor the measuring values
with the engine running and thus detect faulty engine
operation using a PC or Notebook
l
With the engine shut down certain parameters can
be specifically entered into the control unit from a
PC (parameterization), in order to change the oper-
ating behaviour of the engine.
l The diagnostic software SERDIA can be used to
read out or evaluate the error messages logged in
the control unit.
This procedure displays information like:
l Location of fault (e.g. "engine speed potentiome-
ter", "coolant temperature sensor").
l Type of fault (e.g. "bottom limit value fallen short of",
"sporadic fault").
l
Environmental data/operating data (speed and op-
erating hours at the time of the last occurrence of
the fault).
l Number of fault locations.
l Frequency of fault.
l Fault status (active - fault present / passive - fault no
longer present).
Fault messages for faults that are no longer active or
have been rectified can be deleted with SERDIA.

Function test
In the function test the outputs and the governor rod
travel can be activated with the engine shut down.

Assignment of input / output

Display of the current input and output assignment

Representation of measuring values

There is a vast variety of measuring values available
for selection which can even be used if no EMR-fault
is present (start behaviour, engine sawing, lack of
power).
For this purpose the PC is connected to the diagnostic
interface by means of an interface cable. Communica-
tion with the control unit takes place via a special
EMR-protocol.
Work with SERDIA is described in separate operating
instructions.

220 BOMAG 008 910 36

Checking the engine speed 6.13
6.13 Checking the engine speed

Fig. 1 Diesel engine, transfer case connection

Special tool: RPM-meter, optically/mechanically

BOMAG part-no.: 079 948 98

l Rated speed, see technical data.

Fig. 2 Engine rpm reading (2) in display

008 910 36 BOMAG 221

6.14 Disassembling and assembling the injection valves

6.14 Disassembling and assem- Assembly

bling the injection valves

Disassembly

i Note
When working on the injection system ensure strict
cleanliness.

Fig. 3
l
Install a new seal ring. Apply some assembly paste
Deutz S1 to cap screw and seal ring (Fig. 3).

Fig. 1
l Remove valve cover, injection line and leak fuel re-
turn line (Fig. 1).
l Remove the cap screw for the injection valve.

Fig. 4
l Insert the injection valve (Fig. 4).

Fig. 2
l If the injection valve sits too tight use a knocking tool
(Fig. 2).

i Note
Fig. 5
Make sure to remove the seal ring as well.
l
Tighten the cap nut with 60 - 80 Nm (Fig. 5).

222 BOMAG 008 910 36

Disassembling and assembling the injection valves 6.14

Fig. 6 Fig. 9
l Hold the leak fuel return line with the special pliers, l Assemble the valve cover with a new gasket. Tight-
so that approx. 15 mm protrude. Plug the leak fuel en the screws (Fig. 9).
line on to the injection valve (Fig. 6). l
Tightening torque: 22 Nm
l
Run the engine warm and check for leaks.

Fig. 7
l
Guide leak fuel line and injection line through the
sealing rubber (Fig. 7).

Fig. 8
l Reconnect the injection line without any tension and
tighten it with the claw spanner (Fig. 8).
l
Tightening torque 30 Nm.

i Note
Fasten the lines properly with clamps.

008 910 36 BOMAG 223

6.15 Checking and adjusting the start of commencement

6.15 Checking and adjusting the Exhaust valves not yet closed.
start of commencement Intake valves start to open.

Disassembly

i Note
When working on the injection system ensure strict
cleanliness.

Fig. 4

i Note
Cylinder B3 must be in overlapping position.
l The locking pin of the cranking device must be en-
gaged in the starter ring gear (Fig. 4).
Fig. 1
l Remove the cover (Fig. 1) from the timing gear
housing.

Fig. 5
l Set the vernier to ”0” (Fig. 5).

Fig. 2
! Caution
l
Install the cranking device and crank the engine
The setting of the vernier must not be changed.
with the cranking device (Fig. 2) until ignition TDC is
reached.
i Note
For the adjustment of the commencement start use an
centre distance of 269.2 mm (black scale).

Fig. 3

i Note
Overlapping of valves means (Fig. 3):

224 BOMAG 008 910 36

Checking and adjusting the start of commencement 6.15
Checking the start of commencement

Fig. 9

Fig. 6
i Note
l Remove the cover (Fig. 6).
If the measuring pin (Fig. 9) fits perfectly into the EP-
Checking the start of commencement housing bore, the start of commencement is correct.
In case of deviations the setting must be corrected as
follows:

Fig. 7
l Crank the engine with the cranking device against
the sense of rotation, until a position 30° before ig-
nition TDC is reached (Fig. 7).

i Note
View on flywheel

Checking the start of commencement

Fig. 8
l Crank the engine with the cranking device in sense
of rotation to the start of commencement stated on
the type plate, e.g. 15° before ignition TDC, and in-
sert the measuring pin 110 180 (Fig. 8).

008 910 36 BOMAG 225

6.15 Checking and adjusting the start of commencement

Adjusting / correcting the start of commencement

Fig. 13
l Turn the injection pump camshaft slowly, until the
Fig. 10
locating bore in the locking disc is exactly in line with
l Use the cranking device to return cylinder A1 to ig- the EP-housing. The measuring pin must fit lightly.
nition TDC. The locking pin is engaged.(Fig. 10) The start of commencement is reached (Fig. 13).

Fig. 11 Fig. 14
l
Pull the locking pin and adjust the engine to the l Tighten the screws (Fig. 14) on the drive gear with
commencement start specified on the type plate the measuring pin inserted.
(e.g. 15° before T.D.C.) using the cranking device l Tightening torque: 31 Nm
(Fig. 11).
l
Remove the measuring pin.

Fig. 12
Fig. 15
l Loosen all screws on the drive pinion (Fig. 12).
l Assemble the cover with a new gasket (Fig. 15).
i Note l
Tighten the screws with new copper sealing rings.
Now return the engine exactly to the commencement l
Tightening torque: 21 Nm
start position (e.g. 15° before T.D.C.).

226 BOMAG 008 910 36

Replacement of radial seal on flywheel side 6.16
6.16 Replacement of radial seal on
flywheel side

Fig. 16
l Remove the cranking device.
l Fasten the cover with a new gasket to the timing
gear case. Tighten the screws (Fig. 16). Fig. 1

l Run the engine warm and check for leaks. l Counter and disassemble the flywheel (Fig. 1).

Fig. 2
l
Loosen the radial seal in the seat by tapping it with
a mandrel (Fig. 2).

Fig. 3
l
Carefully drill a hole with a diameter of min. 3-3.5
mm into the radial seal (Fig. 3).

i Note
Cover the drill amply with grease to make sure that no
drilling chips will fall into the crankcase.

008 910 36 BOMAG 227

6.16 Replacement of radial seal on flywheel side

Fig. 4 Fig. 7
l
Turn a self-tapping screw of appropriate thickness
into the drilled hole and pull the radial seal out using i Note
a suitable tool (e.g. valve spring assembly lever) Observe the installation depth!
(Fig. 4).
l 1. Installation depth for initial assembly (Fig. 7)
l 2. Maximum installation depth

Fig. 5
l Attach the guide bush (Fig. 5).
Fig. 8
l Assemble the flywheel using a self-made guiding
mandrel (Fig. 8).

i Note
Ensure correct alignment of close tolerance sleeve
and close tolerance bore in the flywheel.

Fig. 6
l Apply some oil to the sealing lip. Press the radial
seal in with a pressing device.
l The sealing lip points towards the crankshaft. See
the following schematic (Fig. 6).

Fig. 9
l Hold the flywheel and fasten it with new screws
(Fig. 9).
l
Tightening torque: Pre-tensioning value40 Nm
l Retensioning angle30° + 60° + 60°

228 BOMAG 008 910 36

Replacement of radial seal on pump carrier 6.17
6.17 Replacement of radial seal on
pump carrier

Fig. 4
l
Attach the guide bush (Fig. 4).

Fig. 1
l Remove the V-belt pulley (Fig. 1).

Fig. 5
l Apply some oil to the sealing lip.
l Press the radial seal in with a pressing device. The
Fig. 2 sealing lip points towards the crankshaft (Fig. 5).
l
Remove the V-belt hub with vibration damper (Fig.
2).

Fig. 6

Fig. 3 i Note
l
For the disassembly of the front radial seal use the Observe the installation depth: (Fig. 6)
same method as for the disassembly of the radial l
1. Installation depth for initial assembly
seal on the flywheel side (Fig. 3).
l 2. Maximum installation depth

008 910 36 BOMAG 229

6.18 Replacing the thermostats

6.18 Replacing the thermostats

Fig. 7
l
Assemble the V-belt hub with vibration damper.
Counter the flywheel and tighten the screws (Fig. Fig. 1
7). l
Drain off the coolant, catch it and, if necessary, dis-
l
Tightening torque: 183 Nm pose of environmentally.
l Remove the upper part of the thermostat housing
(Fig. 1).

Fig. 8
l Assemble the V-belt pulley and tighten the screws
(Fig. 8). Fig. 2

l
Tightening torque: 183 Nm l
Check thermostats and seals visually, replace if
necessary (Fig. 2).
l
After completion of work run the engine warm and
check for leaks.

Fig. 3
l
Install the thermostats (Fig. 3).

230 BOMAG 008 910 36

Replacing the coolant pump 6.19
6.19 Replacing the coolant pump

Fig. 4
l
Assemble the upper part of the thermostat housing
(Fig. 4). Fig. 1

l
Tighten the screws. l
Drain off the coolant, catch it and, if necessary, dis-
pose of environmentally (Fig. 1).
l Tightening torque: 22 Nm
l Disassemble the coolant line.

i Note
Fill in coolant.

Fig. 2
l
Unscrew all fastening screws for the coolant pump
and disassemble the pump with 3 forcing screws
(Fig. 2).

Fig. 3
l
Check the coolant pump visually. Use new O-rings
if the pump is to be used again (Fig. 3).

i Note
Pos. 1 red O-ring
Pos. 2 black O-ring

008 910 36 BOMAG 231

6.20 Sealing / replacing the oil cooler

! Caution 6.20 Sealing / replacing the oil cool-

Before assembling the O-rings cover them slightly er
with a soap-based gliding agent. Do not use min-
eral oil or grease!

Fig. 1
l Drain off coolant and engine oil, catch it and dis-
Fig. 4
pose of environmentally.
l Stick the new gasket on with some grease (Fig. 4).
l
Disassemble the oil cooler hood (Fig. 1).

Fig. 5
Fig. 2
l Attach the coolant pump and tighten the screws
(Fig. 5).
l
Disassemble the oil cooler (Fig. 2).
l Tightening torque: 21 Nm

Fig. 3

Fig. 6
l
Install new O-rings (Fig. 3).
l Assemble the coolant line with a new seal. Tighten
the screws (Fig. 6).
l Tightening torque: 21 Nm

i Note
Fill in coolant.

232 BOMAG 008 910 36

Replacing the cylinder head gasket 6.21
6.21 Replacing the cylinder head
gasket

i Note
When replacing cylinder, piston and conrod the thick-
ness of the cylinder head gasket must be determined
by measuring.
If only the cylinder head gasket is to be changed, the
same thickness as the old one must be used.
The marking of the 3 different thicknesses (can be
Fig. 4
read in assembled condition):
l
Install the oil cooler. Tighten the screws (Fig. 4).
one notch or bore
l
Tightening torque: 21 Nm two notches or bores
three notches or bores

Fig. 5
l Install the new gasket (Fig. 5). Fig. 1
l
Disassemble the valve cover (Fig. 1).

Fig. 6
l Install the oil cooler hood. Tighten the screws (Fig. Fig. 2
6).
l
Disassemble injection lines, leak fuel lines and the
l Tightening torque: 21 Nm piping for the pre-heating device (Fig. 2).

i Note
i Note
Fill up engine oil and coolant Use an open end spanner.

008 910 36 BOMAG 233

6.21 Replacing the cylinder head gasket

Determine the cylinder head gasket

Fig. 3
l
Remove the valve covers (Fig. 3).
Fig. 6
l Place the measuring instrument on the measuring
i Note plate. Set the dial gauge to zero with slight pre-ten-
For re-installation of the valve cover with oil filler plug sion.(Fig. 5)
write down the respective cylinder number.

Fig. 7
Fig. 4 l
Move the piston to T.D.C. Place the measuring unit
l
Disassemble the rocker arm blocks, remove the across the close tolerance sleeves and measure
push rods (Fig. 3). the biggest protrusion. The mean value of both
measurements is measurement ”X”.(Fig. 6)

Example:
l Dial gauge 0.39 mm
l Dial gauge 0,45 mm

Measurement "X" + 0,84 mm 2 = 0,42 mm

i Note
This measurement must be taken on all pistons.

Fig. 5
l
Remove the cylinder heads (Fig. 4).

234 BOMAG 008 910 36

Replacing the cylinder head gasket 6.21
Cylinder head

Fig. 8
l
Compare measurement ”X” with the table and de-
Fig. 10
termine the correct cylinder head gasket. (Fig. 8).
l Attach the cylinder heads. Apply some oil to the cyl-
inder head screws and turn them in (Fig. 10).
Piston protrusion X Marking of cylinder
head gasket
-0,05 - 0,10 mm 1 bore or 1 notch
i Note
Cylinder head fastening screws may be reused up to
0,10 - 0,30 mm 2 bores or 2 notches
five times, if approved.
0,30 - 0,81 mm 3 bores or 3 notches

Example:

Dimension ”X” 0,42 mm, use cylinder head gasket

with 3 holes/notches.

Fig. 11
l Tighten the cylinder head fastening screws cross-
wise (Fig. 11).
l
Tightening torque: Pre-tensioning value50 – 60 Nm
Fig. 9 l Retensioning angle: 120° + 120° + 60°.
l Install the new cylinder head gasket ”Top up”. (Fig.
9).

i Note
The sealing faces for the cylinder head gasket must
be clean and free of oil.
Mind the close tolerance sleeves.

008 910 36 BOMAG 235

6.21 Replacing the cylinder head gasket

Valve drive
i Note
This adjustment is made by displacing the pillow
blocks.

Fig. 12
l Insert the push rod (Fig. 12)
Fig. 15

i Note l Tighten the screws.

Make sure that the push rod is correctly seated in the l Tightening torque: 61 Nm (Fig. 15)
pan of the plunger, as otherwise the push rod may
drop into the crankcase.
i Note
After this work you must check and, if necessary, ad-
just the valve clearance.

Fig. 13
l Assemble the rocker arm block with the inserted
screws and align it to the push rods/valves.
Fig. 16
l
Tighten the screws slightly (Fig. 13). l Reconnect the leak fuel return line (Fig. 16).

i Note
Observe the installation direction.

Fig. 17
l Install a new gasket for the valve cover (Fig. 17).

Fig. 14
l
Check the end float of the rocker arms (Fig. 14).
l Permissible end float: 0.2 - 0.4 mm

236 BOMAG 008 910 36

Replacing the cylinder head gasket 6.21

Fig. 18 Fig. 21
l
Assemble the valve covers. Tighten the screws. l
Tighten the injection lines with an open end spanner
(Fig. 21).
l
Tightening torque: 22 Nm (Fig. 18)
l
Tightening torque: 30 Nm
i Note
When assembling the valve cover with oil filler plug
observe the cylinder number noted during disassem-
bly.

Fig. 22
l Tighten the screws of the injection line mounting
brackets (Fig. 22).
l
Tightening torque: 22 Nm
Fig. 19
l Insert the sealing rubber.
l Push the leak fuel return line through. (Fig. 19).

Fig. 23
l Completely assemble the leak fuel return lines (Fig.
23).
Fig. 20
l Guide the injection line through the sealing rubber
and fasten it to the injection valves and the injection
pump without any tension (Fig. 20).

008 910 36 BOMAG 237

6.22 Check, adjust the valve clearance

Valve cover 6.22 Check, adjust the valve clear-

ance

i Note
The valve clearance must be
l 0.25 mm for intake valves,
l
0.3 mm for exhaust valves.

i Note
The standard valve clearance adjustment can be per-
formed on a cold or warm engine, after it has cooled
Fig. 24
down for at least 0.5 hours (oil temperature 80 °C).
l Install a new gasket for the valve cover (Fig. 24).

Fig. 25 Fig. 1
l
Attach the valve cover. Tighten the screws (Fig. 25). l Remove all valve covers (Fig. 1).
l
Tightening torque: 22 Nm

i Note
After completion of work run the engine warm and
check for leaks.

Fig. 2
l Remove the cover (Fig. 2) from the timing gear
housing.

238 BOMAG 008 910 36

Check, adjust the valve clearance 6.22

Fig. 3 Fig. 6
l Install the cranking device and crank the engine
with the cranking device (Fig. 2), until the overlap- i Note
ping of valves on cylinder no. A1 (Fig. 5) is reached. IN = intake valve (Fig. 6)
EX = exhaust valve

Fig. 4

i Note
Fig. 7
Overlapping of valves means (Fig. 3):
Exhaust valves not yet closed. Checking the valve clearance

Intake valves start to open.

l A feeler gauge of appropriate thickness 1 (Fig. 7)
must fit with little resistance between rocker arm (2)
and valve (3).
l If the gap is too narrow or too wide for the feeler
gauge, the valve must be adjusted.

Adjusting the valve clearance

Fig. 5
l Adjust the valves on cylinder no. B3 (Fig. 5).

Fig. 8
l Slacken the counter nut (Fig. 8). Adjust the set-
screw with a screwdriver, until the feeler gauge can

008 910 36 BOMAG 239

6.23 Checking, replacing the generator V-belt

be inserted and pulled out with little resistance after 6.23 Checking, replacing the gen-
retightening the counter nut.
erator V-belt
i Note
Tighten the counter nut with 20 Nm. ! Danger
Danger of injury!
Check the setting again with the feeler gauge.
Work on the generator V-belt must only be per-
l
Perform tests and adjustments on all other adjusta-
formed with the engine shut down.
ble valves. As a control measure mark each adjust-
ed valve with chalk.
Check the V-belt

Fig. 9
l Assemble all valve covers (Fig. 9) and tighten the
screws with 22 Nm. Fig. 11
l
Inspect the entire circumference of the V-belt (Fig.
11) visually for damage and cracks. Replace dam-
i Note
aged or cracked V-belts.
Check the gasket, replace if damaged.
l Check with thumb pressure whether the V-belt can
be depressed more than 5 to 10 mm between the V-
belt pulleys, retighten if necessary.

Retighten the V-belt

Fig. 10
l Remove the cranking device (Fig. 10).
l
Fasten the cover with a new gasket to the timing
gear housing.
l
Tighten the screws with 21 Nm.
Fig. 12
l Slacken the fastening screws 3 and 4 (Fig. 12)
slightly.
l Loosen the counter nut (2).
l
Turn down tensioning screw (1) in direction of ar-
row, until the correct V-belt tension is reached.
l Retighten hexagon screws and counter nut.

240 BOMAG 008 910 36

Service the combustion air filter 6.24
Changing the V-belt 6.24 Service the combustion air fil-
ter

! Caution
Perform cleaning, maintenance and repair work
only with the engine shut down. Do not start the
engine after removing the filter element.

Fig. 13
l Slacken the fastening screws 3 and 4 (Fig. 13)
slightly.
l Loosen the counter nut (2).
l Turn tensioning screw (1) in direction of arrow to the
stop.
Fig. 15
Maintenance of the dry air filter is due when control
light 4 (Fig. 15) in the fault monitoring board lights per-
manently when the engine is running.
However, the filter cartridge must be replaced at the
latest after two years.
After completion of the filter service reset the indicator
piston back to "Zero" by pressing the button.
l
Open the engine hood completely and secure it.

Removing the main filter element

Fig. 14
l
Unscrew the fastening screw 2 (Fig. 14) for the
spacer disc (1).
l Unscrew clamping screws (4).
l Push the flexible coupling (3) to the side.
l Take the old V-belt off the V-belt pulley.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
l
Reassemble the coupling.

Fig. 16
i Note
Retighten new V-belts after a running time of 15 min-
l
Open the service flap 1 (Fig. 16) in front of the air
utes. filter.
l Unscrew the wing nut from the air filter lid and re-
move the lid.

008 910 36 BOMAG 241

6.24 Service the combustion air filter

and down inside the cartridge, until it if free of dust

(Fig. 18).

Fig. 17
l Pull the main filter element (Fig. 17) with light turn-
ing movements.
Fig. 19
l Examine the filter cartridge with a torch for cracks
Cleaning the main filter element
and holes in the paper bellows (Fig. 19).

!Caution
Caution
!
If necessary, the main filter element may be
Do not continue to run the machine with a dam-
cleaned up to five times. It must be renewed at the
aged main filter element. If in doubt use a new
latest after a maximum utilization period of two
main filter element.
years.
The number of cleaning intervals of the main filter Installing the main filter element
element can be marked on the safety element with
a ball pen or a felt pen.
l
Slide the main filter element carefully into the hous-
ing.
Cleaning does not make sense if the main filter el-
ement is covered with a sooty deposit. Use a new When closing the housing cover the main filter ele-
filter cartridge. ment is automatically forced in the correct position.
Incorrectly handled inserts may be ineffective be-
cause of damage (e.g. cracks) and cause damage Changing the safety filter element
to the engine.
Replace the safety cartridge if the main filter ele- ! Caution
ment is defective! The safety filter element must not be cleaned and
Additional cleaning intervals between two filter should not be used again after it has been re-
services signalized by the fault monitoring board moved.
are not necessary.
Break the seal only to replace the safety filter ele-
ment.
The safety filter element must be replaced:
If the main filter element is defective.
after five service intervals of the filter cartridge,
at the latest after 2 years,
if the warning light comes on again after servicing
the main filter cartridge.
l Remove the housing cover and pull the main filter
element off.

Fig. 18
l Blow the cartridge out with compressed air (max. 5
bar) from inside to outside by moving the tube up

242 BOMAG 008 910 36

Check the coolant level 6.25
6.25 Check the coolant level

! Danger
Danger of scalding!
Fill up coolant only when the engine is cold.

! Caution
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.

Fig. 20
l Unscrew the wing nut and pull the safety element
(Fig. 20) out by turning it lightly.
l Install the new safety cartridge and fasten it with the
wing nut.
l Reassemble main filter element and cover.

Caution
!

Make sure that the cover locks engage correctly.

Fig. 21
l
Unscrew the radiator cap (Fig. 21) and check the
coolant level.
l
Fill in coolant up to the “MAX” mark.

For quality of coolant refer to the chapter 5.2, fuels

and lubricants.

008 910 36 BOMAG 243

6.26 Change the coolant

6.26 Change the coolant 6.27 Check the engine oil level

! Danger i Note
Danger of scalding! The machine must be in horizontal position. Just be-
fore testing run the engine approx. 2 minutes with idle
Change the coolant only when the engine is cold.
speed. Shut down the engine.

Environment
Catch running out coolant and dispose of environ-
mentally.

Fig. 24
l Pull the dipstick (Fig. 24) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out again.
Fig. 22
l
The oil level must be near the ”Max”-mark.
l
Unscrew the plug, open the drain tap (Fig. 22), let
the coolant run out and catch it. l
If the oil level is too low top up oil immediately.
l
Screw the plug back in and close the drain tap once For quality of oil refer to the table of fuels, lubri-
all coolant has run out. cants and filling capacities.

Fig. 23
l Open the radiator cap (Fig. 23) and fill in coolant.

For quality of coolant refer to the chapter 5.2, fuels

and lubricants.
l
Start the diesel engine and run it warm to operating
temperature.
l Let the engine cool down and check the coolant lev-
el again, top up if necessary.

244 BOMAG 008 910 36

Changing engine oil and oil filter cartridges 6.28
6.28 Changing engine oil and oil fil-
ter cartridges

i Note
Drain the engine oil only when the engine is warm.
Preferably use oils of ACEA-classification E4-99 -
SAE 10W / 40. This enables utilization of the longest
oil change intervals.

Oil change intervals (operating hours) for ACEA

quality
E4-99 = 250 operating hours
Fig. 26
l Thoroughly clean the outside of both filter cartridges
Danger
!
(Fig. 26).
Danger of scalding!
l Unscrew the filter cartridges using an appropriate
Danger of scalding when draining off hot oil! filter wrench.
l Clean the sealing face on the filter carrier from any
Environment dirt.
Environmental damage! l Slightly oil the rubber seal on the new filter cartridg-
Do not let old oil seep into the ground, but dispose es.
off environmentally.

Fig. 27
Fig. 25 l
Turn the new filter cartridges (Fig. 27) on by hand,
l
Open the bottom cover (Fig. 25). until the seal contacts.
l
Unscrew the drain plug and catch running out oil. l Tighten the filter cartridges for another half turn.
l
Turn the drain plug tightly back in.

Fig. 28
l Fill in new engine oil (Fig. 28).

008 910 36 BOMAG 245

6.29 Check fastening of engine / turbocharger / combustion air hos-

For quality and quantity of oil refer to the table of 6.29 Check fastening of engine /
fuels and lubricants.
turbocharger / combustion air
l Tighten the oil filler cap properly.
hoses
! Caution
Before starting crank the engine with the starter
motor until the oil pressure warning light goes
out.
l After a short test run check the oil level on the dip-
stick, if necessary top up to the top dipstick mark.
l Check filter cartridge and drain plug for leaks after a
short test run.
l Shut the engine down and wait for about 15 min-
utes, so that all oil can flow back into the oil sump.
l Check the oil level again, if necessary fill up to the
Max.-mark.
Fig. 29
l Check charge air line (Fig. 29) and intercooler for
tight fit and leaks.
l Check exhaust pipe and lubrication oil line to and
from the exhaust turbo charger for tight fit and
leaks.
l Check connecting sockets for tight fit.

Fig. 30
l
Check combustion air pipe and connecting sockets
for tight fit (Fig. 30).

246 BOMAG 008 910 36

Engine conservation 6.30
6.30 Engine conservation 6.31 Cleaning the engine
If the engine is to be shut down for a longer period of
time (e.g. over winter), please consult the service de- ! Caution
partment of the engine manufacturer for further de- After cleaning the coolers it is mandatory to clean
tails. the engine.
Cover all parts of the electrical system, do not
subject to the direct water jet.
l Blow the engine dry with compressed air. Flush lose
dirt with a water jet out of the V-shaped space be-
tween the cylinders.

Fig. 31
l
Drain bores 1 (Fig. 31) and 2 (Fig. 32) must be free,
remove blockage if necessary.
l
In case of oily contamination spray the engine with
cold cleansing agent and spray it off with a water jet
after s sufficient soaking time.

Fig. 32
l Drain bores 2 (Fig. 32) and 1 (Fig. 31) must be free,
remove blockage if necessary.
l
After wet cleaning run the engine warm to evapo-
rate all water residues and to avoid corrosion.
l Reinstall the service covers.

008 910 36 BOMAG 247

6.32 Fuel pre-filter / water separator (SEPAR filter)

6.32 Fuel pre-filter / water separa-

tor (SEPAR filter)

Fig. 1 Fuel pre-filter

1 Filter element
2 Seal kit
3 Drain valve
4 Drain valve runout
5 electrical connection for water level indicator
The fuel pre-filter / water separator mainly consists of:
l
the centrifugal water separator
l the dirt / water collecting bowl with water level warn-
ing connection
l
and the filter element

248 BOMAG 008 910 36

Fuel pre-filter / water separator (SEPAR filter) 6.32
Function:
The fuel lift pump draws in fuel through port B on the
filter. Inlet A is closed.

Fig. 2 SEPAR filter Phase 1:

1 Outlet C Fuel flow from the inlet into the centrifuge. The centri-
2 Inlet A , closed. fuge itself does not rotate. On the contrary, the fuel is
3 Phase 3 rotated by the geometry of the centrifuge.
4 Drain cock Phase 2:
5 Phase 2 The fuel leaving the centrifuge flows against the outer
6 Phase 1 wall of the collecting bowl. There the motion of the
7 Inlet B fuel is braked. Due to the inertia of the heavier dirt and
water particles these components are forced to the
8 Phase 4
outside and sink down into the collecting bowl by grav-
9 Phase 5 ity.
10 Outlet D, closed
Phase 3:
11 Bleeding screw
The fuel now flows up past the outside of the centri-
fuge while it is still rotating inside the bowl. In this
phase smaller dirt and water particles move towards
the middle of the bowl, where the water particles com-
bine to larger droplets. There they are taken up by the
larger middle wing of the centrifuge, from which they
finally drop down. This is due to the fact, that the low-
est pressure in the bowl is at the lowest point in the
centrifuge.

008 910 36 BOMAG 249

6.32 Fuel pre-filter / water separator (SEPAR filter)

Phase 4:
The fuel is still rotating in front of the filter element.
Further dirt and water particles gather at this point and
drop down into the bowl.

Phase 5:
The water resistant filter element cleans out smaller
dirt and water particles, which may have remained in
the fuel.
Once the water level reaches the height of the warn-
ing contacts, the warning lamp in the cockpit will come
on.

250 BOMAG 008 910 36

Checking, cleaning the water separator 6.33
6.33 Checking, cleaning the water 6.34 Changing the fuel prefilter ele-
separator ment

! Caution ! Danger
When working on the fuel system do not use open Fire hazard!
fire, do not smoke.
No open fire, do not smoke, do not spill any fuel.
Do not inhale any fuel fumes.
Environment
Catch running out fuel and dispose of environ-
mentally. Environment
Catch running out fuel, do not let it seep into the
ground.
i Note
The service intervals for the water separator depend
on the water content in the fuel and can therefore not
be determined precisely. After taking the engine into
operation you should therefore check the filter bowl in-
itially every day for signs of water.

Fig. 5
l Unscrew the hexagon screws (Fig. 5) from the filter
cover and take the cover off.
l Take the filter element out of the filter housing.
l Insert the new filter element into the filter housing.
Fig. 3
l
Check the seal of the filter cover, replace if neces-
l
Place a collecting vessel (Fig. 3) under the drain sary.
bore.
l Install the filter cover with seal and tighten the hex-
l
Open the drain tap. agon screws crosswise.

Fig. 4
Fig. 6
l Drain the fuel off until there is no water left (Fig. 4). l Place a collecting vessel (Fig. 6) under the drain
l Close the drain tap. opening.

008 910 36 BOMAG 251

6.35 Change the fuel filter cartridge

l Open the drain tap. 6.35 Change the fuel filter cartridge
l Drain off fuel, water and dirt, then close the drain
cock.
! Danger
Fire hazard!
Bleeding the fuel prefilter
No open fire, do not smoke, do not spill any fuel.

i Note Do not inhale any fuel fumes.

Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and Environment
makes starting impossible. Catch running out fuel, do not let it seep into the
Therefore bleed the fuel system after changing the ground.
fuel prefilter. l
Open the left hand engine compartment doors.

Fig. 7
Fig. 9
l
Slacken the bleeding screw (Fig. 7) on the fuel pre- l Loosen both fuel filters (Fig. 9) using a suitable filter
filter for 2 to 3 turns. wrench and screw it off.
l Clean the sealing face on the filter carriers from any
dirt.

Fig. 8
l
Operate the hand pump (Fig. 8) manually, until fuel
flows out of the slackened bleeding screw (Fig. 7) Fig. 10
without air bubbles. l
Slightly oil the rubber seal on the new filter cartridg-
l Then tighten the bleeding screw while pumping. es (Fig. 10).
l
Fill the filter cartridge with clean diesel fuel.
l Turn the new filter cartridge on by hand, until the
seal contacts.
l
Then tighten hand-tight.

252 BOMAG 008 910 36

Special tools, Deutz engine (BF8M 1015C) 6.36
6.36 Special tools, Deutz engine
(BF8M 1015C)

i Note
Co. Wilbär
P.O.Box 140580
D - 42826 Remscheid

Conventional tools

Fig. 11
l If necessary bleed the fuel system with the help of
the hand pump (Fig. 11).
l Check the filter cartridge for leaks after a short test
run.

Fig. 1
l Reinforced spanner sockets SW 14, 900S (Wilbär)
(Fig. 1).
l Reinforced spanner sockets SW 17, 900S (Wilbär).

Fig. 2
l
Open end spanner SW 17 for injection lines 4550-1
(Wilbär)(Fig. 2)

008 910 36 BOMAG 253

6.36 Special tools, Deutz engine (BF8M 1015C)

Fig. 3 Fig. 6
l Measuring pin to check the start of delivery 110 l Special pliers for assembly of
180 (Wilbär) (Fig. 3). leak fuel line110 120 (Wilbär) (Fig. 6).

Fig. 4 Fig. 7

BOMAG part-no.: 079 947 11

l Assembly tool for crankshaft seal
rear142 930 (Wilbär) (Fig. 7).
l
Cranking device with mechanical TDC-
sensor and angle scale to check start of com-
mencement (Fig. 4).

Fig. 8
l Assembly tool for crankshaft seal
Fig. 5 front142 930 (Wilbär)(Fig. 8)

BOMAG part-no.: 079 947 61

l
Puller for injection valves in connection
with 110 030 (Wilbär) (Fig. 5).

254 BOMAG 008 910 36

Special tools, Deutz engine (BF8M 1015C) 6.36

Fig. 9

BOMAG part-no.: 079 947 18

l Extracting device (Fig. 9).

Fig. 10
l
Slotted nut spanner 110 130 (Wilbär) (Fig. 10).

008 910 36 BOMAG 255

6.37 Explanation of symbols

6.37 Explanation of symbols

256 BOMAG 008 910 36

Explanation of symbols 6.37

008 910 36 BOMAG 257

6.37 Explanation of symbols

258 BOMAG 008 910 36

Explanation of symbols 6.37

008 910 36 BOMAG 259

6.37 Explanation of symbols

260 BOMAG 008 910 36

7 Milling drive, mechanics

008 910 36 BOMAG 261

262 BOMAG 008 910 36
Milling drive 7.1
7.1 Milling drive The highly elastic dry clutch is a switchable dry friction
clutch, which transfers the drive torque by means of
friction.
Torque peaks occurring during operation are damp-
Milling clutch ened.
A hydraulically operated friction clutch (Fig. 11) trans-
mits the drive torque via a V-belt pulley to the V-belts.

Fig. 11 Engine with friction clutch

l
Maximum torque = 6490 Nm.
l
Maximum speed = 2100 rpm
l Maximum oil pressure = 45 bar
l Weight approx. 185 kg
l
Total length approx. 465 mm
l
Diameter approx. 552 mm
l
Required oil volume per switching operation with
new outer discs 0.058 litres.
l Required oil volume per switching operation with
worn outer discs 0,189 litres.
l Clutch is open when no pressure is applied

Fig. 12

008 910 36 BOMAG 263

7.1 Milling drive

Fig. 13 Sectional drawing

264 BOMAG 008 910 36

Milling drive 7.1

Fig. 14 Oil supply

The oil is supplied through the hydraulic line (Fig. 14).

Working principle of the clutch

On the hydraulically switchable clutch the oil is sup-
plied through an axial bore in the shaft and a rotor con-
nection into the cylinder chamber and thus determines
the torque.
The torque introduced via ring gear 1 (Fig. 15) is trans-
ferred by the teeth to the friction discs (2), and, if hy-
draulic pressure is applied, by friction via inner disc (3)
and pressure disc (4) to clutch hub (5).
The transferable torque is proportional to the oil pres-
sure.
The pressure springs (10) in the clutch force the oil
back out of the clutch when the clutch is disengaged.
Any clutch wear is compensated by the increasing
travel of piston (6) during the engagement process.

008 910 36 BOMAG 265

7.1 Milling drive

Overview clutch repair

Fig. 15 Overview clutch repair 11 Bolt

1 Ring gear 12 Grooved ball bearing
2 Outer discs / friction discs 13 Self-aligning roller bearing
3 Inner discs 14 Socket head cap screw
4 Pressure disc 15 Intermediate flange
5 Coupling hub 16 Elastic coupling
6 Piston 17 Flanged shaft
7 Cylinder 18 Circlip
8 Rotary connection 19 Belleville springs
9 Oil supply, axial bore 20 Bell
10 Pressure springs

266 BOMAG 008 910 36

Milling drive 7.1
Repair and maintenance work
i Note
The clutch requires only little maintenance. The oil The seals should be checked when performing repair
pressure 3 (Fig. 16) and the wear of the friction coat- work on the clutch. They should be replaced if any
ing needs to be checked from time to time. wear or damage is found.

! Danger
Perform repair or service work only with the en-
gine shut down, the emergency stop switch de-
pressed and the machine reliably secured against
accidental starting.
Danger of burning! The clutch may be very hot.
Fire hazard! The clutch must not come in contact
with caustic or grease containing cleansing
agents.
Fire hazard! The friction linings must never be
cleaned with solvents like gasoline, acetone or
kerosene. Oily and contaminated clutch linings
Fig. 16 Oil pressure gauge (3) in the display
must be replaced.
Unprofessional disassembly of the clutch can
i Note
lead to severe injury. The clutch is preloaded with
In case of a fault the corresponding symbol will be dis- a spring force!
played on screen. The bell symbol accompanies the
Danger of injury! Before commissioning of the
warning buzzer. Press the ENTER-key to switch off
machine make sure that all tools and working aids
the warning buzzer.
have been removed from the clutch.

! Caution
Ensure strict cleanliness when performing repair
work. Leaks occurring a short while after a repair
can almost every time be traced back to dirty hy-
draulic connections.
Friction discs must be free of oil and grease.
The specified hydraulic pressure must not be ex-
ceeded (not even temporarily).
Check the supply line for leaks.
Observe the tightening torques.
After a shut-down caused by blockage you should
Fig. 17 Fault message clutch pressure lower than 39 bar or higher
than 50 bar always allow the system to cool down for approx.
20 minutes, to prevent unnecessary overheating
Bearing of the clutch.
l
The grooved ball bearings (12) are lifetime lubricat-
ed.
l The self-aligning roller bearing (13) is fitted with a
relubrication device.

i Note
During repair and maintenance work the roller bear-
ings should be checked. In case of bearing damage
(e.g. grinding noises) these must be replaced by new
bearings.

Seals and gaskets

l Seals and gaskets do not require any particular
maintenance.

008 910 36 BOMAG 267

7.1 Milling drive

Concentricity faults and side runouts Inspection of concentricity faults and side ru-
nouts on flywheel and centrings on engine hous-
ing and on the guide bearing.

The more accurate the alignment, the more relia-

ble the drive the higher the lifetime of the clutch-
es.
1 Check the side runout TPM of the flywheel to the
centring on the engine housing using a dial gauge
with magnetic stand. The permissible deviation is
0.2mm.
2 Check the concentricity fault (eccentricity) TRM of
the flywheel to the centring on the engine housing
using a dial gauge with magnetic stand. The per-
missible deviation is 0,2 mm.
3 Check the side runout TPS of engine housing to
the centring on the flywheel by means of a dial
gauge with magnetic stand. The permissible devi-
ation is 0.05 mm over a radius of 100 mm.
4 Check the concentricity fault TRM of the engine
housing to the centring on the flywheel using a dial
gauge with magnetic stand. The permissible devi-
ation is 0.13 mm. Mark the point of the largest de-
viation.
5 Check the concentricity fault TRF of the engine
housing to the centring on the guide bearing using
a dial gauge with magnetic stand. The permissible
deviation is 0.13 mm. Mark the point of the largest
deviation.
6 Calculation of the concentricity deviation Tm of
the centrings on flywheel and guide bearing.
Tm = TRS - TRF / 2
Points with highest deviation are on the same side.
Tm = TRS + TRF / 2
Points of highest deviation are opposite each other.
The permissible deviation is 0.2 mm.

The permissible concentricity fault is 0.15 mm.

Fig. 18

268 BOMAG 008 910 36

Milling drive 7.1
Faults and rectification

The clutch slips under load

Cause Remedy
Oil pressure too low Adjust oil pressure to required level
Outer discs worn Replace outer discs
Grease on friction areas Clean the affected steel or cast iron parts with gasoline or
acetone
Grease on outer discs Replace the outer discs with new ones

Hub and pressure disc heat up to more than 120°C when engaged
Cause Remedy
Clutch slipping, oil pressure too low Adjust oil pressure to required level

Hub and pressure disc heat up when switched off

Cause Remedy
Pressure disc (4) and inner disc (3) seized on bolt Re-establish light axial movement of parts (3 +4) on bolt
(11) (11)
The pressure disc does not release, because the Ensure appropriate relieving of the cylinder
pressure in the cylinder (7) does not drop
Pressure disc (4) does not release, because the Assemble new pressure springs
pressure springs (10) have settled

008 910 36 BOMAG 269

7.1 Milling drive

Power transmission
The power to the milling drive / reduction gear is trans-
mitted via hydraulically tensioned V-belts (Fig. 19).

Fig. 19
1 Tensioning wheel
2 Hydraulic cylinder
3 Dry friction clutch with V-belt pulley
4 Milling drive with V-belt pulley
5 V-belt

270 BOMAG 008 910 36

Milling drive 7.1
Milling drive / reduction gear
The milling drive (Fig. 20) is mounted inside the milling
drum and reduces the input speed down to the milling
drum speed.

Fig. 20 Milling drum with reduction gear and bearing

Fig. 21 Reduction gear

008 910 36 BOMAG 271

7.1 Milling drive

Milling drum Apart from this, the drum must also throw the milled
The milling drum (Fig. 22) is equipped with welded material onto the gathering belt.
holders, changeable holders and round shank cutting
teeth.

Fig. 22 Milling drum Tooth space: 16 mm

Technical data: Cutting diameter: 1070 mm
Milling width: 2000 mm Conveyor worms: 3 + 3 maximum wear resistance of
tools.
Milling depth: 320 mm
Number of teeth: 168

Fig. 23 Structure of milling drum 6 Ejector

1 Drum (Fig. 23) 7 Cutting teeth
2 Flange
3 Spirals / helix
4 Cutting tool holder with base
5 Side cutter

272 BOMAG 008 910 36

Milling drive 7.1

Fig. 24 Holding system KPF301

1 Cutting tool (Fig. 24)
2 Cutting tool holder
3 Base

Fig. 25 Special tool

008 910 36 BOMAG 273

7.1 Milling drive

Milling housing information to the milling depth control via a rope sen-
The side plates (Fig. 26) close the milling housing sor.
from the sides. They slide on grade shoes and provide

Fig. 26 Milling housing with side plate, right hand side

Fig. 27 Side plate adjustment, left hand side 5 Grade shoes

1 Rope sensor, height adjustment
2 Rope
3 Side plate
4 Hydraulic cylinder

274 BOMAG 008 910 36

Milling drive 7.1
Hold-down Gathering foot
The hold-down prevents the breaking out of large Due to the contact pressure applied to the asphalt
lumps and thus protects the gathering belt from being coating by this device, no large volume material lumps
damaged. can be cut.

Fig. 28 Hold-down with gathering foot

1 Hold-down
2 Gathering foot
3 Hydraulic cylinder

008 910 36 BOMAG 275

7.1 Milling drive

Scraper shield
The scraper shield (Fig. 29) closes the milling housing
to the back. Changeable segments made of tungsten
carbide protect it against wear.

Fig. 32 Shield fixed

If material is to be left laying (Fig. 32) or for partial
loading the shield can be hydraulically fixed in any de-
sired height.
Fig. 29 Scraper shield
For changing the wear parts the flap can be opened
wide and will lock automatically.

Fig. 30 Shield floating

For neat levelling of the milled area (Fig. 30) the shield
floats over the processed material and seals the back
of the milling housing.

Fig. 31 Shield fixed

For clean levelling (Fig. 31) of the milled area to a
loose gravel or sand layer the shield is hydraulically
fixed in the desired position.

276 BOMAG 008 910 36

Checking, replacing the milling drum V-belt 7.2
7.2 Checking, replacing the mill- i Note
ing drum V-belt Before loosening the stop screw measure the length
and write it down.

! Danger
Danger of accident!
Perform this work only with the engine shut down!

Check the V-belt

Fig. 35
l Loosen the counter nut 1 (Fig. 35) and tighten the
stop screw (2).
l
Take the old V-belt off.
l
Fit the new V-belt to the V-belt pulleys.

Fig. 33
l Return the idler pulley to its original position and
tighten the counter nut.
l
Check the entire circumference of the V-belts (Fig.
33) for damage and cracks. Replace damaged or
l Reassemble the cover.
cracked V-belts.

Fig. 34
l
Check the V-belt pulley for signs of wear (Fig. 34).

new V-belt pulley A=14.24 mm

Worn V-belt pulley A=15.24 mm

Changing the V-belt

l Start the engine and raise the machine to highest
position.
l Shut down the engine.
l
Open the side flap and remove the cover

008 910 36 BOMAG 277

7.3 Change the oil in the milling drum reduction gear

7.3 Change the oil in the milling 7.4 Oil change in milling drum
drum reduction gear bearing

! Danger ! Caution
Life hazard! Drain oil only at operating temperature.
Shut down the engine and remove the ignition key
before accessing the milling drum. Environment
Additionally attach a warning tag stating "Do not Catch old oil and dispose of environmentally.
start the engine!" to the dashboard. l Park the machine horizontally.

Environment
Catch the oil and dispose of environmentally.
l
Park the machine so that milling drum is in horizon-
tal position.

Fig. 37
l
Clean and unscrew the drain and level control plugs
(Fig. 37).
l Drain and catch all oil.
l Screw the drain plug back in and tighten it.
Fig. 36
l Turn the milling drum with the crank handle 2 (Fig.
36) until the drain plug (3) is in bottom position.
l Clean and unscrew plug (3).
l
Drain and catch all oil.
l
Turn drain plug (3) in and tighten it.
l Fill in oil through the oil level control bore (1), until it
has reached the bottom edge of the bore.

For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.

Fig. 38
l Fill in oil through the oil level control bore, until it
reaches the bottom edge of the bore. (Fig. 38).
l Screw the level control plug back in and tighten it.

For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.

278 BOMAG 008 910 36

Checking/replacing cutting tools, scraper 7.5
7.5 Checking/replacing cutting
tools, scraper

i Note
The cutting tools are mounted in replaceable holders.

Danger
!

Life hazard!
Shut down the engine and remove the ignition key
before accessing the milling drum.
Additionally attach a warning tag stating "Do not Fig. 41
start the engine!" to the dashboard. l Shut down the engine 25 (Fig. 41) and pull out the
l Raise the machine completely. ignition key.
l Attach a warning tag "Do not start the engine, main-
tenance work" to the dashboard.

! Danger
Life hazard!
Access the space under the machine only with the
milling drum stopped.

Checking the cutting tools

l
Rotate the drum by hand and check cutting tools
and holders.
Fig. 39
l
Check whether the cutting tools rotate in their hold-
ers.
l
Unlock all four safety supports and fold them down
(Fig. 39).
l
If necessary turn the rear track drives in "Manual"
mode fully to the right.

Fig. 42
Cutting tool in good condition (Fig. 42).

Fig. 40
l
Swing the scraper flap completely open, until the
safety hooks (Fig. 40) click into place.
The warning lamps on both sides are flashing.

008 910 36 BOMAG 279

7.5 Checking/replacing cutting tools, scraper

Fig. 43 Fig. 46
Cutting tool with even wear (Fig. 43), must be re- Tool tip with eroded body (Fig. 46). The cutting tool
placed after short term use. must be replaced immediately.

Fig. 44 Fig. 47
If the cutting tool is in this condition (Fig. 44), the hold- Tool tip broken off (Fig. 47). The cutting tool must be
er must perhaps also be changed, because the cutting replaced immediately.
tool cannot rotate. This causes uneven wear.
Replacing the cutting tool

! Danger
Wear goggles and gloves when changing the cut-
ting tools. Injury by hard metal splinters!

Fig. 45
Cutting tool showing uneven wear (Fig. 45). The cut-
ting tool must be replaced immediately.

Fig. 48
l Knock out damaged or worn off cutting tools with a
hammer and a special tool (Fig. 48).

280 BOMAG 008 910 36

Checking/replacing cutting tools, scraper 7.5
Replacing the tool holders

Fig. 49
l Knock in the new cutting tool fully with a copper or
Fig. 52
plastic hammer (Fig. 49) and check whether it can
rotate freely. l Knock out damaged or worn off cutting tool holders
with a hammer and a special tool (Fig. 52).
Checking the tool holders

Fig. 53

Fig. 50 l Knock in the new cutting tool holders fully with a

Tool holder in good condition (Fig. 50). copper or plastic hammer (Fig. 53) and check
whether the cutting tool can rotate freely.

Checking the scraper bars

Fig. 51
If the tool holder is in such a condition (Fig. 51) it must
be replaced immediately.
Fig. 54
Check the condition of the scraper bars (Fig. 54), re-
place if necessary.
Replace the scraper bars when the edges are blunt or
broken.

008 910 36 BOMAG 281

7.6 Replacing bases/holders

Replacing the scraper bars 7.6 Replacing bases/holders

Fig. 55
Unscrew fastening screws 1 (Fig. 55) and take off
scraper bars (2). Fig. 56
Mount the new scraper bars and tighten the fastening l Removing the old holders.
screws.
l Make sure that the surface is clean.

Fig. 57
l Position the new holder with the help of locating
pins.
l
Tack weld one of the front edges.
l
Tack weld the diagonally opposite rear edge.
l Weld in several layers 1 (Fig. 57).

282 BOMAG 008 910 36

Lubricating the milling drum 7.7
7.7 Lubricating the milling drum 7.8 Lubricating the dry clutch

Milling drum Lubrication interval approx. 1000 h.

Fig. 58 Fig. 60
l Lubricate the bearings (Fig. 58) with three strokes l Lubricate the bearings (Fig. 60) with three strokes
from the grease gun. from the grease gun.

i Note
Relubrication quantity approx. 40 g

! Caution
Use a special lubrication grease.
See section "Table of fuels and lubricants".

Fig. 59
l Lubricate the labyrinth seal bearings (Fig. 59) with
three strokes from the grease gun.

008 910 36 BOMAG 283

7.9 Checking the wear of the friction lining

7.9 Checking the wear of the fric- 7.10 Friction lining / replacing the
tion lining outer discs

Notes on safety

! Danger
Perform repair or service work only with the en-
gine shut down, the emergency stop switch de-
pressed and the machine reliably secured against
accidental starting.
Danger of burning! The clutch may be very hot.
Fire hazard! The clutch must not come in contact
with caustic or grease containing cleansing
agents.
Fire hazard! The friction linings must never be
Fig. 61 Distance between ring gear and first friction disc cleaned with solvents like gasoline, acetone or
kerosene. Oily and contaminated clutch linings
Measuring the outer discs
must be replaced.
l
Remove the plug Unprofessional disassembly of the clutch can
lead to severe injury. The clutch is preloaded with
i Note spring force!
The distance must be measured with the clutch en- Danger of injury! Before commissioning of the
gaged and the drive stopped. machine make sure that all tools and working aids
have been removed from the clutch.
If the distance exceeds 15 mm, the friction discs need
to be replaced
Condition upon delivery = 6 mm ! Caution
Ensure strict cleanliness when performing repair
work. Leaks occurring a short while after a repair
can almost every time be traced back to dirty hy-
draulic connections.
Friction discs must be free of oil and grease.
The specified hydraulic pressure must not be ex-
ceeded (not even temporarily).
Check the supply line for leaks.
Observe the tightening torques.
After a shut-down caused by blockage you should
always allow the system to cool down for approx.
20 minutes, to prevent unnecessary overheating
of the clutch.

284 BOMAG 008 910 36

Friction lining / replacing the outer discs 7.10
Disassembling and dismantling the
clutch

Fig. 62 Fig. 64

l Disassemble V-belt pulley, V-belts, hydraulic line, l Unscrew the socket head cap screw with washer.
lubrication line and bell support (Fig. 62). l Disassemble elastic coupling (16, see clutch repair
overview) and intermediate flange (15).
l
Remove the clutch from the flanged shaft (17) using
the extraction thread in the hub (5, see clutch repair
overview) and a suitable extracting device.

Fig. 63

! Danger Fig. 65

Danger of squashing!
Danger
!
Do not stand or step under loads being loaded.
Unprofessional disassembly of the clutch can
l Remove cover plates (Fig. 63) from the bell and at- lead to severe injury. The clutch is preloaded with
tach lifting tackle to the clutch. spring force!
l Unscrew the bell from the engine housing and care- Secure clutch hub 5 (Fig. 65), inner disc (3), outer
fully lift off the complete clutch. disc (2) and pressure disc (4) with two threaded
rods M12 and hexagon nuts.
Disassemble circlip (18) and loosen the hexagon
nuts carefully, until the springs (10) are relieved.
l Disassemble all parts mounted to hub (5).

i Note
Check the friction areas on parts (2, 3 and 4) for wear
and cracks. In case of cracks or flatness faults the af-
fected parts must be replaced or their friction faces
need to be reworked (dead smoothing).

008 910 36 BOMAG 285

7.10 Friction lining / replacing the outer discs

The untensioned length of the compression springs (e.g. grinding noises) these must be replaced by new
(10) must be checked. If the springs have settled for bearings.
more than 10%, they must be replaced by new ones. l Reinstall the clutch.
Untensioned length = 127.8 mm
Installing the clutch
i Note
The Belleville springs (19, see clutch repair overview)
must also be checked.

The assembly height L0 should be 1.3 +/- 0.1 mm.

l
Clean all parts and cover them slightly with a thin
coat of molybdenum sulphide paste or a similar lu-
bricant.

! Caution
Do not lubricate the friction faces on clutch hub
(5), inner disc (3), pressure disc (4) and the outer
discs (2). The friction faces must, under no condi-
tion, be treated or come in contact with grease, oil Fig. 67
or other conserving agents!
l Push the rubber disc of the elastic coupling into the
outer ring gear and slide the bell with intermediate
i Note flange into the centring in the engine housing (Fig.
When performing repair work on the clutch all seals 67).
should be checked. They should be replaced if any
wear or damage is found.
l
Install new outer disc(s) and reassemble the clutch.

i Note
Observe the tightening torques and the notes for liquid
screw retention agents (see clutch repair overview).

Fig. 68
l Insert the screws with Loctite and tighten them (Fig.
68).
l Assemble the covering plates.

Fig. 66

!Caution
Observe correct arrangement of Belleville springs
(Fig. 66) when reassembling.

i Note
During repair and maintenance work the roller bear-
ings should be checked. In case of bearing damage

286 BOMAG 008 910 36

Friction lining / replacing the outer discs 7.10

Fig. 69
l Assemble bell support and V-belt pulley (Fig. 69).
l Connect oil supply and lubricant line.

Caution
!

Check the oil supply for leaks.

008 910 36 BOMAG 287

7.10 Friction lining / replacing the outer discs

288 BOMAG 008 910 36

8 Conveyor belts, mechanics

008 910 36 BOMAG 289

290 BOMAG 008 910 36
Conveyor belts 8.1
8.1 Conveyor belts

Loading conveyor belt

For optimal loading of the milled material the loading
belt can be infinitely swivelled, lowered or lifted.
For optimal loading of the road milling machine the
loading belt can be hydraulically folded in.

Fig. 70 Loading belt folded in

Fig. 71 Loading belt, high and low belt speed

The belts speeds are infinitely adjustable.
1 Drive roller with hydraulic motor and tensioning
device
2 Reversing roller
3 Folding mechanism

008 910 36 BOMAG 291

8.1 Conveyor belts

Fig. 72 Loading belt folded in

Fig. 73 Folding mechanism with limit switch

1 Limit switch
2 Hydraulic cylinder

292 BOMAG 008 910 36

Conveyor belts 8.1
Gathering belt The belts speeds are infinitely adjustable.
Hold-down and gathering belt can be hydraulically
tensioned and slide in floating mode.

Fig. 74 Gathering belt with hold-down and gathering foot

Fig. 75 Gathering belt

1 Guide roller
2 Upper supporting roller
3 Output roller with conveyor belt motor
4 Lower support rollers
5 Clamping device
6 Reversing roller

008 910 36 BOMAG 293

8.1 Conveyor belts

Conveyor belt motor

Fig. 76 Sectional drawing

294 BOMAG 008 910 36

Checking, tightening the conveyor belts 8.2
8.2 Checking, tightening the con-
veyor belts

Check

Fig. 78
l For tensioning loosen the counter nuts (Fig. 78) on
both sides and tension the conveyor belt with the
screw.

Fig. 77 i Note
l Check the condition of the conveyor belts (Fig. 77). Tension evenly on both sides.
l Conveyor belts showing cracks and peel-offs must Center the belt.
be replaced immediately. Increase the tension on the side to which the belt is
l
Check supporting and reversing rollers for cleanli- running off, or reduce the tension on the opposite
ness, clean if necessary. side.
Run the conveyor belt a few minutes to check.
i Note
Dirt deposits on the rollers cause the belt to run out of Checking the supporting rollers
centre.
l Check the conveyor belt tension.

Tensioning loading and unloading belts

! Danger
Danger of injury!
Keep a safe distance when the conveyor belt is
running.
Do not adjust the tension while the belt is running.

Fig. 79
l Check the condition and movability of the rollers
(Fig. 79).
l If necessary remove any dirt deposits from the roll-
ers.
l Switch on the conveyor belt and check the centring.

008 910 36 BOMAG 295

8.3 Checking the safety ropes

8.3 Checking the safety ropes 8.4 Lubricating the conveyor belts

Loading conveyor belt

Fig. 80
l Check the condition of the safety ropes (Fig. 80), re-
place if necessary. Fig. 81
l Lubricate the articulated joint (Fig. 85) with three
strokes from the grease gun.

Fig. 82
l Lubricate the conveyor belt beam (Fig. 82) with
three strokes from the grease gun.

Fig. 83
l
Lubricate the front drive roller holders (Fig. 83) with
three strokes from the grease gun.

296 BOMAG 008 910 36

Lubricating the conveyor belts 8.4
Gathering belt

Fig. 84
l Lubricate the roller bearings (Fig. 84) with three
Fig. 87
strokes from the grease gun.
l Grease the threaded spindle (Fig. 87).

Fig. 85
Fig. 88
l Grease the threaded spindle (Fig. 85).
l Lubricate the front drive roller holders (Fig. 88) with
Folding linkage for unloading conveyor three strokes from the grease gun.
belt

Fig. 89

Fig. 86
l Lubricate the bearings (Fig. 89) with three strokes
from the grease gun.
l Lubricate all grease nipples (Fig. 86) with three
strokes from the grease gun.

008 910 36 BOMAG 297

8.5 Folding / unfolding the loading conveyor belt

8.5 Folding / unfolding the loading

conveyor belt

Folding the loading conveyor belt in

Fig. 92
l Fold the conveyor belt in completely (Fig. 92).

Fig. 90
l Lower the conveyor belt completely (Fig. 90).
l Lower the front of the machine.
l
Raise the rear of the machine
This eases placing the front frame of the loading con-
veyor belt to the ground.

Fig. 93
l Insert the securing clamps (Fig. 93) on both sides.

Unfolding the conveyor belt

l Perform these steps in reverse order to unfold the
conveyor belt.

Fig. 91
l Loosen the interlock (Fig. 91) between fixed and
movable frame section.
l Raise the loading conveyor belt.

298 BOMAG 008 910 36

9 Travel drive, mechanics

008 910 36 BOMAG 299

300 BOMAG 008 910 36
Travel drive 9.1
9.1 Travel drive l Differential lock for slippage free traction
l Height adjustable supports.
Crawler track
l Four steerable crawler tracks with highly resistant
polyurethane track plates.

Fig. 94 Steerable crawler tracks

Fig. 95 Travel motor

008 910 36 BOMAG 301

9.1 Travel drive

Crawler track

Fig. 96
1 Track wheel
2 Grease nipple
3 Tensioning wheel
4 Supporting rollers
5 Travel motor
6 Travel gear
7 Track plate
8 Track
9 Travel motor with speed transducer
10 Spring loaded track tensioner with integrated
grease cylinder

302 BOMAG 008 910 36

Travel drive 9.1
Travel gear
The travel gear reduces the output speed of the travel
motor to a lower speed.

Fig. 97 Travel gear

Four track steering

Fig. 98 Four track steering l

Front and rear automatically synchronized.
The following steering modes are possible: l Crab walk.
l Front and rear, rear steering optionally with auto-
matic centring.

008 910 36 BOMAG 303

9.1 Travel drive

Adjusting the track width

Fig. 99 Setting the track width

Front and rear track pairs must be exactly in line to
each other

i Note
The corresponding settings are made on the tie rods.

304 BOMAG 008 910 36

Checking the track plates 9.2
9.2 Checking the track plates 9.3 Retightening the track shoe
fastening screws

Fig. 100
l Check the condition of the track plate coating (Fig. Fig. 101
100), replace if necessary. l Retighten all fastening screws for the track shoes
(Fig. 101).

008 910 36 BOMAG 305

9.4 Checking the track drive

9.4 Checking the track drive Checking bolts and bushings

! Danger i Note
Danger of accident! The inner wear of bolts and bushings cannot be
checked as long as the track remains assembled.
Perform this work only with the engine shut down! Wear is characterized by an extension of the track.

Checking the track tension

! Caution
A wrong track tension causes higher wear.

Fig. 104
l
Measure the length over the centers of five track
link bolts with a tape measure (Fig. 104).

new track B=560 mm

Fig. 102
Replace the track if B=566 mm
l Check the track tension, if necessary adjust on the
track tensioner (Fig. 102).
l In order to tension the track clean the fitting (arrow)
and press in grease with a grease gun.

Checking the track links

Fig. 105
l
Measure the outer diamter of the bush (Fig. 105).

new bush C=37 mm

Replace the track if C=34.3 mm

Fig. 103
l Measure the height of the track links (Fig. 103). Replacing the track

new track link A=70 mm ! Caution

Replace the track if A=68.2 mm Replace also the track drive wheel.
l Move the machine until the connecting bolt with the
notch is in top position.

306 BOMAG 008 910 36

Checking the track drive 9.4
l Shut down the engine and pull out the ignition key. Checking the track wheels
l Relieve the track.

Fig. 108
Fig. 106 l Check the height of the running surface to the guid-
l Press the connecting bolt (Fig. 106) out with an hy- ing (Fig. 108).
draulic press.
new track wheel E=16 mm
l Take off the track and remove the track plates.
l Clean the track plates, check their condition and fit Replace the track wheel if E=18 mm
them to the new track.
Checking the track drive wheel
Checking the supporting rollers
!Caution
i Note Always replace the track drive wheel when replac-
For easier measuring you may choose one supporting ing the crawler track.
roller each at the beginninga and the end of the track
drive.

Fig. 109
l Check the wear on the teeth (Fig. 109).
Fig. 107
l Check the diameter of both running surfaces (Fig.
107).
i Note
Replace when the depth of the wearijng is close to the
hardening depth.
new supporting roller D=135 mm
Nominal value:
Replace the supporting roller if D=132.5 mm
F=4,2 mm hardening depth

008 910 36 BOMAG 307

9.5 Lubricating the travel drive

9.5 Lubricating the travel drive 9.6 Lubricating the steering sys-
tem

Fig. 110
l Lubricate the pin (Fig. 110) with three strokes from Fig. 111
the grease gun. l Lubricate the tie rods (Fig. 111) with three strokes
from the grease gun.

Fig. 112
l Lubricate the steering cylinder bearings (Fig. 112)
with three strokes from the grease gun.

Posts

Fig. 113
l
Lubricate the bushings (Fig. 113) with three strokes
from the grease gun.

308 BOMAG 008 910 36

Oil change in track drive gear 9.7
9.7 Oil change in track drive gear

! Caution
Drain oil only at operating temperature.

Environment
Catch old oil and dispose of environmentally.
l Park the machine horizontally.

Fig. 114
l
Move the machine, until the drain plug (Fig. 114) is
in lowest position.
l
Clean and unscrew the drain and level control
plugs.
l Drain and catch all oil.
l Screw the drain plug back in and tighten it.

Fig. 115
l Fill in oil through the oil level control bore, until it
reaches the bottom edge of the bore. (Fig. 115).
l Screw the level control plug back in and tighten it.

For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.

008 910 36 BOMAG 309

9.7 Oil change in track drive gear

310 BOMAG 008 910 36

10 Pump transfer case

008 910 36 BOMAG 311

312 BOMAG 008 910 36
Transfer case 10.1
10.1 Transfer case

Fig. 1 Engine with transfer case

A highly elastic coupling between engine and transfer
case ensures a clearance free connection between
clutch hub and drive shaft.

Fig. 2 Coupling

008 910 36 BOMAG 313

10.1 Transfer case

Fig. 3 Cross section of transfer case

Technical data:
l Rigid housing made of grey cast iron
l
Induction hardened gears with ground tooth flanks
l Oil bath lubrication, pressure circulation lubrication

314 BOMAG 008 910 36

Transfer case 10.1
Notes on assembly: Hydraulic pumps must be oil tight connected to the
Heavy blows with a hammer must be strictly avoided, mounting flanges and should not apply any axial pres-
because roller bearings, circlips and other internal sure to the gearbox shafts!
parts could be damaged! The coupling pieces or splines must be thoroughly lu-
bricated before assembly, we recommend the use of
Optimol White T or Staburags NBU 30 PTM.

Fig. 4 Pump transfer case without pumps

Fig. 5 Pump transfer case with pumps

008 910 36 BOMAG 315

10.2 Check the oil level in the pump drive gear

10.2 Check the oil level in the pump 10.3 Change the oil in the pump
drive gear drive gear

i Note i Note
Check the oil level only in cold condition and with the Drain oil only at operating temperature.
engine shut down.
Danger
!

Danger of scalding!
Danger of scalding when draining off hot oil!

Environment
Environmental damage!
Catch old oil and dispose of environmentally.
l Remove the bottom cover.

Fig. 6
l Unscrew the plug (Fig. 6).
l
Check the oil level on the dipstick.
l
The oil level must be near the "Max"-mark.
l Top up oil, if necessary.

For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.

Fig. 7
l
Unscrew the drain hose (Fig. 7) from the socket.
l
Drain off and catch old oil.
l
Once all old oil has run out remove the oil drain
hose.

Fig. 8
l Fill in new oil (Fig. 8).

316 BOMAG 008 910 36

Change the oil in the pump drive gear 10.3
For quality and quantity of oil refer to the table of
fuels, lubricants and filling capacities.

Fig. 9
l Check the oil level on the dipstick (Fig. 9), if neces-
sary correct the filling level.

008 910 36 BOMAG 317

10.3 Change the oil in the pump drive gear

318 BOMAG 008 910 36

11 Hydraulics

008 910 36 BOMAG 319

320 BOMAG 008 910 36
11.1 Service Training Hydraulics

008 910 36 BOMAG 321

11.1 Service Training Hydraulics

322 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 323

11.1 Service Training Hydraulics

324 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 325

11.1 Service Training Hydraulics

326 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 327

11.1 Service Training Hydraulics

328 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 329

11.1 Service Training Hydraulics

330 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 331

11.1 Service Training Hydraulics

332 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 333

11.1 Service Training Hydraulics

334 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 335

11.1 Service Training Hydraulics

336 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 337

11.1 Service Training Hydraulics

338 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 339

11.1 Service Training Hydraulics

340 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 341

11.1 Service Training Hydraulics

342 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 343

11.1 Service Training Hydraulics

344 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 345

11.1 Service Training Hydraulics

346 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 347

11.1 Service Training Hydraulics

348 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 349

11.1 Service Training Hydraulics

350 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 351

11.1 Service Training Hydraulics

352 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 353

11.1 Service Training Hydraulics

354 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 355

11.1 Service Training Hydraulics

356 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 357

11.1 Service Training Hydraulics

358 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 359

11.1 Service Training Hydraulics

360 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 361

11.1 Service Training Hydraulics

362 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 363

11.1 Service Training Hydraulics

364 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 365

11.1 Service Training Hydraulics

366 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 367

11.1 Service Training Hydraulics

368 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 369

11.1 Service Training Hydraulics

370 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 371

11.1 Service Training Hydraulics

372 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 373

11.1 Service Training Hydraulics

374 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 375

11.1 Service Training Hydraulics

376 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 377

11.1 Service Training Hydraulics

378 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 379

11.1 Service Training Hydraulics

380 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 381

11.1 Service Training Hydraulics

382 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 383

11.1 Service Training Hydraulics

384 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 385

11.1 Service Training Hydraulics

386 BOMAG 008 910 36

Service Training Hydraulics 11.1

Service Training
Description about the 18 solenoid valves

Pos. Designation Pos. in wiring diagram Pos. in hydraulic diagram Measuring values
the first No are the No in circuit
page No
1 Auxiliary hydraulics 30Y6 1 0/24 V
2 Post front, left 36Y1 2 prop.solenoid
0-1200 mA
3 Water filling pump 42V1 3 0/24 V
4 Post rear 36Y3/4 4 0/24 V
5 Conveyor belt up / down 27Y1/2 5 0/24 V
6 Conveyor belt right / left 27Y3/4 6 0/24 V
7 Conveyor belt in / out 33Y2/4 7 0/24 V
8 Conveyor belt bout / in 33Y3/5 8 0/24 V
9 Milling drive clutch 30Y7 9 0/24 V
10 Grade shoes, left 24Y1 10 0/24 V
11 Grade shoes, right 24Y2 11 0/24 V
12 Scraper door - pretension 39Y3 12 0/24 V
13 Scraper door up / down 39Y1/2 13 0/24 V
14 Gathering belt foot up / 27Y7/8 14 0/24 V
down
15 Steering rear 36Y5/6 15 0/24 V
16 Post front, right 36Y2 16 prop.solenoid
0-1200 mA
17 Water spray pump 33Y6 17 0/24 V
18 Belt tensioner - rotor drive 30Y8 18 0/24 V

BM 600 / 200 -H3-

008 910 36 BOMAG 387

11.1 Service Training Hydraulics

388 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 389

11.1 Service Training Hydraulics

390 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 391

11.1 Service Training Hydraulics

392 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 393

11.1 Service Training Hydraulics

394 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 395

11.1 Service Training Hydraulics

396 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 397

11.1 Service Training Hydraulics

398 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 399

11.1 Service Training Hydraulics

400 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 401

11.1 Service Training Hydraulics

402 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 403

11.1 Service Training Hydraulics

404 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 405

11.1 Service Training Hydraulics

406 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 407

11.1 Service Training Hydraulics

408 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 409

11.1 Service Training Hydraulics

410 BOMAG 008 910 36

Service Training Hydraulics 11.1

008 910 36 BOMAG 411

11.1 Service Training Hydraulics

412 BOMAG 008 910 36

12 Hydraulic cylinder

008 910 36 BOMAG 413

414 BOMAG 008 910 36
Repairing hydraulic cylinders 12.1
12.1 Repairing hydraulic cylinders ! Danger
Before disconnecting any hydraulic connections
i Note you must make sure that the engine has been shut
down and the system pressure has been relieved.
Piston rod seals are the main causes for friction and
leakage. With increasing age of the seals it may hap- All vertically arranged cylinders must be lowered,
pen that the hydraulic cylinder will move slower with pressure accumulators must be emptied and all
reduced power. consumers, the movement of which could possi-
bly generate pressure, must be blocked.
All components that had been removed and all
lines must be closed, so that no dirt can enter into
the system.

Fig. 1 Hydraulic cylinder Sealing

1 Piston rod l
Once the cylinder has been removed, retract the
2 Interlock piston rod completely and disconnect all connec-
3 Piston seals tions.
4 O-ring
5 O-ring i Note
6 Seal The cylinder can be carefully operated with com-
pressed air.
7 Dust seal
8 Cylinder l
Drain off all hydraulic fluid by operating the cylinder
manually.
9 Cylinder head
10 Ring nut
11 Bushing Environment
Catch running out hydraulic oil and dispose of en-
12 Piston
vironmentally.
l
Disassemble ring nut 10 (Fig. 1) and cylinder head
(9).
l Pull piston rod (1) with piston (12) out of the cylinder
(8).
l
Remove the interlock (2) and disassemble the pis-
ton (12) from the piston rod (1).

Caution
!

Before assembling the sealing elements you

should clean the complete cylinder system from

008 910 36 BOMAG 415

12.1 Repairing hydraulic cylinders

processing residues, chips, dirt and other foreign

particles.
During assembly seals should not be pulled over
sharp edges, threads, fitting keyways etc. Such
points must be thoroughly covered before assem-
bly. Sharp edges must be deburred or provided
with a chamfer or a radius.
Sharp tools must never be used.
Seals, piston rod and cylinder tube must be oiled
or greased before assembly.
l Replace seals (3, 4, 5, 6 and 7) and check bushing
(11).
l Reassemble the piston (12) to the piston rod (1) and
install the interlock (2).
l Push piston (12) with piston rod (1) into the housing.

! Caution
Take care of the seals.
l Slide the cylinder head (9) over the piston rod (1)
and tighten the ring nut (10).

Commissioning

i Note
Operate the cylinder several times with low load and
pressure. Due to trapped air hydraulic cylinders may
initially perform erratically, but normally vent them-
selves after a few stroked
Check for leaks before taking the machine back into
service.

416 BOMAG 008 910 36

13 Suppliers documentation

008 910 36 BOMAG 417

418 BOMAG 008 910 36
13.1 Steering and working pump A10V ......

008 910 36 BOMAG 419

13.1 Steering and working pump A10V ......

420 BOMAG 008 910 36

Steering and working pump A10V ...... 13.1

RDE 92703-02-R/12.00

Reparaturanleitung - A10VO 25 DFR Baureihe 52

A10VNO 41-85 DFR Baureihe 52

Repair instructions - A10VO 25 DFR Series 52

A10VNO 41-85 DFR Series 52

008 910 36 BOMAG 421

RDE 92703-02-R/12.00
13.1
Hinweis / Inhalt
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Notice / Contents Repair Instructions A10V(N)O

HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material shown
entsprechen dem Informationsstand zum Zeitpunkt der herein were as accurate as known at the time this
Drucklegung dieser Unterlage. publication was approved for printing.
Änderungen können den Service am Produkt beein- For repair, please use only original spare parts.
flussen, Verpflichtungen entstehen uns daraus nicht. Optional equipment and accessories may add cost to the
Methoden und Vorrichtungen sind Empfehlungen, für basic unit, and some options are available only in
deren Resultat wir keine Haftung übernehmen können. combination with certain models or other options.
Reparaturen nur mit Original-Ersatzteilen durchführen. For the available combinations refer to the relevant data
sheet for the basic unit and the desired option.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf
Adjustment and tests have to be carried out on the test
dem Teststand vorzunehmen.
bench under operating temperatures.
Schutz von Personen und Eigentum ist durch Vor- Protection of personnel and property has to be guar-
kehrungen sicherzustellen. anteed by appropriate measures.
Sachkenntnis, die Voraussetzung für jede Servicearbeit, Expert knowledge, the precondition of any service work,
vermitteln wir in unseren Schulungskursen. can be obtained in our training courses.

INHALT Seite/ CONTENTS

Page

A10V(N)O A10V(N)O

Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-6 Sealing the drive shaft
Steuerventil abdichten / reinigen 7 Sealing / cleaning the control valve
Pumpe demontieren 8-10 Disassemble the pump
Triebwerk ausbauen 11 Remove rotary group
Stellsystem ausbauen 12 Remove control device
Welle / Lager ausbauen 13 Remove shaft / beaerings
Überprüfungshinweise 14-15 Inspection hints
Pumpe montieren 16-17 Pump assembly
Abstimmung Lagerung 18 Adjustment of taper roller bearing
Pumpe montieren 19-24 Pump assembly
Steuerventil: Hinweise für DR, DFR, DFR 1 25 Control valve: Guidelines for the DR, DFR, DFR 1
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente 26 Tools, auxiliary tools, tightening torques

2 Brueninghaus Hydromatik
422 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Schnittbild
13.1
Reparaturanleitung A10V(N)O
Sectional view Repair Instructions A10V(N)O

NG 41-85
Verschlußschraube OHNE Ringnut
Size 41-85
Plug WITHOUT groove

NG 25
Verschlußschraube MIT Ringnut
Size 25
Plug WITH groove

008 910 36 BOMAG Brueninghaus Hydromatik

423 3
RDE 92703-02-R/12.00
13.1
Allgemeine Reparaturhinweise
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
General repair guidelines Repair Instructions A10V(N)O

Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!

Attention!
Observe the following guidelines when carrying out repairs
on hydraulic units!

Alle Öffnungen der Hydraulikaggregate verschließen.

Close off all openings of the hydraulic unit.

Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK
Ersatzteile verwenden.

Replace all of the seals.

Use only original BRUENINGHAUS HYDROMATIK
spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all sealing and sliding surfaces for wear.

Attention: Re-work of the sliding surfaces by using, for
example abrasive paper, can damage the surface.

Hydraulikaggregate vor Inbetriebnahme mit

Hydrauliköl befüllen.

Fill the hydraulic unit with hydraulic oil

before commissioning.

4 Brueninghaus Hydromatik
424 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Triebwelle abdichten
13.1
Reparaturanleitung A10V(N)O
Sealing the drive shaft Repair Instructions A10V(N)O

2
1

1 2

1. Sicherungsring, 2. Wellendichtring, 3. Lager

1. Circlip, 2. Shaft seal, 3. Bearing

Triebwelle abkleben.
Sicherungsring ausbauen.
Wellendichtring nach vorne entnehmen.

Protect the drive shaft.

Remove the circlip.
Remove shaft seal to front.

008 910 36 BOMAG Brueninghaus Hydromatik

425 5
RDE 92703-02-R/12.00
13.1
Triebwelle abdichten
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Sealing the drive shaft Repair Instructions A10V(N)O

Nach der Demontage des gelaufenen Wellendicht-

rings, einfetten des neuen WDR.
Sichtkontrolle Welle, Gehäuse.

Change the shaft seal and check its sliding surface

(drive shaft) and housing, grease the sealing ring.
Visual check shaft seal and housing.

Wellendichtring vorsichtig mit Montagewerkzeug bis

Anschlagring einpressen.

Assembling of the sealing ring carefully down to the

distance ring.

Sicherungsring einsetzen.

Assemble the snap ring.

Sitzkontrolle des Sicherungsrings in der Nut.

Visual check to ensure that the circlip is correctly

located in the groove.

6 Brueninghaus Hydromatik
426 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Steuerventil abdichten / reinigen
13.1
Reparaturanleitung A10V(N)O
Sealing / cleaning the control valve Repair Instructions A10V(N)O

Steuerventil abbauen
* Maß * festhalten!
Dichtfläche (1) kontrollieren.
O-Ringe (2) kontrollieren.

Remove the control valve

Measure dimension * and note
* down!
Check sealing surface (1).
Check O-rings (2).

2
1

008 910 36 BOMAG Brueninghaus Hydromatik

427 7
RDE 92703-02-R/12.00
13.1
Pumpe demontieren
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Disassemble the pump Repair Instructions A10V(N)O

Übersicht
Overview

8 Brueninghaus Hydromatik
428 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Pumpe demontieren
13.1
Reparaturanleitung A10V(N)O
Disassemble the pump Repair Instructions A10V(N)O

Demontageposition
Lage der Anschlußplatte zum Gehäuse der
Pumpe kennzeichnen.

Disassembly position
Mark the location of the connection plate
on the housing of pump.

Steuerventil abbauen.

Remove the control valve.

008 910 36 BOMAG Brueninghaus Hydromatik

429 9
RDE 92703-02-R/12.00
13.1
Pumpe demontieren
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Disassemble the pump Repair Instructions A10V(N)O

*
*

4 Befestigungsschrauben * ausbauen.

Remove the 4 socket screws *.

Anschlußplatte abheben und absetzen.

Verteilerplatte kann herunterfallen - festhalten
beim Abheben der Anschlußplatte.

Remove connection plate and store down.

Control plate can drop down - keep tight
while removing connection plate.

10 Brueninghaus Hydromatik
430 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Triebwerk ausbauen
13.1
Reparaturanleitung A10V(N)O
Remove rotary group Repair Instructions A10V(N)O

Lager der Anschlußplatte mit Abzieher

ausbauen.
Dichtfläche nicht beschädigen.

Pull bearing of the connection plate out using

a bearing puller.
Do not damage the sealing surface.

Lager und Scheibe ausbauen.

Dichtfläche nicht beschädigen.

Remove bearing and shim.

Do not damage the sealing surface.

Triebwerk in horizontaler Lage herausziehen.

Remove the rotary group in a horizontal

position.

008 910 36 BOMAG Brueninghaus Hydromatik

431 11
RDE 92703-02-R/12.00
13.1
Stellsystem ausbauen
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Remove control device Repair Instructions A10V(N)O

1
2
3

Verschlußschraube (1) mit Dichtring (2)

ausbauen.
Verstellkolben (3) (-flache Seite*- ) mit
Werkzeug fassen und herausziehen.

Remove plug (1) with seal (2).

Pull out control piston (3)
(-flat surface*-) with tool.

Ausbau Kolbenstange und

Schwenkwiege
Innenliegende Schwenkwiege (5) mit
5
Werkzeug fassen und in Pumpe um
Z-Achse leicht drehen.
Z Kolbenstange (4) entnehmen.
Schwenkwiege (5) entnehmen.

Remove piston rod and swash plate.

Turn swash plate (5) inside of the
housing slightly along Z-axis with tool.
Remove piston rod (4).
Remove swash plate (5).

Lagerschalen und Feder entnehmen.

Auf Einbaulage achten!

Remove bearing shells and bearing.

Attention for position!

12 Brueninghaus Hydromatik
432 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Welle / Lager ausbauen
13.1
Reparaturanleitung A10V(N)O
Remove shaft / bearings Repair Instructions A10V(N)O

Triebwelle mit Lager entnehmen.

Remove drive shaft with bearing.

Sicherungsring und Wellendichtring ausbauen.

Remove circlip and shaft seal.

Kegelrollenlager-Außenring mit Ab- und

Auszieher aus Gehäuse-Preßsitz herausziehen.
Alle Verschlußschrauben demontieren.

Pull out outer race of tapered bearing out of

housing press seat.
Use bearing puller.
Remove all plugs.

008 910 36 BOMAG Brueninghaus Hydromatik

433 13
RDE 92703-02-R/12.00
13.1
Überprüfungshinweise
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Inspection hints Repair Instructions A10V(N)O

Alle Lager und Dichtungen erneuern.

Renew all bearings and seals.

Kontrolle:
1. Verzahnung ausgeschlagen, Passungsrost
2. Einlaufrille vom Wellendichtring
5 3. Lagersitz
2 3 4 4. Verzahnung - Mitnahme Zylinder
1
5. Lagersitz

Check:
1. Wear on slines, fretting
2. Drive shaft seal wear grooves
3. bearing seat
4. Splines for cylinder drive
5. Bearing seat

Kontrolle:
* Gleitfläche riefenfrei.
* Beweglichkeit Kolbenstange prüfen

Check:
Sliding surface free of grooves.
* Check for freedom of piston rod movement

Kontrolle:
Lagerbahnen

Check:
Bearing surfaces

Kontrolle!
Rückzugeinrichtung riefenfrei, keine Einlaufspuren
im Gleitschuhbereich.

Check!
That the retaining plate is free of grooves and
that there is no wear in the slipper pad area.

14 Brueninghaus Hydromatik
434 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Überprüfungshinweise
13.1
Reparaturanleitung A10V(N)O
Inspection hints Repair Instructions A10V(N)O

Kontrolle!
Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).

Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).

Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

Riefenfrei, keine Einlaufspuren

Free of grooves, no signs of wear.

Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).

Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).

Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.

Check!
Mounting surface - control plate undamaged

008 910 36 BOMAG Brueninghaus Hydromatik

435 15
RDE 92703-02-R/12.00
13.1
Pumpe montieren
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Lageraußenring mit Vorrichtung einpressen.

Press-in distance ring with tool.

Welle in Lager einstecken.

Wellendichtring nicht beschädigen!

Assemble shaft in correct position.

Do not cut shaft seal!

16 Brueninghaus Hydromatik
436 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Pumpe montieren
13.1
Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Lageraußenringe des hinteren Lagers mit Vorrich-

tung in Anschlußplatte einpressen.

Press-in outer racer of rear bearing into

connection plate

Anschlußplatte gemäß der Kennzeichnung

montieren.
4 Befestigungsschrauben anziehen.

Assemble connection plate to pump acc. sign.

Pull 4 socket screws tight.

Abstimmung der Triebwerkslagerung siehe

Folgeseite.
Anschließend Anschlußplatte demontieren.

Adjustment of taper roller bearing set see

following page.
Disassemble connection plate.

008 910 36 BOMAG Brueninghaus Hydromatik

437 17
RDE 92703-02-R/12.00
13.1
Abstimmung Lagerung
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Adjustment of taper roller bearing Repair Instructions A10V(N)O

Montage Abstimmung (Kegelrollenlager)

Taper roller bearing initial tension

Pos. 12

0 - 0,05

Abstimmung der Triebwerkslagerung Adjustment of taper roller bearing set

Die Vorspannung der Triebwerkslagerung muß im Cast iron housing must have initial tension of the
Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der bearings: 0 ..... 0,05 mm, grind Pos. 12 if necessary.
Abstimmscheibe Pos. 12 hergestellt werden.

18 Brueninghaus Hydromatik
438 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Pumpe montieren
13.1
Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Montagehinweis Wellendichtring siehe Seite 6.

Assembly instruction shaft seal see page 6.

Lagerschalen und Feder einlegen

Mit Fett fixieren.

Fit in bearing shells and spring.

Fix with grease.

008 910 36 BOMAG Brueninghaus Hydromatik

439 19
RDE 92703-02-R/12.00
13.1
Pumpe montieren
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

5 Schwenkwiege (5) und Kolbenstange (4)

Z einsetzen.
4 Anschlag Feder beachten.
Richtige Lage der Feder beachten.

Assemble swash plate (5) and piston rod (4)

into pump.
Spring guide pin in correct position.
Check correct position of the spring.

1 Kolbenstange (4), Verstellkolben (3), Dichtung (2),

und Verschlußschraube (1) montieren.
2
Verschlußschraube anziehen.
3 Nenngröße 25, 45, 63 MA =190 Nm + 20 Nm
Nenngröße 85 MA = 320 Nm + 20 Nm
Mit Loctite 242 sichern.

Assemble piston rod (4), control piston (3),

seal (2), and plug (1).
Pull plug tight.
Size 25, 45, 63 MA =190 Nm + 20 Nm
Size 85 MA = 320 Nm + 20 Nm
Secure with Loctite 242.

20 Brueninghaus Hydromatik
440 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Pumpe montieren
13.1
Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.

Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and slipper pad.

008 910 36 BOMAG Brueninghaus Hydromatik

441 21
RDE 92703-02-R/12.00
13.1
Pumpe montieren
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Rotationsgruppe montieren!
Montagehilfe:
Mit O-Ring Kolben festhalten.

Fit rotary group!

Assembly aid:
Hold the pistons by using an O-ring.

Lager und Abstimmscheibe auf Welle

montieren.

Assemble bearing and adjustment shim to

shaft.

22 Brueninghaus Hydromatik
442 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Pumpe montieren
13.1
Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

O-Ring in Anschlußplatte einlegen.

Mit Fett fixieren.
Verteilerplatte auf Anschlußplatte legen.
Mit Fett fixieren.
Auf richtigen Sitz zum Fixierstift achten.

Fit O-ring.
Fix with grease.
Fit control plate.
Fix with grease.
Check correct position to pin.

Anschlußplatte montieren.
Auf richtige Lage zum Gehäuse achten.
Markierung
Schrauben entsprechend Tabelle Seite 26
anziehen.

Assemble connection plate.

Check the correct position to housing.

Sign
Pull screws tight acc. list page 26.

008 910 36 BOMAG Brueninghaus Hydromatik

443 23
RDE 92703-02-R/12.00
13.1
Pumpe montieren
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Pump assembly Repair Instructions A10V(N)O

Ventil anbauen.

Assemble control valve.

Fertigmontage

Nochmals die Gehäusemarkierungen prüfen.

Final pump assembly

Double check of the housing signs.

24 Brueninghaus Hydromatik
444 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ......
Steuerventil: Hinweise für DR, DFR, DFR 1
13.1
Reparaturanleitung A10V(N)O
Control valve: Guidelines for the DR, DFR, DFR 1 Repair Instructions A10V(N)O

Alle abgebildeten Ventile dieser Seite in Blendenlage offen (s. Skizzen-Einbaulage).

All of the valves shown on this page have the orifice shown in its open condition (see sketches - installation location)

Steuerventil DR / DR control valve

Beide X-Anschlüsse verschlossen / Both X-ports are plugged
Förderstromregler blockiert / Flow controller is blocked

Einbaulage der Blende ∅ 0,6

Blende / Orifice 0,6 mm Position of the orifice ∅ 0,6

Steuerventil DFR / DFR control valve

Ein X-Anschluß verschlossen / One X-port is plugged Bypassdüse /
X
X Decompression-orifice

P A T

Steuerventil DFR 1 / DFR 1 control valve

Ein X-Anschluß verschlossen / One X-port is plugged
Bypassdüse X-T mit Stopfen verschlossen / Bypass orifice X-T is closed using a plug

Stopfen / Plug X

P A T

Adapter am DFR-Steuerventil für metrische Verrohrung

des Steueranschlusses X (ohne Blende).

Adapter on the DFR control valve for metric piping

of the pilot connection X (without orifice).

008 910 36 BOMAG Brueninghaus Hydromatik

445 25
RDE 92703-02-R/12.00
13.1
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Steering and working pump A10V ......
Reparaturanleitung A10V(N)O
Tools / auxiliary tools / tightening torques Repair Instructions A10V(N)O

Verwendete Loctite-Sorten
alle Abreißstopfen Nr. 601
sonst Nr. 242

Loctite types used:

For all break-off plugs No. 601
For all other parts No. 242

Anziehdrehmomente /
Tightening torques

Festigkeitsklassen 8,8; 10,9; 12,9

Bolt tensile strength grade:

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8,8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220

MA 10,9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670

12,9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000

MA (Nm) = max. Anziehdrehmoment (geölte Schrauben μ = 0,125)

MA (Nm) = max. tightening torque (lubricated screws μ = 0,125)

26 Brueninghaus Hydromatik
446 BOMAG 008 910 36
RDE 92703-02-R/12.00
Steering and working pump A10V ...... 13.1
Reparaturanleitung A10V(N)O
Repair Instructions A10V(N)O

Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen, Tel. (07308) 820, Fax (07308) 7274, E-Mail: [email protected]
Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Fax (07451) 8221, E-Mail: [email protected]

008 910 36 BOMAG Brueninghaus Hydromatik

447 27
13.1 Steering and working pump A10V ......

448 BOMAG 008 910 36

13.2 Travel pump A4VG 71 ... 180

008 910 36 BOMAG 449

13.2 Travel pump A4VG 71 ... 180

450 BOMAG 008 910 36

Travel pump A4VG 71 ... 180 13.2
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 92 003-02-R/03.03
Verstellpumpe A4VG 71-180 ersetzt/replaces 01.02

Variable Pump A4VG 71-180

Baureihe/Series 32

Reparaturanleitung / Repair Instructions

008 910 36 BOMAG 451

13.2 Bosch Rexroth AG | Mobile Hydraulics
2 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Hinweis / Inhalt
Notice / Contents

HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.

INHALT CONTENTS
Seite/
Page

A4VG A4VG

Schnittbild 3-4 Sectional view

Allgemeine Reparaturhinweise 5 General repair instructions
Dichtsätze und Baugruppen 6-9 Seal kits and sub assembly groups
Triebwelle abdichten 10 Sealing of the drive shaft
Hilfspumpe abdichten 11 Sealing of the boost pump
Stellkolbendeckel abdichten 12-13 Sealing of the control piston cover
Speisedruckventil abdichten 14 Sealing of the boost pressure valve
Druckbegrenzungsventil abdichten 15 Sealing of the pressure relief valve HD
Druckabschneidung abdichten 16 Sealing of the pressure cut-off valve
Ansteuergerät abdichten 17 Sealing of the control device
Ansteuergerät HW 18 Control device HW
Ansteuergeräte EP - HD 19-22 Control devices EP - HD
4/3 Wegeventil DA 23 Control device DA
Regelventil abdichten / überprüfen 24 Sealing of the regulator valve
Pumpe demontieren 25-29 Pump disassembly
Verstellung demontieren 30-31 Dismantling of the control
Zylinder demontieren 32 Dismantling of the cylinder
Überprüfungshinweise 33-34 Inspection notes
Stellkolben, Triebwerk montieren 35-37 Positioning piston, rotary group assembly
Triebwerk einbauen 38-41 Installation of the rotary group
Pumpe montieren 42-44 Assembly of the pump
Montageanweisung für Anziehdrehmomente 45-48 Assembly guidelines for tightening torques
Sicherheitsbestimmungen 49-50 Safety regulations
Einstellhinweise 51-57 Adjustment instructions

452 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.23
Schnittbild
Sectional view

HW/D

EP/D HD/D

008 910 36 BOMAG 453

13.2 Bosch Rexroth AG | Mobile Hydraulics
4 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Schnittbild
Sectional view

DA/D

454 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.25
Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying
out repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill the hydraulic units with the operating medium

before commissioning.

008 910 36 BOMAG 455

13.2 Bosch Rexroth AG | Mobile Hydraulics
6 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

Peripheral seal kit.

Triebwerk komplett.

Complete rotary group.

Stellkolben

Positioning piston

456 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.27
Stellkolben - Turcon-Glyd-Ring Dichtung
Positioning piston - Turcon-Glyd-ring seal

Deckel Stelldruck

Führungsbuchse
Stellzylinder
Turcon-Glyd-Ring
Lecköl
Pumpengehäuse

Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstellung At present the change of the control into Turcon seal is made
der Verstellung auf Turcon-Dichtungen. for A4VG.
Die Stückliste der kompletten Einheit erhält dabei eine neue The parts list of the complete unit will receive a new identification
Ident.- Nummer. number.
Typenschlüssel, Typnummer und Außenabmeßungen bleiben Type reference and outside dimensions remain unchanged
dabei unverändert. (Pumpengehäuse ändert sich nur im Bereich (pump housing will change at the area of the positioning piston.
vom Stellkolben. Stellkolben ändert sich in eine angefaste Positioning piston will change into chamfering design).
Ausführung).

Pumpengehäuse / Pump housing Pumpengehäuse / Pump housing

mit Lagerbuchse / with bush ALT / OLD mit Turcon-Dichtung / with Turcon seal NEU / NEW

* *

Die Umstellung der Verstellung auf Turcon-Dichtung ist The change of the control into Turcon seal design
im allgemeinen mit einer Funktionsverbesserung improves in general the function (DA-behaviour, lower
verbunden (DA-Verhalten, geringerer Temperatureinfluß temperature-influence on control times).
auf Stellzeiten).

Bei gleicher Düsenbestückung können sich die Stellzeiten The control times will slightly change with the same throttle
geringfügig verändern. sections. Therefore our customers have to be informed
about this change.

008 910 36 BOMAG 457

13.2 Bosch Rexroth AG | Mobile Hydraulics
8 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Baugruppen
Sub assemblies

Anschlußplatte

Valve plate

Ansteuergerät HW
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

Control device HW
Note:
Size 71 control device as size 40 - 56 with flat seal.

alt / old Ansteuergerät HD

Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

Control device HD
Note:
neu / new Size 71 control device as size 40 - 56 with flat seal.

Ansteuergerät EP
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

alt / old Control device EP

Note:
Size 71 control device as size 40 - 56 with flat seal.

neu / new

4/3 Wegeventil DA
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.
alt / old
Control device DA
Note:
neu / new Size 71 control device as size 40 - 56 with flat seal.

458 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.29
Baugruppen
Sub assemblies

Hilfspumpe

Boost pump

Regelventil

Control valve

HD - Ventil

High pressure valve

ND - Ventil

Low pressure valve

Druckabschneidung

Pressure cut-off

008 910 36 BOMAG 459

13.2 Bosch Rexroth AG | Mobile Hydraulics
10 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring ausbauen.

Protecting the drive shaft.

Remove retaining ring.

Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes fitted

with rubber.
Pull out shaft seal with pliers.

Wellendichtring mit Buchse auf Anschlag

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
leicht einfetten.

Press-in shaft seal with bush to stop.

Lightly grease the seal, dust lips and shaft seal ring.

460 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
11

Hilfspumpe abdichten
Sealing of the boost pump

*
*
Achtung!
* Angefaste "Seite" zum Deckel montieren.

Note!
* Mount chamfered side facing cover.

Lage kennzeichnen,
Befestigungsschrauben ausbauen.

Mark position,
remove fixing screws.

Deckel abdrücken.

Pry-off cover.

Kontrolle:
O-Ring, Nut, Lauffläche, Anschlußplatte.

Check:
O-ring, groove, gliding surface, connection plate.

008 910 36 BOMAG 461

13.2 Bosch Rexroth AG | Mobile Hydraulics
12 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Stellkolbendeckel abdichten
Sealing of the control piston cover

Achtung!
Korrekt mechanische 0-Lageneinstellung
überprüfen

Attention!
Check correct mechanical 0-position.

Lage kennzeichnen.

Mark position.

Deckel verdrehen und mit leichten

Hammerschlägen lösen.

Rotate cover and release by tapping gently

with hammer.

462 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
13

Stellkolbendeckel abdichten
Sealing of the control piston cover

Deckel kennzeichnen. Maß X festhalten, Konter-

mutter lösen, Stellschraube gegenhalten.

Mark cover. Must be fixed, loosen counter nut,

hold adjustment screw.
X

Deckel demontieren.

Remove cover.

Deckel von Stellschraube "abschrauben".

Lift off by turning the setting screw.

Kontrolle!
O-Ring (1), Nut (2), Gehäuse (3).

Check!
O-ring (1), groove (2), housing (3).

Achtung!
Korrekte mechanische Nullageneinstellung muß
nach Einbau im Gerät bzw. Prüfstand erfolgen.
(siehe Einstellhinweise Seite 54)

Attention!
Adjustment of the correct zero position to be carried
out after installation into the machine or on the test
bench.
(see adjustment instructions on page 54)

008 910 36 BOMAG 463

13.2 Bosch Rexroth AG | Mobile Hydraulics
14 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Speisedruckventil abdichten
Sealing of the boost pressure valve

Ventil komplett ausbauen.

Hinweis:
Einstellschraube nicht verändern.
Achtung!
Nach Einbau Ventileinstellung überprüfen!

Remove valve completely:

Note:
Do not change adjustment screw.
Attention!
Check valve setting after installation.

464 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
15

Druckbegrenzungsventil abdichten
Sealing of the pressure relief valve HD

Ventil komplett ausbauen.

Kontrolle: O-Ring, Gehäuse.
Wechsel der Dichtmutter - Einstellmaß (*)
festhalten.
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.

Remove valve completely.

Control: O-ring, housing.
Replacement of the tightening nut, record
measure (*).
Attention!
After assembly check "valve setting".
*

008 910 36 BOMAG 465

13.2 Bosch Rexroth AG | Mobile Hydraulics
16 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Druckabschneidung abdichten
Sealing of the pressure cut-off valve

Einstellteil komplett ausschrauben.

Kontrolle: O-Ring, Gehäuse.
Wechsel der Dichtmutter - Einstellmaß (*)
festhalten.
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.

Unscrew setting cartridge completely.

Control: O-ring, housing.
Replacement of the tightening nut, record
measure (*).
Attention!
After assembly check "valve setting".

466 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
17

Ansteuergerät abdichten
Sealing of the control device

DA
DA alt / old
HD
alt / old

DA
neu / new
HD
neu / new EP
alt / old

HW

EP
neu / new
NG 71 ... 125

NG 180

Ansteuergerät abbauen. Remove control device.

NG 71: Abdichtung der Ansteuergeräte wie NG 40 - 56 Size 71: Sealing of control device as size 40 - 56
mit Flachdichtung. with flat seal.
Achtung! Korrekte hydraulische Nullageneinstellung überprüfen. Attention! Check correct hydraulic 0-position.

Befestigungsschrauben demontieren.

Remove fixing screws.

Ansteuergerät abdrücken.

Pry-off the control unit.

Kontrolle
Dichtfläche (1), Flachdichtung (2), O-Ringe (3).

Check
Sealing surface (1), gasket (2), O-rings (3).

008 910 36 BOMAG 467

13.2 Bosch Rexroth AG | Mobile Hydraulics
18 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Ansteuergerät HW
Control device HW

NG 90-180
Size 90-180

Kontrolle:
O-Ringe und Dichtung.

Check:
O-rings, gasket.

468 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
19

Ansteuergeräte EP - HD
EP - HD Control devices

Ansteuergerät HD - EP alt (NG 90 - 180)

HD - EP (Size 90 - 180) control unit old

HD alt / old

EP alt / old HD alt / old

EP alt / old

Neues Ansteuergerät HD - EP (NG 71)

New HD - EP (Size 71) control unit alt / old

131,0 mm
neu / new

77,4 mm
202,0 mm

alt / old
214,4 mm

neu / new

008 910 36 BOMAG 469

13.2 Bosch Rexroth AG | Mobile Hydraulics
20 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Ansteuergeräte EP - HD
EP - HD Control devices

Ansteuergerät HD neu (NG 90 - 180)

HD - control unit new (Size 90 - 180)

Ansteuergerät EP neu (NG 90 - 180)

EP - control unit new (Size 90 - 180)

470 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
21

Ansteuergeräte EP - HD
EP - HD Control devices

* Markierung Montageposition HD *
* Marking the assembly position HD
*

* *

* Markierung
Montageposition HD * Assembly position marker HD

Wird von EP- auf HD-Ausführung umgebaut - Is converted from EP into the HD version -
Deckelposition beachten siehe Markierung take note of the cover position, see marker

Leckölkanal offen wird geschlossen. The open leakage port is plugged

Zugfeder tauschen! Exchange the tension spring!

008 910 36 BOMAG 471

13.2 Bosch Rexroth AG | Mobile Hydraulics
22 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Ansteuergeräte EP - HD
EP - HD Control devices

Markierung Montageposition EP Die neuen Proportionalmagnete müssen bei der Inbe-

Assembly position marker EP triebnahme entlüftet werden. Wird die Luft nicht aus
* dem Ankerraum entfernt, kann es zum Schwingen der
Hydraulische Nullage
Ansteuerung kommen.
Hydraulic zero position
Zum Entlüften ist am Ende des Magneten, im Messing-
Klemmschraube teil, ein kleiner Gewindestift M4, SW 2 vorhanden.
Clamping screw Dieser Gewindestift ist max. 2 Umdrehungen heraus-
* zudrehen und nach dem Entlüften mit 1 Nm wieder
festzuziehen.
Bei der Ausführung mit Nothand mit Federrückzug muß
zum Entlüften die Kunststoffmutter mit Gummibalg
entfernt und nach dem Entlüften mit 5+1 Nm wieder
angeschraubt werden.

Entlüftungsschraube * max. 2 Umdrehungen herausdrehen. The new proportional solenoids must be bled during
Bleed screw *. Unscrew by commissioning. If the air is not removed from the
a max. of 2 turns armature chamber oscillations at the control can occur.

* * For bleeding purposes there is, on the end of the sole-

noid, in the brass component a small set screw M4,
2A/F. This can be unscrewed by a maximum of 2 turns
and then after completion of the bleeding tightened to
a maximum of 2 Nm.
For the version with hand override and spring return
the plastic nut with rubber coating has to be removed
for bleeding. After bleeding it has to be replaced and
tightened with 5+1 Nm.

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

* *
Markierung
Klemmschraube 6,1 Nm Anziehmoment 5+1 Nm
Montageposition EP
Clamping screw 6,1 Nm Steckschlüssel SW 26
Assembly position
marker EP Tightening torque 5+1 Nm
26 A/F socket spanner
Hydraulische Nullage
Exzenterstift
Hydraulic
zero point
Eccentric pin
Beim Lösen der Klemmschraube
Exzenterstift - Hydraulische Nullage festhalten.

When loosening the clamping screw

Hold the eccentric pin - hydraulic zero point

472 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
23

4/3 Wegeventil DA
Control device DA

4/3 Wegeventil DA alt (NG 90 - 180)

DA - control unit old (Size 90 - 180)

Ablaufdrossel

4/3 Wegeventil DA neu (NG 90 - 180)

DA - control unit new (Size 90 - 180)

Anziehmoment 5+1 Nm
Steckschlüssel SW 26
Tightening torque 5+1 Nm
26 A/F socket spanner

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

008 910 36 BOMAG 473

13.2 Bosch Rexroth AG | Mobile Hydraulics
24 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Regelventil abdichten/überprüfen
Sealing of the regulator valve

Blende überprüfen.
Keine Beschädigung.

Inspect orifice.
No damage.

Gewinde abkleben.
O-Ring einsetzen.

Cover threads.
Insert O-ring.

474 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
25

Pumpe demontieren
Removing of the pump

EP, HD, HW
Verschlußschraube / Stift
Locking screw / pin

DA
Verdrillschraube /
Timing adjustment screw

Ansteuergerät abbauen.

Remove control device.

Hilfspumpe ausbauen.
Hinweis:
Einbaulage kennzeichnen.

Remove auxiliary pump.

Note:
Mark assembly position previously.

008 910 36 BOMAG 475

13.2 Bosch Rexroth AG | Mobile Hydraulics
26 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Pumpe demontieren
Removing of the pump

Anschlußplatte mit Hilfspumpe

Achtung: Drehrichtung wird immer mit Blick

auf die Triebwelle angegeben.

Port plate with auxiliary pump

Attention: Direction of rotation is always

indicated with view on the drive shaft.

z.B. Drehrichtung "Rechts"

e.g. "clockwise" direction of rotation

Drehrichtung "rechts"
2 1
Breite Seite zur Sichel "rechts".

1. O-Ring,
2. Entlastungskanal

Direction of rotation "clockwise"

2
Broadside to the crescent "clockwise"

1. O-ring
2. Discharge channel

476 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
27

Pumpe demontieren
Removing of the pump

Drehrichtung "links"

"Counterclockwise" direction of rotation

2 1 1. O-Ring,
2. Entlastungskanal

1. O-ring
2. Discharge channel

Verschleißplatte 71 - 180

Wear plate 71 - 180

008 910 36 BOMAG 477

13.2 Bosch Rexroth AG | Mobile Hydraulics
28 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Pumpe demontieren
Pump disassembly

Lage der Verdrillschraube markieren (1).

Einstellmaß festhalten.
Verdrillschraube auf Demontageposition stellen (2).

Mark the position of the indexing screw (1).

Record setting measure.
Set the indexing screw to disassembly position (2).
X

Lage der Hilfspumpe und Anschlußplatte

markieren.
Anschlußplattenbefestigung lösen.

Mark position of the connection plate.

Loosen connection plate fixation.

Anschlußplatte und Steuerplatte abheben.

Lift off port plate and control plate.

1. Zylinder nach unten drücken, nicht beschädigen.

2. Verdrillschraube herausdrehen.

1. Press the cylinder to the bottom, do not damage.

2. Remove fixing indexing screw.

Zylinder komplett mit Kolben und

Rückzugeinrichtung ausbauen.

Push off hydraulic section of rotary group.

478 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
29

Pumpe demontieren
Pump disassembly

WDR / Sicherungsring ausbauen.

Remove radial seal ring and retaining ring.

Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with slide hammer strokes.

Schwenkwiege / Lager komplett ausbauen.

Remove swash plate / bearing cups.

Gelenkstift ausbauen.

Remove joint pin.

008 910 36 BOMAG 479

13.2 Bosch Rexroth AG | Mobile Hydraulics
30 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Verstellung demontieren
Dismantling of the control

Alt / Old
Neu / New

Alt / Old

Neu / New

Lage vom Deckel markieren, Maß "Nullage" fest-

halten - Mutter lösen.

Mark position of the cover, note measure of

"zero position" - loosen nut.

Deckel abdrehen.

Remove cover.

480 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
31

Verstellung demontieren
Dismantling of the control

Lage des Deckels markieren.

Befestigungsschrauben lösen, abbauen.

Mark position of the cover.

Loosen locking screw, remove cover.

Stellzylinder ausbauen.

Remove positioning ring.

Vorrichtung aufsetzen und Feder vorspannen.

Aufnahmering ausbauen.

Fit tool device and preload spring.

Remove take-off ring.

Ringe ausbauen.
Sicherungsring ausbauen.
Achtung: Teile stehen unter Federvorspannung.

Remove rings.
Remove safety ring.
Attention: Parts are under spring load.

008 910 36 BOMAG 481

13.2 Bosch Rexroth AG | Mobile Hydraulics
32 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Zylinder demontieren
Dismantling of the cylinder

Kolben mit Rückzugeinrichtung ausbauen.

Tragkugel mit Tellerfedersäule abheben.

Remove piston with retaining plate.

Remove retaining ball with spring cup assembly.

Sicherungsring ausbauen.

Remove safety ring.

Scheibe 1, 2

Disc 1, 2

1 2

482 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
33

Überprüfungshinweise
Inspection notes

Lager Lagerschalen Kontrolle!

Bearing Bearing cup Käfig-Paar (1),
Lagerschalenpaar (2).
2
Check!
Cage set (1),
Bearing cup set (2).

Kontrolle!
Lagerbahnen (1)

Check!
Bearing surfaces (1)

Kontrolle!
Gleitfläche riefenfrei.

Check!
Sliding surface free from scoring.

Kontrolle!
Rückzugeinrichtung riefenfrei.

Check!
Check that return device is free of scoring.

Kontrolle!
1 1. Verzahnung "ausgeschlagen", Passungsrost.
2 2. Laufflächen.
1 3. Lauffläche - Wellendichtring.
3
1
Check!
1. Splines for damage or fretting.
2. Running surfaces.
3. Groove cut by shaft seal.

008 910 36 BOMAG 483

13.2 Bosch Rexroth AG | Mobile Hydraulics
34 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Überprüfungshinweise
Inspection notes

Kontrolle!
Lauffläche (1) keine Kratzer, keine Metall-
einlagerungen, kein Axialspiel (2), (Kolben nur
satzweise tauschen).

Check!
Check that there are no scratches or metal deposits
on sliding surface (1), and there is no axial play (2),
(otherwise: pistons must be replaced in sets).

Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

Kontrolle!
Zylindergleitfläche (1) riefenfrei.
Steuerplatte (2) nicht riefig.

Check!
Cylinder surface (1) free of scoring.
Control plate (2) without scoring.

Kontrolle!
Stellkolben - Schwenkwiegenverbindung
Gleitstein (1), Nut im Stellkolben (2), Stellkolben.

Check!
Positioning piston - cradle linkage
Gliding stone (1), groove at the positioning piston
(2).
Positioning piston.

484 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
35

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Stellkolben montieren.
Hinweis:
Auf korrekten Sitz der geteilten Ringe "achten".

Assemble positioning piston.

Instruction:
Observe correct fit of the divided rings.

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring

Hilfswerkzeuge / Auxiliary tools:
Montagezange / Assembly pliers: B+S x M22

Montage / Assembly A4VG

2
3

3
2
Pos. / Pos. / Pos. / Pos. /
1
Item 1 Item 2 / 3 Item 2 / 3 Item 1

Pos. / Item 1: Stangenführungsring montieren.

Install barguide ring.

Pos. / Item 3: O-Ring montieren.

Install O-ring.

008 910 36 BOMAG 485

13.2 Bosch Rexroth AG | Mobile Hydraulics
36 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring

Dichtring (Pos. 2) in die Montagezange einlegen.

Fit the seal ring (Item 2) into the assembly tool.

Dichtring mit Zangenschenkel nierenförmig zu-

sammendrücken. Die Verformung von Turcon-Dich-
tungen ist sorgfältig vorzunehmen, damit die Dicht-
kanten nicht beschädigt werden.

Press the seal ring into the kidney shape using the
assembly tool. The deformation of the Turcon seal
has to be done with care so as not to damage the
sealing edges.

Dichtring ins Gehäuse einführen und in der

Aufnahmenut plazieren. Dann Spannung lösen und
Montagezange herausziehen. Lage des Dicht-
ringes prüfen - eventuell mit dem Finger
egalisieren.

Position the seal ring into the housing and place it

into the groove. Release the tension and withdraw
the assembly tool.
Check the position of the seal ring if necessary
straighten using a finger.

Führungsdorn in Stellkolben einbauen.

Insert guide thorn into the positioning piston.

Führungsdorn / A4VG28 I: 277 5 017

Guide thorn: A4VG40 I: 277 5 017
A4VG56 I: 277 5 018
A4VG71 I: 277 5 019
A4VG90 I: 277 5 020
A4VG125 I: 277 5 021
A4VG180 I: 277 5 022
A4VG250 I: 277 5 023

Führungsdorn leicht einfetten.

Stellkolben mit Führungsdorn einbauen.

Grease slightly guide thorn.

Install positioning piston with guide thorn.

486 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
37

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Stellkolben ins Gehäuse einsetzen.

Hinweis:
Stellkolben vor Einbau einölen.

Insert positioning piston into the housing.

Instruction:
Oil positioning piston before assembly.

Stellkolben mit Hebel (Id.Nr. 2774491) ausrichten.

* Führung für Gleitstein - Schwenkwiege

Position stroke piston with lever (Id.No. 2774491).

* Sliding stone guidance in the piston.

Lagerschalenpaar einsetzen.

Insert bearing cup set.

Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett

Assemble bearing, wire, gliding stone and

articulating pin.
Assistance: Devices e.g. - Clamp / rubber rings /
grease

Schwenkwiege komplett ins Gehäuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehäuse
"achten".
Montagehilfe ausbauen.

Insert completely swivel cradle into the housing.

Pay attention for correct seat of the swivel cradle in
the housing.
Remove auxiliary device.

008 910 36 BOMAG 487

13.2 Bosch Rexroth AG | Mobile Hydraulics
38 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwerk einbauen
Installation of the rotary group

Kontrolle: Sitz der Schwenklager in der

Lagerbahn.
Schwenkwiege mittig stellen mit Meßvorrichtung
(Uhr oder Tiefenmaß)
Punkt 1 und 2 kontrollieren - gleiches Maß.

Check: Location of the swivel-bearing

in the bearing.
Centralise by using a measuring device (dial gauge
or depth measurement).
Check points 1 and 2 - they should have the same
dimension.

Gelenkstift montieren.

Fit joint pin.

488 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
39

Triebwerk einbauen
Installation of the rotary group

Haltevorrichtung montieren.
Mit Gewindestift Schwenkwiege festhalten.
Keine Gewaltanwendung.

Fit holding device.

Hold swash plate in position utilising the set screw.
Do not use force.

Haltevorrichtung "Schwenkwiege" A4V

Holding device "swivel cradle" A4V

Teil/Part 3 Teil/Part 4

∅ ∅
6, 7, 8, 9
∅ ∅
3, 4, 5

∅ ∅

Teil/Part 5
∅
2
∅
1

Pos./Item Benennung/Designation Stck./Qty.

1 Winkel/Angle 2
2 Gewindestift/Threaded pin 2
3 Scheibe/Shim 2
4 Scheibe/Shim 2
5 Scheibe/Shim 2
6 Zyl. Schraube/Cyl. screw M12 x 25 DIN 912 2
7 Zyl. Schraube/Cyl. screw M14 x 25 DIN 912 2
8 Zyl. Schraube/Cyl. screw M16 x 30 DIN 912 2
9 Zyl. Schraube/Cyl. screw M20 x 35 DIN 912 2

008 910 36 BOMAG 489

13.2 Bosch Rexroth AG | Mobile Hydraulics
40 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwerk einbauen
Installation of the rotary group

Neue Montageposition!
Triebwelle mit Lager und Wellendichtring
einbauen (siehe Seite 10).

Assemble drive shaft with bearings and radial

seal rings (see at page 10).

Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and piston pad.

490 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
41

Triebwerk einbauen
Installation of the rotary group

Vorrichtung ausbauen.
Zylinder mit Kolben und Rückzugeinrichtung
einbauen.

Remove holding device.

Fit cylinder complete with pistons and retaining device.

Montagehilfe:
Mit O-Ring Kolben festhalten.

Assembly aid:
Hold the pistons by using an O-ring.

008 910 36 BOMAG 491

13.2 Bosch Rexroth AG | Mobile Hydraulics
42 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwerk montieren DA
Assembly of the rotary group DA

Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung! Geräuschkerben sind drehrichtungs-
bezogen eingeschliffen.

Control plate clockwise rotation - indexed in the

R direction of rotation.
Note! Noise grooves are machined - in based on
directionof rotation.

Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung! Geräuschkerben sind drehrichtungs-
bezogen eingeschliffen.
L
Control plate counter clockwise rotation - indexed
in the direction of rotation.
Note! Noise grooves are machined - in based on
direction of rotation.

Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.

For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.

Maß X mit Vorrichtung neu ermitteln.

Zylinder mit Vorrichtung nach unten drücken.
Verdrillschraube bis Anschlag einschrauben -
Maß X - Kerbe in Montageposition drehen.

Re-identify dimension X with device.

Push cylinder down with device.
Screw in eccentric screw till stop - Dimension X -
Turn groove in assembly position.

Hilfsvorrichtung: / A4VG71 I: 277 5 088

X Auxiliary device: A4VG90 I: 277 5 089
A4VG125 I: 277 5 090
A4VG180 I: 277 5 091
A4VG250 I: 277 5 092

Steuerplatte einsetzen - Rechtslauf.

Insert the control plate - clockwise rotation.

492 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
43

Triebwerk montieren DA
Assembly of the rotary group DA

Steuerplatte einsetzen - Linkslauf.

Insert the control plate - Counter- clockwise

rotation.

Anschlußplatte aufbauen.
Achtung! Federvorspannung!
Mit zwei Befestigungsschrauben überkreuz An-
schlußplatte in Gehäuseführung einsetzen -
Fertigmontage!

Assemble connection plate.

Attention! Spring preloaded!
Insert control plate into housing, guidance with two
locking screws crossing over -Finish assembly!

Verdrillschraube - Nach Markierung ausrichten.

Locking screw - Observe adjusting measure.

1. Deckel montieren.
2. Nullage nach Maß einstellen.

1. Assemble cover
2. Adjust zero position according to measure.

008 910 36 BOMAG 493

13.2 Bosch Rexroth AG | Mobile Hydraulics
44 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Triebwerk montieren EP, HD, HW

Assembly of the rotary group EP, HD, HW

Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung! Pos.1 Fixierstift
Geräuschkerben sind drehrichtungsbezogen
eingeschliffen.

Control plate clockwise rotation - indexed in the

direction of rotation.
R Pos.1
Note! Pos.1 Fixing pin
Noise grooves are machined - in based on direction
of rotation.

Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung! Pos.1 Fixierstift
Geräuschkerben sind drehrichtungsbezogen
eingeschliffen.

Control plate counter clockwise rotation - indexed

L Pos.1
in the direction of rotation.
Note! Pos.1 Fixing pin
Noise grooves are machined - in based on direction
of rotation.

Zylinderflächen und DU-Lager einölen, neue

O-Ringe mit Fett einreiben und einsetzen.

Oil the running surfaces of the cylinder barrel and

the DU- bearing. Grease the O-rings and insert
in grooves.

Verschlußschraube

Plug

494 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
45

Triebwerk montieren EP, HD, HW

Assembly of the rotary group EP, HD, HW

Verschlußschraube einbauen.

Screw in the plug.

Anschlußplatte mit Steuerplatte lagerichtig aufset-

zen.
Hinweis:
EP, HD, HW -Steuerplatte mit Fett einsetzen.

Place port block with control plate in correct

position.
Note:
EP, HD, HW - Put control plate with grease.

1. Deckel montieren.
2. Nullage nach Maß einstellen.

1. Assemble cover
2. Adjust zero position according to measure.

008 910 36 BOMAG 495

13.2 Bosch Rexroth AG | Mobile Hydraulics
46 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Pumpe montieren
Assembly of the pump

Achtung!
Korrekte mechanische Nullageneinstellung muß nach
Einbau im Gerät bzw. Prüfstand erfolgen.

Attention!
Adjustments of the correct zero position to be carried out
after installation into the machine or on the bench test.

Hilfspumpe montieren.
Hinweis: Drehrichtung beachten. (Siehe Seite 26, 27)

Assemble auxiliary pump.

Note: Take care of direction of rotation. (See page 26, 27)

Dichtung mit zwei Befestigungschrauben zentrieren und

NG 71 Ansteuergerät einbauen.
Alle vier Schrauben mit halbem Drehmoment anziehen.

Centre the seal using two fixing screws and fit

the control unit.
Tighten all four screws to half of specified torque.

Fünfte Schraube einsetzen und mit Drehmoment = 10,4 Nm

festziehen.
Restliche vier Schrauben nach Drehmoment festziehen.

Fit the fifth screw and tighten to a torque of 10,4 Nm.

Then tighten the other four screws to there correct torque.

Ansteuergerät montieren.

Assemble control device.

496 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
47

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metrischem The values stated are valid for bolts with metric ISO threads
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflagemaßen to DIN 13 part 13, as well as head areas to DIN 912 socked
nach DIN 912 Zylinderschrauben, head cap screws,
DIN 931 Sechskantschrauben mit Schaft bzw. DIN 931 hexagon bolt or
DIN 933 Sechskantschrauben mit Gewinde bis Kopf. DIN 933 hexagon bolts with threads up to the head.

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

008 910 36 BOMAG 497

13.2 Bosch Rexroth AG | Mobile Hydraulics
48 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

498 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
49

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

5. Verschlußschrauben mit Innensechskant, O-Ring und 5. Plugs with internal hexagon, O-ring and UNF-,
UNF-, UN-Gewinde nach SAE J 514 (nach N 02.106) UN- threads to SAE J 514 (nach N 02.106)

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 10
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 35
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

6. SEAL-LOCK-Dichtmuttern (nach N 02.100) 6. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

008 910 36 BOMAG 499

13.2 Bosch Rexroth AG | Mobile Hydraulics
50 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A4V - Düsen / orifices

Gewinde / Anziehdremomente Nm /
Thread Tightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12

500 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
51

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Vor dem Start Before starting

● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver’s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver’s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.

008 910 36 BOMAG 501

13.2 Bosch Rexroth AG | Mobile Hydraulics
52 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Sicherheitsbestimmungen
Safety regulations

Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver’s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.

Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!

Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!

Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!

502 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
53

Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)

Achtung! Attention!
Sicherheitsbestimmungen beachten! Observe safety regulations!

Hinweis: Note:
Nachjustierung nur bei Betriebstemperatur. Readjusting only at operating temperature.

Manometer an "G" anschließen. Connect pressure gauge to "G".

Achtung! Attention!
* Speisedruckeinstellung! * Boost pressure setting!
Nenndruck pH - 20 bar Nominal pressure pH - 20 bar
Höchstdruck pH - 40 bar Peak pressure pH - 40 bar
Bei Max.-Drehzahl. at max. speed.

Hinweis: Note:
Einstelldaten nach Werksauftrag. Setting data is in accordance to the works order.

* bei DA-Ausführung * with the DA version

"G"

008 910 36 BOMAG 503

13.2 Bosch Rexroth AG | Mobile Hydraulics
54 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"

HW HD EP DA

Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschließen.
Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.

Attention!
Observe safety regulations!
Connect both control chambers with a nominal size
6 hose. Avoidance of residual signals from hydraulic
zero position.
Connect pressure gauges to MA and MB. Adjust
the zero position so that with at blocked drive both
pressure gauges indicate the same pressure valve.
Note:
Ascertain the zero position dead band.

504 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
55

Einstellhinweise - Hydraulische "Nullage"

Adjustment instructions - Hydraulic "zero position"

* *
*

HW HD EP
Achtung!
Sicherheitsbestimmungen beachten!

Attention!
Observe safety regulations!

Manometer an X1 und X2 anschließen.

* Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Excenterjustierung - nicht über ± 90° verdrehen.

Connect pressure gauges to X1 and X2.

Adjust the zero position so that with a block drive
both pressure gauges indicate the same pressure
value.
Note:
Eccentric adjusting - Do not turn more than ± 90°.

008 910 36 BOMAG 505

13.2 Bosch Rexroth AG | Mobile Hydraulics
56 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Adjustment instructions - HP- valves (High pressure) and pressure cut-off

Druckabschneidung Achtung!
Pressure cut-off Sicherheitsbestimmungen beachten!
HD-Ventil ohne Bypass
1. HD-Ventile sind immer 10% höher eingestellt als die
Druckabschneidung.
Bei Veränderung eines Einstellwertes immer beide
kontrollieren.
2. Nachjustierung nur bei Betriebstemperatur
Manometer an MA und MB anschließen.
Druckabschneidung: Maß X Einstellschrauben notieren!
Einstellschraube auf Block drehen.
HD-Ventile: Mit geringer Pumpenmenge über Ventile fahren.
Einstellwert kontrollieren.
(Nur kurzzeitig "Temperatur“.)
Drucklos "Einstellwert“ verändern - Kontrolle
Druckabschneidung:
Einstellschraube auf Maß (*) zurückdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD-Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.
Zum Blockieren der Druckabschneidung beim Überprüfen
der Hochdruckventile die Einstellschraube Pos. 1 mit gelöster Pos.1
Kontermutter Pos. 2 bis zum Anschlag mit Item 1
max. 2 Nm im drucklosen Zustand eindrehen!
Bei größerem Kraftaufwand als 2 Nm werden sonst Federteller
und Feder verbogen. Druckabschneidungseinstellung ist nicht Pos.2
mehr gewährleistet. Item 2

To block the pressure cut-off when testing the high pressure

valves, the adjustment screw (item 1), with the lock-nut (item 2)
loosened, has to be screwed in
with a max. torque of 2 Nm in the depressurised condition
until the end stop is reached. Attention!
Forces larger than 2 Nm bends the spring and spring plate. Observe safety regulations.
The pressure cut-off setting can then no longer be guaranteed. HP valve without bypass-function
1. HP valves are always adjusted 10% higher than the
pressure cut-off.
If one setting value is changed, always check both values.
2. Readjusting only at operating temperature.
HD- Ventile Connect pressure gauge MA and MB.
HP- valves Pressure cut-off: Note measurement X for setting screw!
Turn setting screw to the blocked position.

HP valves: Operate the valves with small pump flow over the
valves.
Check setting value. (only for a short time "temperature“).
Change zero pressure "setting value“ - then check.

Pressure cut-off:
Turn back setting screw to measurement (*).
Check pressure value and readjust if necessary.
Attention! Observe the 10% pressure difference
between the HP valves and the pressure cut-off!
Note: Setting data is in accordance with the works order.

506 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
57

Einstellhinweise - Bypassventil
Adjustment instructions - Bypass valve

A4VG 71 - 90 Pos.1
ca. 2 Umdrehungen
10 Nm

Pos.1
Anziehdrehmoment /
Tightening torque
20 Nm

150 Nm

100 Nm

Pos.1 Neu / New Alt / Old

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit Vehicle with hydrostatic transmission and gear shift without idling
hydrostatischem Fahrantrieb und Schaltgetriebe ohne Leerlauf- setting position (free wheeling).
stellung (Freilauf).

Hydrostatischer Antrieb / Bypaß-Schaltung Hydrostatic transmission / Bypass-switching

In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. In this case the travel transmission is switched on to free
Zu diesem Zweck haben die in der Verstellpumpe integrierten wheeling.For this purpose the variable displacement pump has
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. incorporated high pressure relief valves with bypass function.
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird The screw (item 1) is unscrewed to such an extent, that the valve
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich cartridge is released and free oil circulation is possible.
ist.

A4VG 125 - 250

Bypass-Schaltung
ca. 2 Umdrehungen
Pos.1 200 ± 10 Nm

008 910 36 BOMAG 507

13.2 Bosch Rexroth AG | Mobile Hydraulics
58 A4VG
Travel | RDE
pump 92 003-02-R/03.03
A4VG 71 ... 180

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Achtung!
Sicherheitsbestimmungen beachten!

Überprüfung der Einstelldaten

Betriebstemperatur soll während des Über-
prüfungsvorgangs weitgehend konstant
gehalten werden.
Antriebsmotor starten, Leerlaufdrehzahl

Blockzustand
Fahrtrichtungsschalter "0“
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Meßgeräte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*

Blockzustand
Fahrtrichtungsschalter - vorwärts
(Straßengang und Festgebremst)

Einstelldaten Pumpe A4V/DA überprüfen

Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube
Verdrillung
Regelende
Regelbeginn HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube

Hinweis:
Excenterjustierung - Drehrichtung beachten

Hinweis: * Einstelldaten nach Werksauftrag!

508 BOMAG 008 910 36

RDE 92 003-02-R/03.03
Travel pump A4VG| A4VG
71 ... 180 Mobile Hydraulics | Bosch Rexroth AG 13.2
59

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Attention!
Observe safety regulations!

Check setting data.

Operating temperature should be kept largely
constant during the check procedure.
Start prime mover, idle speed.

Block position
Drive direction switch - "0“.
Slowly increase motor speed up to the max.
motor speed and thereby observe measuring
instruments.

Boost pressure:
Idle speed of prime mover
Psp = approx. 15 - 20 bar
max. motor speed
Psp = . . . . . . . . . bar*

Block position
Drive direction switch - forward
(Road gear and fully applied brake)

Check setting data pump A4VIDA

Begin of control:
Timing HD 40 - 50 bar
adjustment screw
Motor speed . . . . . rpm* Psp . . . . . . . bar*
HD . . . . . . . bar*
Begin of control Readjusting - control start screw

End of control
HD . . . . . . . . bar
Motor speed . . . . . . rpm* Psp . . . . . . . bar*
Readjusting timing adjustment screw

Note:
Eccentric adjusting - observe direction of
rotation

* Setting data according to order!

008 910 36 BOMAG 509

13.2 Travel pump A4VG 71 ... 180

Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
[email protected]
www.boschrexroth.com/brm

© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 92 003-02-R/03.03

510 BOMAG 008 910 36

13.3 Conveyor belt pump A10VG 28 ... 56

008 910 36 BOMAG 511

13.3 Conveyor belt pump A10VG 28 ... 56

512 BOMAG 008 910 36

Conveyor belt pump A10VG 28 ... 56 13.3
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 92 750-01-R/03.03
Verstellpumpe A10VG 28/63 ersetzt/replaces 10.02

Variable Pump A10VG 28/63

Baureihe/Series 10

Reparaturanleitung / Repair Instructions

008 910 36 BOMAG 513

13.3 Bosch Rexroth AG | Mobile Hydraulics
2 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Hinweis / Inhalt
Notice / Contents

HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen entsprechen Specifications, descriptions and illustrative material shown here
dem Informationsstand zum Zeitpunkt der Drucklegung dieser in were as accurate as known at the time this publication was
Unterlage. approved for printing.
Änderungen können den Service am Produkt beeinflussen, Ver- BRUENINGHAUS HYDROMATIK reserves the right to dis-
pflichtungen entstehen uns daraus nicht. continue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für deren Re- specifications, materials, or design without notice and without
sultat wir keine Haftung übernehmen können. incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Optional equipment and accessories may add cost to the basic
Fabrik-Nr. bestellt, sind die Basis guter Reparaturen. unit, and some options are available only in combination with
certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf dem
Teststand vorzunehmen. For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vorkehrungen si-
cherzustellen. Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen. Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.

INHALT CONTENTS
Seite/
Page

A10VG A10VG

Schnittbild 3-4 Sectional view

Allgemeine Reparaturhinweise 5 General repair instructions
Dichtsätze und Baugruppen 6-8 Seal kits and sub assembly groups
Triebwelle abdichten 9 Sealing of the drive shaft
Hilfspumpe abdichten 10-12 Sealing of the boost pump
Stellkolbendeckel abdichten 13 Sealing of the control piston cover
Ventile abdichten 14 Sealing of the valves
Druckabschneidung abdichten 15 Sealing of the pressure cut-off valve
Regelventil abdichten 16 Sealing of the regulator valve
Steuergerät demontieren 17 Removal of the control unit
Ansteuergeräte 18-22 Control units
Pumpe demontieren 23-25 Pump disassembly
Triebwerk ausbauen 26 Removal of the rotary group
Stellkolben demontieren 27-28 Disassembly of the positioning piston
Überprüfungshinweise 29-31 Inspection notes
Turcon-Glyd-Ring montieren 32 Turcon-Glyd-ring
Pumpe montieren 33-35 Assembly of the pump
Triebwerk einbauen 36 Installation of the rotary group
Triebwerk einbauen HW, HD, EP 37-38 Installation of the rotary group HW, HD, EP
Triebwerk einbauen DA 39 Installation of the rotary group DA
Pumpe montieren 40-41 Assembly of the pump
Montageanweisung für Anziehdrehmomente 42-45 Assembly guidelines for tightening torques
Sicherheitsbestimmungen 46-47 Safety regulations
Einstellhinweise 48-55 Adjustment instructions

514 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.33
Schnittbild
Sectional view

mit Druckabschneidung
with pressure cut-off

HW

ohne Druckabschneidung
without pressure cut-off

HDD EPD

008 910 36 BOMAG 515

13.3 Bosch Rexroth AG | Mobile Hydraulics
4 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Schnittbild
Sectional view

DA

516 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.35
Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill the hydraulic units with the operating medium

before commissioning.

008 910 36 BOMAG 517

13.3 Bosch Rexroth AG | Mobile Hydraulics
6 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Dichtsätze und Baugruppen

Seal kits and sub-assemblies

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

Peripheral seal kit.

Triebwerk komplett.

Complete rotary group.

Stellkolben

Positioning piston

2 3
1. Anschlußplatte Standard,
1
2. Anschlußplatte mit Druckabschneidung
3. Anschlußplatte DA mit Druckabschneidung

1. Standard connection plate

2. Connection plate with pressure cut-off
3. DA connection

518 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.37
Dichtsätze und Baugruppen
Seal kits and sub-assemblies

Ansteuergerät HW

Control unit HW

Ansteuergerät HW mit Nullagenanzeige

Control unit HW with zero indicator

alt / old

neu / new Ansteuergerät HD

Control unit HD

alt / old

neu / new
Ansteuergerät EP

Control unit EP

alt / old

neu / new

4/3 Wegeventil DA

Control unit DA

008 910 36 BOMAG 519

13.3 Bosch Rexroth AG | Mobile Hydraulics
8 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Dichtsätze und Baugruppen

Seal kits and sub-assemblies

Hilfspumpe mit Verschleißplatte

Boost pump with wear plates

1
2

1. HD - Ventil
2. HD - Ventil mit Bypass
3. ND - Ventil

1. High pressure valve

2. High pressure valve with bypass function
3. Low pressure valve

Druckabschneidung

Pressure cut-off

3
2

1. DA - Regelventil, verstellbar mit Hebel

1
2. DA - Regelventil, festeingestellt
3. Zuschaltventil

1. DA control valve, adjustable via a lever

2. DA control valve, fixed
3. Switching valve

520 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.39
Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring ausbauen.

Protect the drive shaft (e.g. masking tape).

Remove the retaining ring.

Blechschraube in die mit Gummi gefüllten Löcher

eindrehen.
Mit Zange WDR herausziehen.

Screw the metal screws into the holes that are

fitted with rubber.
Withdraw the shaft seal using pliers.

Wellendichtring mit Buchse auf Anschlag

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
leicht einfetten.

Press-in shaft seal with bush to stop.

Lightly grease the seal, dust lips and shaft seal ring.

008 910 36 BOMAG 521

13.3 Bosch Rexroth AG | Mobile Hydraulics
10 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Hilfspumpe abdichten
Sealing of the boost pump

Achtung!
* "Angefaste Seite" zum Deckel montieren.

Note!
* Mount the "chamfered side" towards the cover.

Befestigungsschrauben ausbauen.

Remove fixing screws.

Deckel abdrücken.

Pry-off cover.

Einbaulage kennzeichnen.

Mark position.

522 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
11

Hilfspumpe abdichten
Sealing of the boost pump

O-Ring ausbauen.

Remove O-ring.

Hilfspumpe abdrücken.

Pry off the boost pump.

2
1. Verschleißplatte
2. Fixierstift

1. Wear plate
2. Locating pin
1

3 1. Kantsil-Ring
1
2. Entlastungsnut
2 3. Fixierstift

1. Kantsil-ring
2. Unloading channel
3. Locating pin

Verschleißplatte einsetzen.
Drehrichtung beachten!

Fit wear plate taking the direction of rotation

account.

008 910 36 BOMAG 523

13.3 Bosch Rexroth AG | Mobile Hydraulics
12 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Hilfspumpe abdichten
Sealing of the boost pump

Verschleißplatte einsetzen.
Drehrichtung "Rechts" bei Blick auf die Triebwelle.
Achtung! Fixierstift

Fit wear plate.

Direction of rotation "clockwise" looking on the drive
shaft.
* Attention! Locating pin

Saugseite - suction side

Verschleißplatte einsetzen.
Drehrichtung "Links" bei Blick auf die Triebwelle.
Achtung! Fixierstift

Fit wear plate.

Direction of rotation "anti-clockwise" looking on the
drive shaft.
*
Attention! Locating pin
Saugseite - suction side

Linkslauf - anti-clockwise

Rechtslauf - clockwise

Hilfspumpe montieren.

Fit boost pump

O-Ring und Deckel montieren.

Fit O-ring andcover plate.

524 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
13

Stellkolbendeckel abdichten
Sealing of the control piston cover

Achtung!
Korrekte mechanische 0-Lageneinstellung
überprüfen!

Attention!
Check that the mechanical "0"-position is
correct!

Kontermutter ausbauen, Stellschraube gegenhalten.

Maß X
Deckel kennzeichnen. Maß festhalten, Konter-
mutter lösen.

Remove lock unit, whilst holding the adjustment

screw, mark the cover plate, ascertain the
dimension, loosen locknut.

Deckel von Stellschraube "abschrauben".

Remove the cover from the adjustment screw by

unscrewing it from the adjustment screw.

Kontrolle! O-Ring (1), Nut (2), Gehäuse und

Deckel (3).
Achtung!
Korrekte mechanische 0-Lageneinstellung muß
nach Einbau im Gerät bzw. Prüfstand erfolgen.

Check! O-ring (1), groove (2), housing with

cover (3).
Attention!
The correct mechanical "0" position has to be
adjusted after the unit has been built into the
machine or on a test rig.

008 910 36 BOMAG 525

13.3 Bosch Rexroth AG | Mobile Hydraulics
14 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Ventile abdichten
Sealing of the valves

PHD -Ventil mit Bypass

PHD -valve with bypass-function

PSP-Ventil

PSP -valve

Gewinde vor Montage des neuen O-Ringes

abkleben.
(Beschädigungsschutz).

Cover threads before fitting new O-rings.

(Damage protection).

*
Ventilkegel mit Druckfeder ausbauen.
Stützring
* mit Bypassfunktion

Remove valve poppet with compression spring.

* with bypass function
*

O-Ring

O-Ring und Stützring mit Hilfswerkzeug (Hülse)

aufziehen.

Place on O-ring and back-up ring

with auxiliary tool (sleeve).

526 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
15

Druckabschneidung abdichten
Sealing of the pressure cut-off valve

Wechsel der Dichtmutter.

Einstellmaß festhalten (*).
*
Exchanging the sealing nut.
Ascertsion the adjustment dimension (*).

Achtung!
Nach Einbau "Ventileinstellung" überprüfen.

Attention!
After assembly check "valve setting".

008 910 36 BOMAG 527

13.3 Bosch Rexroth AG | Mobile Hydraulics
16 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Regelventil abdichten
Sealing of the control valve

Regelventil ausbauen.

Remove control valve.

Blendendurchmesser nicht beschädigen.

Kontrolle:
Blendendurchmesser

Do not damage the orifice diameter.

Check: Orifice diameter.

Gewinde vor Montage des neuen O-Ringes

abkleben.

Before fitting the new O-ring cover the threads

(e.g. tape).

528 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
17

Steuergerät demontieren
Removing of the control unit

HW

alt / old
DA alt / old
neu / new

HD

neu / new

EP alt / old
neu / new
HW mit Nullagenschalter
HW with zero position switch

* Befestigungsschrauben demontieren.
*
* Remove fixing screws.

Ansteuergerät abdrücken.

Pry-off the control unit.

Kontrolle
Dichtfläche (1), Flachdichtung (2), O-Ringe (3).

Check
Sealing surface (1), gasket (2), O-rings (3).

008 910 36 BOMAG 529

13.3 Bosch Rexroth AG | Mobile Hydraulics
18 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Ansteuergeräte
Control units

Ansteuergerät HW
NG / Size 28
HW control unit

NG / Size 45

4/3 Wegeventil DA

DA control unit

Anziehmoment 5+1 Nm
Steckschlüssel SW 26
Tightening torque 5+1 Nm
26 A/F socket spanner

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

530 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
19

Ansteuergeräte
Control units

Ansteuergerät HD - EP alt
HD - EP control unit old
HD alt / old

EP alt / old

HD alt / old

EP alt / old

Neues Ansteuergerät HD - EP
New HD - EP control unit old

202,0 mm

131,0 mm
214,4 mm

77,4 mm

008 910 36 BOMAG 531

13.3 Bosch Rexroth AG | Mobile Hydraulics
20 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Ansteuergeräte
Control units

Ansteuergerät HD neu
HD - control unit new

Ansteuergerät EP neu
EP - control unit new

532 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
21

Ansteuergeräte
Control units

* Markierung Montageposition HD *
* Marking the assembly position HD
*

*
*

* Markierung * Assembly position marker HD

Montageposition HD

Wird von EP- auf HD-Ausführung umgebaut - Is converted from EP into the HD version -
Deckelposition beachten siehe Markierung take note of the cover position, see marker

Leckölkanal offen wird geschlossen. The open leakage port is plugged

Zugfeder tauschen! Exchange the tension spring!

008 910 36 BOMAG 533

13.3 Bosch Rexroth AG | Mobile Hydraulics
22 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Ansteuergeräte
Control units

Markierung Montageposition EP Die neuen Proportionalmagnete müssen bei der Inbe-

Assembly position marker EP triebnahme entlüftet werden. Wird die Luft nicht aus
* dem Ankerraum entfernt, kann es zum Schwingen der
Hydraulische Nullage
Ansteuerung kommen.
Hydraulic zero position
Zum Entlüften ist am Ende des Magneten, im Messing-
Klemmschraube teil, ein kleiner Gewindestift M4, SW 2 vorhanden.
Clamping screw Dieser Gewindestift ist max. 2 Umdrehungen heraus-
* zudrehen und nach dem Entlüften mit 1 Nm wieder
festzuziehen.
Bei der Ausführung mit Nothand mit Federrückzug muß
zum Entlüften die Kunststoffmutter mit Gummibalg
entfernt und nach dem Entlüften mit 5+1 Nm wieder
angeschraubt werden.

Entlüftungsschraube * max. 2 Umdrehungen herausdrehen. The new proportional solenoids must be bled during
Bleed screw *. Unscrew by commissioning. If the air is not removed from the
a max. of 2 turns armature chamber oscillations at the control can occur.

* * For bleeding purposes there is, on the end of the sole-

noid, in the brass component a small set screw M4,
2A/F. This can be unscrewed by a maximum of 2 turns
and then after completion of the bleeding tightened to
a maximum of 2 Nm.
For the version with hand override and spring return
the plastic nut with rubber coating has to be removed
for bleeding. After bleeding it has to be replaced and
tightened with 5+1 Nm.

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

* *
Markierung
Klemmschraube 6,1 Nm Anziehmoment 5+1 Nm
Montageposition EP
Clamping screw 6,1 Nm Steckschlüssel SW 26
Assembly position
marker EP Tightening torque 5+1 Nm
26 A/F socket spanner
Hydraulische Nullage
Exzenterstift
Hydraulic
zero point
Eccentric pin
Beim Lösen der Klemmschraube
Exzenterstift - Hydraulische Nullage festhalten.

When loosening the clamping screw

Hold the eccentric pin - hydraulic zero point

534 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
23

Pumpe demontieren
Pump disassembly

HD alt/old

EP alt/old

HD neu/new

EP neu/new

Druckabschneidung
Pressure cut-off

DA alt/old
DA neu/new

Excenterschraube
Eccentric screw

008 910 36 BOMAG 535

13.3 Bosch Rexroth AG | Mobile Hydraulics
24 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Pumpe demontieren
Pump disassembly

Lage der Hilfspumpe und Anschlußplatte

markieren.
Hilfspumpe abbauen.

Mark position of the boost pump and the port plate.

Remove the boost pump.

DA-Ausführung:
Lage der Verdrillschraube markieren (1).
Verdrillschraube auf Demontageposition stellen (2).

DA-design:
Mark the position of the eccentric screw (1).
Set the eccentric screw to disassembly position
(2).

Anschlußplattenbefestigung lösen. Anschlußplatte

abheben.

Remove connecting plate fixing screws.

Lift off the connection plate.

Steuerplatte abdrücken.
Lage notieren.

Lift off control plate.

Note position.

Kontrolle!
2 4 O-Ring mit Nut (1)
3 O-Ring mit Nut (2)
Fixierstift - Steuerplatte (3) Bei DA - kein Stift
1 T - Ablauf verschlossen (4)
Check
O-ring and groove (1)
O-Ring and groove (2)
Locating pin - control plate (3) type DA has no pin
T drain plugged (4) open for type DA

536 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
25

Pumpe demontieren
Pump disassembly

DA-Ausführung
Zylinder nach unten drücken (1).
Verdrillschraube herausdrehen (2).
Triebwerk ausheben (3).

DA- version
Press the cylinder downwards (1).
Remove the eccentric screw (2).
Lift out the rotary group (3).

"Ausbauen"
1. Zylinder
2. Schwenkwiege
3. Gelenkstift

"Remove"
1. Cylinder
2. Swash plate
3. Joint pin

Sicherungsring, WDR ausbauen.

Remove retaining ring, remove drive shaft seal.

008 910 36 BOMAG 537

13.3 Bosch Rexroth AG | Mobile Hydraulics
26 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Triebwerk ausbauen
Removal of the rotary group

Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with light hammer strokes.

Lagerschalen ausbauen.

Remove bearing shells.

Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

Sicherungsring demontieren.
Feder und Druckstifte ausbauen.

Remove circlip.
Remove spring and pressure pins.

538 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
27

Stellkolben demontieren - Gehäuse mit Buchse

Disassembly of the positioning piston - housing with bush

Steuergerät abbauen.

Remove control unit.

Stellkolben (1) ziehen.

Pull out control piston (1).

Stellkolben zerlegen.

Disassemble the control piston.

008 910 36 BOMAG 539

13.3 Bosch Rexroth AG | Mobile Hydraulics
28 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Stellkolben demontieren - Gehäuse mit Turcon-Glyd-Ring

Disassembly of the positioning piston - housing with Turcon-Glyd-ring

Steuergerät abbauen.

Remove control unit.

Stellkolben (1) ziehen.

Pull out control piston (1).

Stellkolben zerlegen
(Gehäuse Turcon-Glyd-Ring Abdichtung).

Disassemble the control piston

(Housing Turcon-Glyd-ring).

540 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
29

Überprüfungshinweise
Inspection notes

Alle Lager erneuern.

Replace all bearings.

Kontrolle!
1. Verzahnung, ausgeschlagen, Passungsrost.
2. Lauffläche.
3. Einlaufrillen vom Wellendichtring.

Check!
1. Splines, wear steps, corrosion.
2. Running surfaces.
3. Grooves made by the shaft seal.

Stellkolbenlaufbüchse (1) riefenfrei, nicht

ausgelaufen.
1
Check that the control piston guide bush (1)
1
is free of grooves and is free of wear.

Kontrolle!
Stellkolben (1) riefenfrei.

Check!
Control piston (1) is not scored.

008 910 36 BOMAG 541

13.3 Bosch Rexroth AG | Mobile Hydraulics
30 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Überprüfungshinweise
Inspection notes

Kontrolle!
Gleitfläche riefenfrei.

Check!
Sliding surface free of grooves.

Kontrolle!
Verbindung Gleitstein/Schwenkzapfen spielfrei.

Check!
That the connection of slide ring/swivel pin is free
of play.

Kontrolle!
Rückzugeinrichtung riefenfrei (1), keine Einlaufs-
puren (2)
im Gleitschuhbereich.

Check!
That the retaining plate is free of grooves (1) and
that there is no wear (2) in the slipper pad area.

Kontrolle!
Lauffläche (1) keine Kratzer, keine Metallein-
lagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).

Check!
Check to see that there are no scratches or metal
deposits
on the sliding surface (1), and that there is no axial
play (2),
(pistons must only be replaced as a set).

Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

542 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
31

Überprüfungshinweise
Inspection notes

Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen,
keine Einlagerungen,
Steuerplatte nicht riefig (nur satzweise
austauschen).

Check!
Cylinder sliding surface free of grooves, no wear,
no embedded foreign particles. That there are no
scratches on the control plate. (Only replace them
as a set).

Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.

Check!
Mounting surface - control plate undamaged

Hinweis:
Bohrung bei DA-Regelung offen. (gültig nur bei
A10VG 45).

Information:
Hole for DA-control is open, without DA control valve
it is plugged.

Kontrolle!
Lagerbahnen (1)

Check!
Bearing surfaces (1)

Riefenfrei, keine Einlaufspuren

Free of grooves, no wear.

008 910 36 BOMAG 543

13.3 Bosch Rexroth AG | Mobile Hydraulics
32 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Gehäuse - Turcon-Glyd-Ring montieren

Assemble housing - Turcon-Glyd-ring

Dichtring in die Montagezange einlegen.

Fit the seal ring into the assembly tool.

Dichtring mit Zangenschenkel nierenförmig

zusammendrücken. Die Verformung von Turcon-
Dichtungen ist sorgfältig vorzunehmen, damit die
Dichtkanten nicht beschädigt werden.

Press the seal ring into the kidney shape using the
assembly tool. The deformation of the Turcon seal
has to be done with care so as not to damage the
sealing edges.

O-Ring in Nut einlegen.

Dichtring ins Gehäuse einführen und in der
Aufnahmenut plazieren. Dann Spannung lösen und
Montagezange herausziehen. Lage des Dicht-
ringes prüfen - eventuell mit dem Finger
egalisieren.

Position the seal ring into the groove.

Position the seal ring into the housing and place it
into the groove. Release the tension and withdraw
the assembly tool. Check the position of the seal
ring if necessary straighten using a finger.

Kalibrieren des Dichtringes mit einem Kalibrierdorn

(Stellkolben) - mit langer Schräge 10o bis 15o.

Calibrate the seal ring using a cylindrical plug gauge

(positioning piston) at an angle of 10o to 15o.

544 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
33

Pumpe montieren
Assembly of the pump

Lagerschalenpaar einsetzen.

Insert bearing shells.

Stellkolben ins Gehäuse einsetzen.

Hinweis:
Stellkolben vor Einbau einölen.

Insert positioning piston into the housing.

Instruction:
Oil positioning piston before assembly.

Stellkolben mit Hebel (Id.Nr. 2774491) ausrichten.

* Führung für Gleitstein - Schwenkwiege

Position stroke piston with lever (Id.No. 2774491).

* Sliding stone guidance in the piston.

Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett

Assemble the bearing, wire, slide ring and joint pin

Assemble aids:
e.g. - clips / rubber rings / grease

Schwenkwiege komplett ins Gehäuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehäuse
"achten".
Montagehilfe ausbauen.

Insert the swash plate into the housing.

Ensure that the swivel-bearing is correctly located
in the housing.
Remove assembly aid.

008 910 36 BOMAG 545

13.3 Bosch Rexroth AG | Mobile Hydraulics
34 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Pumpe montieren
Assembly of the pump

Kontrolle: Sitz der Schwenklager in der

Lagerbahn.
Mittig stellen mit Meßvorrichtung (Uhr oder
Tiefenmaß)
Punkt 1 und 2 kontrollieren - gleiches Maß.

Check: Location of the swivel-bearing

in the bearing.
Centralise by using a measuring device (dial gauge
or depth measurement).
Check points 1 and 2 - they should have the same
dimension.

Gelenkstift montieren.

Fit joint pin.

546 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
35

Pumpe montieren
Assembly of the pump

Haltevorrichtung montieren.
Mit Gewindestift Schwenkwiege festhalten.
Keine Gewaltanwendung.

Fit holding device.

Hold swash plate in position utilising the set screw.
Do not use force.

Haltevorrichtung "Schwenkwiege" A4V

Holding device "swivel cradle" A4V

Teil/Part 3 Teil/Part 4

∅ ∅
6, 7, 8, 9
∅ ∅
3, 4, 5

∅ ∅

Teil/Part 5
∅
2
∅
1

Pos./Item Benennung/Designation Stck./Qty.

1 Winkel/Angle 2
2 Gewindestift/Threaded pin 2
3 Scheibe/Shim 2
4 Scheibe/Shim 2
5 Scheibe/Shim 2
6 Zyl. Schraube/Cyl. screw M12 x 25 DIN 912 2
7 Zyl. Schraube/Cyl. screw M14 x 25 DIN 912 2
8 Zyl. Schraube/Cyl. screw M16 x 30 DIN 912 2
9 Zyl. Schraube/Cyl. screw M20 x 35 DIN 912 2

008 910 36 BOMAG 547

13.3 Bosch Rexroth AG | Mobile Hydraulics
36 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Triebwerk einbauen
Installation of the rotary group

Neue Montageposition!
Triebwelle mit Lager und Wellendichtring einbau-
en.

Assemble drive shaft with bearings and radial seal

rings.

Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.

Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.

Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and piston pad.

548 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
37

Triebwerk einbauen HW / HD / EP
Installation of the rotary group HW / HD / EP

Vorrichtung ausbauen.
Zylinder mit Kolben und Rückzugeinrichtung
einbauen.

Remove holding device.

Fit cylinder complete with pistons and
retaining device.

Montagehilfe:
Mit O-Ring Kolben festhalten.

Assembly aid:
Hold the pistons by using an O-ring.

Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.

For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.

Fixierstift für Steuerplatte einsetzen.

Bei DA - Ausführung mit Verdrillschraube
ohne Fixierstift.

Fit locating pin for control plate.

For the DA version with eccentric screw without
locating pin.

008 910 36 BOMAG 549

13.3 Bosch Rexroth AG | Mobile Hydraulics
38 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Triebwerk einbauen HW / HD / EP
Installation of the rotary group HW / HD / EP

Steuerplatte Rechtslauf
* Fixierstift
* Control plate, clockwise rotation
* Locating pin

Steuerplatte Linkslauf
* * Fixierstift

Control plate, anti-clockwise rotation

* Locating pin

Zylinderflächen einölen, neue O-Ringe mit Fett

einreiben und einsetzen.

Oil the cylinder surfaces, grease the new O-rings

and fit into place.

Lagerichtig aufsetzen.
Hinweis:
HW, HD, EP Steuerplatte mit Fett auf
Anschlußplatte.

Place in correct position.

Note:
HW, HD, EP - Locate the control plate on the
connection plate using grease.

550 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
39

Triebwerk einbauen DA
Installation of the rotary group DA

Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.

For the version with eccentric screw:

Push the cylinder down - screw in the eccentric
screw in the eccentric screw until dimension x is
reached.
* groove in assembled position.

Maß X mit Vorrichtung neu ermitteln.

Zylinder mit Vorrichtung nach unten drücken.
Verdrillschraube bis Anschlag einschrauben -
Maß X - Kerbe in Montageposition drehen.

Re-identify dimension X with device.

Push cylinder down with device.
Screw in eccentric screw till stop - Dimension X -
Turn groove in assembly position.

Ident. Nummer Hilfsvorrichtung/

Ident- No. Auxiliary device
NG / Size 28 = Ι 2 775 075
NG / Size 45 = Ι 2 774 882
NG / Size 63 = Ι 2 775 076

Steuerplatte Rechtslauf mit Verdrillschraube

Control plate, clockwise rotation with eccentric

screw

Max. Einschraubtiefe beachten.

Einstellhinweis beachten

Max. depth - take into account!

Lagerichtig aufsetzen.
Bei DA Steuerplatte auf Zylinderfläche legen.

Place in correct position.

For the DA version, place control plate on the
cylinder surface.

008 910 36 BOMAG 551

13.3 Bosch Rexroth AG | Mobile Hydraulics
40 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Pumpe montieren
Assembly of the pump

Schrauben über Kreuz anziehen.

Verdrillschraube auf Markierung drehen.

Tighten the screws aross corners.

Turn the eccentric screw until the marker is reached.

Hilfspumpe montieren.

Fit boost pump.

Ansteuergerät mit Dichtung montieren.

Fit control device with seal.

552 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
41

Pumpe montieren
Assembly of the pump

Ansteuergerät mit Dichtung montieren.

Fit control device with seal.

Dichtung mit zwei Befestigungschrauben

zentrieren und Ansteuergerät einbauen.
Alle vier Schrauben mit halbem Drehmoment an-
ziehen.

Centre the seal using two fixing screws and fit

the control unit.
Tighten all four screws to half of specified torque.

Fünfte Schraube einsetzen und mit

Drehmoment = 10,4 Nm festziehen.
Restliche vier Schrauben nach Drehmoment
festziehen.

Fit the fifth screw and tighten to a torque

of 10,4 Nm.
Then tighten the other four screws to there
correct torque.

008 910 36 BOMAG 553

13.3 Bosch Rexroth AG | Mobile Hydraulics
42 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metri- The values stated are valid for bolts with metric
schem ISO-Gewinde nach DIN 13 Teil 13, sowie ISO threads to DIN 13 part 13, as well as head
Kopfauflagemaßen nach DIN 912 Zylinder- areas to DIN 912 socked head cap screws, DIN
schrauben, DIN 931 Sechskantschrauben mit 931 hexagon bolt or DIN 933 hexagon bolts with
Schaft bzw. DIN 933 Sechskantschrauben mit threads up to the head.
Gewinde bis Kopf.

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

554 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
43

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

008 910 36 BOMAG 555

13.3 Bosch Rexroth AG | Mobile Hydraulics
44 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 10
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 35
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

6. SEAL-LOCK-Dichtmuttern (nach N 02.100) 6. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

556 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
45

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A10V - Düsen / orifices

Gewinde / Anziehdremomente Nm /
Thread Tightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12

008 910 36 BOMAG 557

13.3 Bosch Rexroth AG | Mobile Hydraulics
46 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Vor dem Start Before starting

● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver’s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver’s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.

558 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
47

Sicherheitsbestimmungen
Safety regulations

Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver’s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.

Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!

Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!

Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!

008 910 36 BOMAG 559

13.3 Bosch Rexroth AG | Mobile Hydraulics
48 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)

Achtung! Attention!
Sicherheitsbestimmungen beachten! Observe safety regulations!

Hinweis: Note:
Nachjustierung nur bei Betriebstemperatur. Readjusting only at operating temperature.

Manometer an "G" anschließen. Connect pressure gauge to "G".

Achtung! Attention!
* Speisedruckeinstellung! * Boost pressure setting!
Nenndruck pH - 20 bar Nominal pressure pH - 20 bar
Höchstdruck pH - 40 bar Peak pressure pH - 40 bar
Bei Max.-Drehzahl. at max. speed.

Hinweis: Note:
Einstelldaten nach Werksauftrag. Setting data is in accordance to the works order.

* bei DA-Ausführung * with the DA version

60 bar

"G"
*

560 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
49

Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"

HW

alt / old
alt / old
DA

neu / new

HD

neu / new

EP alt / old

neu / new
HW mit Nullagenschalter
HW with zero position switch

Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschließen.
Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.
600 bar
Attention!
Observe safety regulations!
Connect both control chambers with a nominal size
600 bar
6 hose. Avoidance of residual signals from hydraulic
zero position.
Connect pressure gauges to MA and MB. Adjust
the zero position so that with at blocked drive both
pressure gauges indicate the same pressure valve.
Note:
Ascertain the zero position dead band.

008 910 36 BOMAG 561

13.3 Bosch Rexroth AG | Mobile Hydraulics
50 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Einstellhinweise - Hydraulische "Nullage"

Adjustment instructions - Hydraulic "zero position"

HD neu/new Achtung!
Sicherheitsbestimmungen
HW beachten!
*
* HD alt/old Attention!
Observe safety regulations!
*

*
*

HW mit Nullagenschalter
HW with zero position switch EP alt/old

EP neu/new

60 bar

60 bar

Manometer (60 bar) an X1 und X2 anschließen.

* Nullage so einstellen, daß bei blockiertem
Antrieb beide Manometer auf gleichem Druck-
wert stehen.
Hinweis:
Excenterjustierung - nicht über ± 90° verdrehen.

Connect pressure gauges(60 bar) to X1 and X2.

* Adjust the zero position so that with a block
drive both pressure gauges indicate the same
pressure value.
Note:
Eccentric adjusting - Do not turn more than ± 90°.

562 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
51

Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung

Adjustment instructions - HP- valves (High pressure) and pressure cut-off

Achtung!
Sicherheitsbestimmungen beachten!

HD-Ventil ohne Bypass

Druckabschneidung 1. HD-Ventile sind immer 10% höher eingestellt als die

Pressure cut-off 2 Druckabschneidung.
1 2. Nachjustierung nur bei Betriebstemperatur
Manometer (600 bar) an MA und MB anschließen.
Druckabschneidung:
Zum Blockieren der Druckabschneidung beim Überprüfen
der Hochdruckventile die Einstellschraube Pos. 1 mit
gelöster Kontermutter Pos. 2 bis zum Anschlag mit
max. 2 Nm im drucklosen Zustand eindrehen!

HD-Ventile: Mit geringer Pumpenmenge über Ventile fahren.

Einstellwert kontrollieren.
(Nur kurzzeitig "Temperatur“.)
Einstellwert verändern - siehe Serviceinfo

Druckabschneidung:
Einstellschraube auf Maß (*) zurückdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD-Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.

Attention!
Observe safety regulations.
HD- Ventile
HP- valves
HP valve without bypass-function
1. HP valves are always adjusted 10% higher than the
pressure cut-off.
2. Readjusting only at operating temperature.
Connect pressure gauge (600 bar) to MA and MB.
Pressure cut-off:
To block the pressure cut-off when testing the high
pressure valves, the adjustment screw (item 1), with the
lock-nut (item 2) loosened, has to be screwed in
with a max. torque of 2 Nm in the depressurised condition
until the end stop is reached.

HP valves: Operate the valves with small pump flow over the
valves.
Check setting value. (only for a short time "temperature“).
Change setting value - see service information.

Pressure cut-off:
Turn back setting screw to measurement (*).
Check pressure value and readjust if necessary.
Attention! Observe the 10% pressure difference
between the HP valves and the pressure cut-off!
Note: Setting data is in accordance with the works order.

008 910 36 BOMAG 563

13.3 Bosch Rexroth AG | Mobile Hydraulics
52 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Einstellhinweise - Bypassventil HW, HD, EP

Adjustment instructions - Bypass valve HW, HD, EP

1
1

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydro- Vehicle with a pure hydrostatic transmission or with a hydrostatic
statischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung drive with gear box without free wheel position.
(Freilauf).
Hydrostatic transmission / Bypass condition
Hydrostatischer Antrieb / Bypaß-Schaltung
In this case the travel drive is switched on to the free wheel
In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. position. For this purpose the high pressure valves of the variable
Zu diesem Zweck haben die in der Verstellpumpe integrierten displacement pump have a so-called bypass function.
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. By turning the relevant screw (item 1) the valve is so released
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird that free oil circulation is made possible.
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich Bypass: Screw in item1 until it is level with the nut.
ist.
Bypass: Pos.1 einschrauben bis eben mit Mutter. Towing speed
Mutter wieder anziehen. The max. towing speed of 2 km/h should not be exceeded.
● Higher permissible speeds are depended on the hydraulic
Schleppgeschwindigkeit motor speed or the selected gear.
Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht
überschreiten. Towing distance
● Höhere zulässige Schleppgeschwindigkeiten The towing distance should not exceed 1 km.
sind abhängig von der Hydromotordrehzahl
bzw. dem eingelegten Gang. ● With no boost avaiable the hydraulic circuit drains.
The heat generation in the hydraulic motor rotary group
Abschleppdistanz has to be taken into account.
Die Schleppentfernung sollte 1 km nicht überschreiten.
● Bei fehlender Einspeisung entleert sich der Termination of the towing operation
Hydraulik-Kreislauf. After termination of the towing operation turn back item 1.
Zu beachten ist die Wärmeentwicklung im The original set pressure value is thereby avaiable.
Hydromotor-Triebwerk. Valve function: Screw back item 1 up to stop.
Screw up the nut.
Abschleppvorgang beendet
Nach beendetem Abschleppvorgang Pos.1 zurückdrehen.
Der ursprüngliche Einstellwert der Hochdruckventile liegt somit
wieder vor.
Ventilfunktion: Pos.1 zurückschrauben bis
Anschlag. Mutter anziehen.

564 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
53

Einstellhinweise - Bypassventil DA
Adjustment instructions - Bypass valve DA

A10VG 28-45 Bypass: Pos.1 einschrauben bis Schraube am Federteller

DA-Control anliegt.Schraube maximal 1/2 Umdr. weiterdrehen!
Bypass: Screw in item 1 until contact, max 1/2 turn more.

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit hydro-

statischem Fahrantrieb und Schaltgetriebe ohne Leerlaufstellung
(Freilauf).
Hydrostatischer Antrieb / Bypaß-Schaltung Vehicle with hydrostatic transmission and gear shift without idling
In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet. setting position (free wheeling).
Zu diesem Zweck haben die in der Verstellpumpe integrierten Hydrostatic transmission / Bypass-switching
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion. In this case the travel transmission is switched on to free
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird wheeling.For this purpose the variable displacement pump has
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich incorporated high pressure relief valves with bypass function.
ist. The screw (item 1) is unscrewed to such an extent, that the valve
Bypass: Pos.1 einschrauben bis Schraube am cartridge is released and free oil circulation is possible.
Federteller anliegt.
Maximal 1/2 Umdrehung weiter drehen. Bypass: Screw in item1 until contact,
Max. 1/2 turn more.
Schleppgeschwindigkeit
Die maximale Schleppgeschwindigkeit sollte 2 km/h nicht
überschreiten. Towing speed
● Höhere zulässige Schleppgeschwindigkeiten sind The max. towing speed of 2 km/h should not be exceeded.
abhängig von der Hydromotordrehzahl bzw. dem ● Higher admissible towing speeds depend on the avaiable
eingelegten Gang. hydr. motor speed and engaged gear shift.

Abschleppdistanz Towing distance

Die Schleppentfernung sollte 1 km nicht überschreiten. The towing distance should not exceed 1 km.
● Bei fehlender Einspeisung entleert sich der Hydraulik- ● If there is a lack of oil boosting, the hydraulic circuit will get
Kreislauf. empty.
Zu beachten ist die Wärmeentwicklung im Hydromotor- Take care of the heat development in the hydr. motor-rotary
Triebwerk. group.

Abschleppvorgang beendet Towing operation terminated

Nach beendetem Abschleppvorgang Pos.1 zurückdrehen. Der After termination of the towing operation turn item 1 back. The
ursprüngliche Einstellwert der Hochdruckventile liegt somit original pressure value setting of the high pressure relief valves
wieder vor. will be avaiable again.
Ventilfunktion: Pos.1 zurückschrauben bis Anschlag. Valve function: Screw back item 1 up to stop.
Mutter anziehen. Screw up the nut.

008 910 36 BOMAG 565

13.3 Bosch Rexroth AG | Mobile Hydraulics
54 A10VG
Conveyor belt | RDE
pump 92 750-01-R/03.03
A10VG 28 ... 56

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Achtung!
Sicherheitsbestimmungen beachten!

Überprüfung der Einstelldaten

Betriebstemperatur soll während des Über-
prüfungsvorgangs weitgehend konstant gehalten
werden.
Antriebsmotor starten, Leerlaufdrehzahl

Blockzustand
Fahrtrichtungsschalter "0“
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Meßgeräte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*

Blockzustand
Fahrtrichtungsschalter - vorwärts
(Straßengang und Festgebremst)
*
Einstelldaten Pumpe A10V/DA überprüfen
* Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube

Regelende
Verdrillung Regelbeginn
HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube

Hinweis:
Excenterjustierung - Drehrichtung beachten

Hinweis: * Einstelldaten nach Werksauftrag!

566 BOMAG 008 910 36

RDE 92 750-01-R/03.03
Conveyor belt pump | A10VG
A10VG 28 ... 56 Mobile Hydraulics | Bosch Rexroth AG 13.3
55

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Attention!
Observe safety regulations!

Check setting data.

Operating temperature should be generally kept
constant during the checking procedure.
Start prime mover, idle speed.

Block position
Drive direction switch - "0“.
Slowly increase motor speed up to the max. motor
speed and observe measuring instruments.

Boost pressure:
Idle speed of prime mover
Psp = approx. 15 - 20 bar
max. motor speed
Psp = . . . . . . . . . bar*

Block position
* Drive direction switch - forwards
(Road gear and fully applied brake)

Check setting data pump A4VIDA

* Start of control:
HD 40 - 50 bar
Motor speed . . . . . rpm* Psp . . . . . . . bar*
HD . . . . . . . bar*
Readjustment of start of control screw
Begin of control
End of control
Timing HD . . . . . . . . bar
adjustment screw Motor speed . . . . . . rpm* Psp . . . . . . . bar*
Readjustment of the indexing screw

Note:
Eccentric adjusting - observe direction of
rotation.

Note: * Setting data is in accordance to the

order work!

008 910 36 BOMAG 567

13.3 Conveyor belt pump A10VG 28 ... 56

Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
[email protected]
www.boschrexroth.com/brm

© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 92 750-01-R/02.03

568 BOMAG 008 910 36

13.4 Travel motor A6VM/VE

008 910 36 BOMAG 569

13.4 Travel motor A6VM/VE

This repair manual describes the fixed displacement motor A6VM, which is identical with the travel mo-
tor A6VE, which differs only by a different housing design.

570 BOMAG 008 910 36

Travel motor A6VM/VE 13.4
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 91 604-01-R/03.03
Verstellmotor A6VM 28...200 ersetzt/replaces 08.01

Variable Displ. Motor A6VM 28...200

Reparaturanleitung / Repair Instructions

008 910 36 BOMAG 571

13.4 Bosch Rexroth AG | Mobile Hydraulics
2 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Typschlüssel
Typschlüssel A6V M / 6 3 W
Axialkolbenmaschine
Schrägachsenbauart, verstellbar A6V
Betriebsart
Motor (Einschubmotor A6VE siehe RD 91606) M
Nenngröße
≅ Schluckvolumen Vg max (cm3) 28 55 80 107 140 160 200
NG 28...200: Fertigung Werk Elchingen
Regel- und Verstelleinrichtung 28 55 80 107 140 160 200
Hydraulische Verstellung Steuerdruckanstieg 10 bar HD1 HD1 *
steuerdruckabhängig 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulische Zweipunktverstellung HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Elektrische Verstellung, Steuerspannung 12 V EP1 EP1 *
mit Proportionalmagnet 24 V EP2 EP2 *
Elektrische Steuerspannung 12 V EZ1 – – – EZ1 *
Zweipunktverstellung, 24 V EZ2 – – – EZ2 *
mit Schaltmagnet 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatische Verstellung, ohne Druckanstieg HA1 HA1 *
hochdruckabhängig mit Druckanstieg Δp = 100 bar HA2 HA2 *
Hydraulische Verstellung, drehzahlabhängig DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulisches Fahrtrichtungsventil DA1 DA1 *
elektrisches Fahrtrichtungsventil 12 V DA2 DA2 *
+ elektrische Vg max-Schaltung 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulisches Fahrtrichtungsventil DA4 DA4 *
elektrisches Fahrtrichtungsventil 12 V DA5 DA5 *
+ elektrische Vg max-Schaltung 24 V DA6 DA6 *
Druckregelung (nur für HD, EP) 28 55 80 107 140 160 200
ohne Druckregelung (kein Zeichen)
Druckregelung, direktgesteuert D
direktgesteuert, mit 2. Druckeinstellung E
fernsteuerbar – – – – – – – G
Übersteuerung der HA-Verstellung (nur für HA1, HA2)
ohne Übersteuerung (kein Zeichen)
hydraulische Übersteuerung T
elektrische Übersteuerung Steuerspannung 12 V U1
24 V U2
elektrische Übersteuerung Steuerspannung 12 V R1
+ elektrisches Fahrtrichtungsventil 24 V R2

* Differentialkolben Gleichgangkolben

572 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.43
Type code
Type code A6V M / 6 3 W
Axial piston unit
Bent axis design, variable displacement A6V
Mode of operation
Motor (plug-in motor A6VE see RE 91606) M
Size
≅ Displacement Vg max (cm3) 28 55 80 107 140 160 200
Sizes 28...200: production plant Elchingen
Control device 28 55 80 107 140 160 200
Hydraulic control pilot pressure increase 10 bar HD1 HD1 *
pilot pressure related 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulic two-position control HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Electrical control, control voltage 12 V EP1 EP1 *
with proportional solenoid 24 V EP2 EP2 *
Electrical control voltage 12 V EZ1 – – – EZ1 *
two-position control, 24 V EZ2 – – – EZ2 *
with switching solenoid 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatic control, without pressure increase HA1 HA1 *
high pressure related with pressure increase Δp = 100 bar HA2 HA2 *
Hydraulic control, speed related DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulic valve for travel direction DA1 DA1 *
electrical valve for travel direction 12 V DA2 DA2 *
+ electrical Vg max-switch 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulic valve for travel direction DA4 DA4 *
electrical valve for travel direction 12 V DA5 DA5 *
+ electrical Vg max-switch 24 V DA6 DA6 *
Pressure control (only for HD, EP) 28 55 80 107 140 160 200
without pressure control (no code)
Pressure control, direct control D
direct control, with 2nd pressure setting E
remote control – – – – – – – G
Override of HA-control (only for HA1, HA2)
without override (no code)
Hydraulic override T
Electrical override control voltage 12 V U1
24 V U2
Electrical override control voltage 12 V R1
+ el. valve for travel direction 24 V R2

* Differential piston Synchronizing piston

008 910 36 BOMAG 573

13.4 Travel motor A6VM/VE

574 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.45
Schnittbild
Sectional drawing

A6VM 55-107 HZ3

A B

max. min.

X T

A6VM 55-107 EZ3

A B

max. min.

A6VM 55-107 HA3

A B

max. min.

A6VM 55-107 HA3U

A B

max. min.

008 910 36 BOMAG 575

13.4 Bosch Rexroth AG | Mobile Hydraulics
6 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Schnittbild
Sectional drawing

A6VM 28-200 HD

A B

max min

X
G

M1 T(T1)

A6VM 28-200 HD
mit Spülventil / with flushing valve

A B

max min

M1 T(T1)

A6VM 28-200 HD1D

mit Druckregelventil / with pressure
control valve

A B

max min

X
G

M1 T(T1)

576 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.47
Schnittbild
Sectional drawing

A6VM 28-200 EP

A B

max min

M1 T(T1)

A6VM 28-200 EP./..A

A B

max min

T(T1) M1

A6VM 28-200 EP./..A

A B

max min

Sa

T(T1) M1

008 910 36 BOMAG 577

13.4 Bosch Rexroth AG | Mobile Hydraulics
8 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Schnittbild
Sectional drawing

A6VM ... DA1

A B X1 X2

max min
G
X3

M1 T(T1)

A6VM ... DA3 A B

X1

X3
max min
G

M1 T(T1)

578 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.49
Schnittbild
Sectional drawing

A6VM 28-200 HA2U

mit Bremsventil / with braking valve

A
S

max min

T(T1) M1

A6VM 28-200 HA1R

mit Spülventil / with flushing valve

A B

max min

T(T1) M1

A6VM ... HA1U

mit Spülventil / with flushing valve

A B

max min

T(T1) M1

008 910 36 BOMAG 579

13.4 Bosch Rexroth AG | Mobile Hydraulics
10 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill up hydraulic aggregates with medium

before start- up.

580 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
11

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

External seal kit.

Gehäuse

Housing

Triebwerk komplett
Hinweis: Pos. 1 - Für Anschlußplatte mit
Pos. 2 Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Complete rotary group

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston
Pos. 1

Pos. 1 Pos. 2 Anschlußplatte mit Stellkolben

Hinweis: Pos. 1 - Für Anschlußplatte mit
Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Port plate with control piston

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston

008 910 36 BOMAG 581

13.4 Bosch Rexroth AG | Mobile Hydraulics
12 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Schaltmagnet / Proportionalmagnet

Solenoid

Deckel mit * Drosselstift.

* Drosselstift "Auftragsbezogen".
* Cover with * throttle pin.
* Throttle pin "as to order requirement".
*
*

*
*
Deckel mit Spül- und Speisedruckventil
* und * Drosselstift
* Drosselstift "Auftragsbezogen".
Cover with flushing and boost pressure valve
and * throttle pin.
* Throttle pin "as to order requirement".

582 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
13

Baugruppen / Steuerteile
Component groups / Control components

z. B. HA EP

HA2
Auftrags-
bezogen *
"as to order
DA
requirement".

HD

008 910 36 BOMAG 583

13.4 Bosch Rexroth AG | Mobile Hydraulics
14 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Baugruppen / Steuerteile
Component groups / Control components

z. B. HZ3 / EZ3

HA3 / HA3U

584 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
15

Dichtmutter austauschen
Replace seal nut

Dichtmutter austauschen.
Zuerst Maß X messen und festhalten.

Replace seal nut.

First measure and record setting height.

Maß X

Beim Anziehen Einstellschraube gegenhalten,

anschließend Einstellhöhe kontrollieren.

When tightening, counterhold setting screw, then

check setting height.

008 910 36 BOMAG 585

13.4 Bosch Rexroth AG | Mobile Hydraulics
16 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring und Scheibe ausbauen.

Protecting the drive shaft.

Remove retaining ring and shim.

Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes

fitted with rubber.
Pull out seal with pliers.

Wellendichtring und Scheibe mit Montagehülse

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
* leicht einfetten
Einpresstiefe beachten! * Marke für Einpresstiefe.
Sicherungsring einbauen.

Press in shaft seal ring and shim with bush to stop.

Take note of press-in depth!
Lightly grease the seal, dust lips and shaft seal ring.
Install * mark for press-in depth of safety ring.

586 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
17

Steuerteile abdichten
Sealing of the control parts

Achtung!
Federvorspannung

1 Attention!
Spring load

1. Deckel / Cover
2. Steuerteil / Control part
1
Kontrolle
Bohrung im Gehäuse, O-Ring, Nut.

Inspect
Drilling in housing, O-ring, groove.

Einstellschraube nicht ausbauen.

2 Kontrolle
O-Ring, O-Ring-Nut, Gehäuse

Do not remove adjustment screw.

Inspect
O-ring, O-ring groove, housing

Montagehilfe
Stift mit Fett einkleben.

2 Assembly aid
Insert pin with grease.

008 910 36 BOMAG 587

13.4 Bosch Rexroth AG | Mobile Hydraulics
18 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Verstellung abdichten
Sealing the hydraulic control

Beispiel: A6VM ... HD Verstellung

Demontageposition:
Deckel Pos. 1 abbauen.

Example: A6VM ... HD control

Pos.1 Disassembly position:
Remove cover pos. 1

1
1. O-Ring
2
2. Stellölzulauf
3. Drosselstift
Einbaulage je nach Steuerteil verschieden.

1. O-ring
2. Input flow of oil control
3. Throttle pin
Installation position differs according to the
3 control components

1
5
1. Stellölzulauf / Input flow of oil control
2 3 2. Hochdruck bzw. Niederdruck / High pressure /
low pressure
3. Hochdruck bzw. Niederdruck / High pressure /
low pressure
4. Lecköl / Leckage oil
4 5. Stellkolben / Control piston

588 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
19

Verstellung abdichten
Sealing the hydraulic control

Pos. 2

Beispiel: A6VM ... Verstellung - Differentialkolben

Demontageposition: Deckel Pos. 2 abbauen.
Achtung! Federvorspannung.
Maß x: Maß festhalten (Regelbeginn).
x
Example: A6VM... control - differential piston
Disassembly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).

1. O-Ring Kontrolle

1. Check of O-ring

1
2 1. Hochdruck - kleine Stellkolbenseite
* 2. Stelldruck
3. Hochdruck - Rückschlagventil
4. Hochdruck - Rückschlagventil
* siehe Serviceinfo

1. High pressure - small control piston side

2. Control pressure
3
4 3. High pressure - check valve
4. High pressure - check valve
* see serviceinfo

008 910 36 BOMAG 589

13.4 Bosch Rexroth AG | Mobile Hydraulics
20 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Abschlußplatte demontieren
Disassembly of the port plate

x Differentialkolben:
Maß X festhalten.

Differential piston:
Note dimension x

Bei "Demontage" der Anschlußplatte

"Triebwerk" immer auf Null schwenken.
Kolbenringe hängen aus der Zylinder-
bohrung aus.

For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Qmin-Schraube
Qmin-screw

Qmin-Schraube ausbauen.
Triebwerk auf 0o schwenken.

Remove Qmin-screw.
Swivel rotary group to 0o.

590 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
21

Abschlußplatte demontieren
Disassembly of the port plate

x Gleichgangkolben:
Maß X festhalten.

Synchronizing piston:
Note dimension x.

Bei "Demontage" der Anschlußplatte "Triebwerk"

immer auf Null schwenken.
* Kolbenringe hängen sonst aus der Zylinder-
bohrung aus.
Qmin-Schraube
For disassembly of the port plate, swivel always
Qmin-screw
rotary group to zero position.
* Piston rings to hang out of the cylinder boring.

Qmin-Schraube und Verschlußschraube ausbauen.

Remove Qmin-screw and plug.

Mit Schraube Qmin Triebwerk auf 0o schwenken.

Swivel rotary group to zero position with screw Qmin

.

008 910 36 BOMAG 591

13.4 Bosch Rexroth AG | Mobile Hydraulics
22 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Abschlußplatte demontieren
Disassembly of the port plate

Anschlußplatte
Lage markieren. Schrauben lösen.
Abbauen

Port plate
Mark position. Loosen screws.
Removal

O-Ring austauschen.
Neuer O-Ring mit etwas Fett einkleben.
Triebwerk nicht ausschwenken.
Kolbenringe hängen aus der Zylinderbohrung aus.

Check O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.

Steuerlinse in Gleitbahn mit Fett einkleben.

Fertigmontage in umgekehrter Reihenfolge.
Anschlußplatte aufsetzen.
Triebwerk senkrecht.

Stick control lens in sliding surface with grease.

Assembly in reversal order.
Mount port plate.
Rotary group vertical.

592 BOMAG 008 910 36

Travel motor A6VM/VE 13.4

008 910 36 BOMAG 593

13.4 Travel motor A6VM/VE

594 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
25

Triebwerk ausbauen
Remove rotary group

Gewindestift in Mittelzapfen einschrauben,

mit Schutzscheibe und Mutter Zylinder befestigen.
Qmax - Anschlagschraube ausbauen.

Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax -stop screw.

Nenngröße / Size 28 : M4 x 60 mm
55 : M5 x 80 mm
80 : M6 x 90 mm
107 : M6 x 100 mm
140 : M8 x 110 mm
160 : M8 x 110 mm
200 : M8 x 110 mm

Triebwerk auspressen!
Bei Wiederverwendung der Lager nicht schlagen.

Press out rotary group!

If the bearings are used again do not hit on the drive
shaft.

008 910 36 BOMAG 595

13.4 Bosch Rexroth AG | Mobile Hydraulics
26 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerk ausbauen
Remove rotary group

Oder mit Abziehvorrichtung ausdrücken.

Or press-out with extraction device.

596 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
27

Triebwerk austauschen
Exchanging of the rotary group

eingepresst
pressed in
Triebwerk komplett
Abstimmung hydraulischer
Teil notwendig.

Complete rotary group

Setting of hydraulic part
necessary.

Triebwerk Baugruppe
1.Mechanischer Teil: Triebwelle mit Lager abgestimmt.
2.Hydraulischer Teil: Abstimmung notwendig *.

Rotary group
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Adjustment necessary *.

Triebwerk: Alle Bauteile

* Abstimmung
Abstimmwerte, Drehmomente siehe Serviceinfo.

Rotary group: All parts

* Setting
Setting value, torque see service information.

008 910 36 BOMAG 597

13.4 Bosch Rexroth AG | Mobile Hydraulics
28 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerk austauschen
Exchanging of the rotary group

Befestigungsschraube (Zylinder) ausbauen.

Zylinder abheben.

Remove fixing screw (cylinder).

Remove cylinder.

Rückzugplatte demontieren.
Schrauben sind eingeklebt. Nach Erwärmen auf
max 120o C mit Torx-Werkzeug demontieren.

Disassemble retaining plate.

Screws are glued. Warm it up to max. 120o C
and remove with Torx-tools.

598 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
29

Überprüfungshinweise
Inspection notes

Kein Passungsrost, nicht ausgeschlagen.

Free of corrosion, erosion or fretting;

no damage to splines or keyways.

Kolben
Riefenfrei und keine Pittings.

Pistons
No scoring and no pittings.

1 2

Mittelzapfen
Riefenfrei und keine Pittings.

Center pin
No scoring and no pittings.

Rückzugplatte
Riefenfrei und keine Ausbrüche.

Retaining plate
No scoring and no evidence of wear

Zylinder / Steuerlinse
1 Bohrungen riefenfrei, nicht ausgelaufen.
2 Gleichmäßiges Tragbild, riß- und riefenfrei.

Cylinder block / control lens

1 Bores free of scoring, no evidence of wear.
2 Faces smooth and even, free of cracks
and scoring.

008 910 36 BOMAG 599

13.4 Bosch Rexroth AG | Mobile Hydraulics
30 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Überprüfungshinweise
Inspection notes

Reglergehäuse
Gleitbahn und Seitenführung riefenfrei,
nicht ausgelaufen.

Control housing
Sliding surface and side guides free of scoring
and no wear.

Sichtkontrolle:
Im Lagerbereich riefenfrei und keine Einlaufspuren.

Visual check:
Bearing areas free of scoring and no evidence
of wear.

600 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
31

Triebwerk montieren / siehe Serviceinformation

Rotary group assembly / see service information

Triebwelle: mechanischer Teil

Rotary group: mechanical part

1 Abstimmung Maß * und Lagerdrehmomente

siehe Serviceinfo.

2
* Adjustment dimension * and bearing torque
see service infoprmation.

Lager aufpressen.
Beim Aufpressen Lagerdrehmoment nicht
überschreiten.

Press on bearing.
Do not exeed bearing torque during press-on.

BOJH
GG
DRTT
GHE

000
000
BOJH
GG
DRTT
GHE

Lager mit Montagehülse vorspannen und laufende Drehmomentenkontrolle.

Preload bearing with assembly sleeve and steady control of the torque.

008 910 36 BOMAG 601

13.4 Bosch Rexroth AG | Mobile Hydraulics
32 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerk montieren
Rotary group assembly

Sicherungsring 1 montieren.
Maß * für Abstimmscheibe mit Endmaß ermitteln
(überkreuz).
Abstimmscheibe einbauen.
Sicherungsring montieren.

1 Assemble safety ring.

Determine dimension * for adjustment disc with fi-
* nal dimensions (crossover)
Install adjustment shim.
Assemble safety ring.

Triebwelle einbaufertig.

Drive shaft ready for assembly.

602 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
33

Triebwerk montieren
Rotary group assembly

Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
(Anziehdremoment siehe Seite 42).

Insert retaining plate with piston and center pin.

Use screw with Precote-coating.
(Tightening torque see page 42).

Auf richtige Schichtung aller Teile achten.

Make sure all parts are fitted in correctly.

Triebwerk auf Null schwenken und Zylinder mit

Gewindestift befestigen. (siehe Seite 25)

Swivel cylinder block to zero position and fix the

cylinder with a threaded pin (see page 25)

008 910 36 BOMAG 603

13.4 Bosch Rexroth AG | Mobile Hydraulics
34 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerk montieren
Rotary group assembly

Triebwerk komplett zum Einbau fertig.

Rotary group completely assembled ready

for assembly.

Montagehülse montieren.

Place assembly sleeve.

Gehäuse auf 80oC erwärmen.

Warm up housing to 80oC.

604 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
35

Triebwerk montieren
Rotary group assembly

Triebwerk ins Gehäuse auf Anschlag einsetzen.

Insert rotary group into housing to seat position.

Nach Einbau des Triebwerks im Gehäuse ist die

Triebwelle bis auf Anschlag nach vorne zu ziehen.

Pull the drive shaft after rotary groupassembly into

housing to seat position.

2 1

Zylinder in Nullposition
ausrichten.
1. Zylinderbefestigungsschraube
demontieren.
2. O-Ring einsetzen.

Fix zero position of cylinder

with Qmax-screw.
1. Disassemble cylinder
fixing screw.
2. Insert O-ring.

008 910 36 BOMAG 605

13.4 Bosch Rexroth AG | Mobile Hydraulics
36 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Triebwerksabstimmung (siehe Serviceinfo)

Rotary group adjustment (see service information)

Mit Schraube Zylinderausschwenkung

vermitteln.

Determine cylinder swivel range to

max. angle with screw.

* * Scheibe
* Disc

Zentrierscheibe aufsetzen.

Place centering disc.

Meßvorrichtung aufbauen.

Mount measuring device.

Maß X überprüfen.

Check dimension X.

606 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
37

Abschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Differential-

* kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf
Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

differential piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to
dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Deckel montieren.

Assemble cover.

Steuerteil montieren.
x
Assemble control components.

008 910 36 BOMAG 607

13.4 Bosch Rexroth AG | Mobile Hydraulics
38 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Anschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Gleichgang-

kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
* Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

synchronizing piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Wellendichtring, Scheiben und Sicherungsring

montieren.
Mit Montagehülse einpressen.
Dicht- und Staublippe, Wellendichtring leicht
einfetten.
Einpresstiefe beachten!

Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.
Lightly grease the seal, dust lips and shaft seal ring.
Take care of press-in depth.

608 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
39

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metrischen The values stated are valid for bolts with metric ISO threads
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflage- to DIN 13 part 13, as well as head areas to DIN 912 socked
maßen nach DIN 912 Zylinderschrauben, DIN 931 head cap screws, DIN 931 hexagon bolt or
Sechskantschrauben mit Schaft bzw. DIN 933 hexagon bolts with threads up to the head.
DIN 933 Sechskantschrauben mit Gewinde bis Kopf.

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

008 910 36 BOMAG 609

13.4 Bosch Rexroth AG | Mobile Hydraulics
40 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

610 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
41

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 20
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 90
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

008 910 36 BOMAG 611

13.4 Bosch Rexroth AG | Mobile Hydraulics
42 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

6. Linsenschrauben mit Innen-TORX, Gewindevor- 6. Oval head screw with inner TORX, thread precoated with
beschichtung mit "precote" "precote"

precote 80 - Rot / Red

Standard / Standard

precote 86 - Blau / Blue

Variante / Variant
* * mit Unterkopfbeschichtung - farblos
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
* with head bottom coating - colorless
siehe Stückliste / as to parts list

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7

7. SEAL-LOCK-Dichtmuttern (nach N 02.100) 7. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

612 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
43

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A6V - Stellkolben / positioning piston

für / for A6V / A7V / A7F / A8V)

Anziehdrehmoment MA für Gewindestift (1) / Anziehdrehmoment MA für Schraube (2) /

Tightening torque MA for threaded pin (1) Tightening torque MA for shaft bolts (2)
(Verbindung: Stellkolben und Stellzapfen / (Verbindung: Stellkolben und Stellzapfen für A6V
Connection: Positioning piston and positioning trunnion Connection: Positioning piston and piston for A6V

M6 : 8,5 Nm M14 x 1,5 : 120 Nm

M8 : 14,0 Nm
M10 : 30,0 Nm
M12 : 52,0 Nm

008 910 36 BOMAG 613

13.4 Bosch Rexroth AG | Mobile Hydraulics
44 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Sicherheitsbestimmungen
Safety regulations

Allgemein General advice

● Machen Sie sich mit der Ausstattung der Maschine ● Make yourself familiar with the equipment of the
vertraut. machine.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den ● Only operate the machine if your are completely familiar with
Bedien- und Steuerelementen sowie der Arbeitsweise der the operating and control elements as well as the functioning
Maschine vertraut gemacht haben. of the machine.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm, ● Use your safety equipment like helmet, safety shoes and
Sicherheitsschuhe und Gehörschutz. hearing protection.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut. ● Make yourself familiar with your working field.
● Benutzen Sie die Maschine nur für den ihr zugedachten ● Only operate the machine for its intended purpose.
Zweck.

Beachten Sie bitte die Richtlinien der Berufsgenossenschaft Please observe the guidelines of the Professional
und des Maschinenherstellers Association and the machine manufacturer.

Vor dem Start Before starting

● Beachten Sie die Bedienungshinweise vor dem Starten. ● Observe the operating instructions before starting.
● Prüfen Sie die Maschine auf auffällige Fehler. ● Check the machine for remarkable faults.
● Fahren Sie die Maschine nicht mit defekten Instrumenten, ● Do not operate the machine with defective instruments,
Kontrolleuchten oder Steuerorganen. warning lights or control elements.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein. ● All safety devices must be in a secure position.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen ● Do not carry with you movable objects or secure them to the
Sie diese an der Maschine. machine.
● Halten Sie die Maschine von öligem und zündfähigem ● Keep oily and inflammable material away from the machine.
Material frei. ● Before entering thc driver’s cabin, check if personsor
● Prüfen Sie vor dem Besteigen der Maschine, ob sich obstacles are beside or beneath the machine.
Personen oder Hindernisse neben oder unter der Maschine ● Be careful when entering the driver’s cabin, use stairs and
befinden. handles.
● Vorsicht beim Besteigen der Maschine, benützen Sie ● Adjust your seat before starting.
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.

614 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
45

Sicherheitsbestimmungen
Safety regulations

Starten Start
● Beim Starten müssen alle Bedienhebel in “Neutralstellung” ● When starting all operating levers must be in “neutral position”.
stehen. ● Only start the machine from the driver’s seat.
● Die Maschine nur vom Fahrersitz aus Starten. ● Check the indicating instruments after start to assure that all
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um functions are in order.
sicher zu gehen, daß alles ordnungsgemäß funktioniert. ● Do not leave the machine unobserved when the motor is
● Lassen Sie die Maschine nicht unbewacht, während running.
der Motor läuft. ● When starting with battery connection cables connect plus
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus with plus and minus with minus. Always connect mass cable
mit Plus und Minus mit Minus. Massekabel (Minus) immer (minus) at last and cut off at first.
zuletzt anschliesen und zuerst abtrennen.

Vorsicht Attention
● Auspuffgase sind lebensgefährlich. Bei Start in ● Exhaust gas is dangerous. Assure sufficient fresh air when
geschlossenen Räumen für ausreichende Luftzufuhr starting in closed rooms!
sorgen!

Hydraulikanlage Hydraulic equipment

1. Hydraulikanlage steht unter hohem Druck! 1. Hydraulic equipment is standing under high pressure.
Unter hohem Druck austretende Hochdruck- Flüssig- High pressure fluids (fuel, hydraulic oil) which escape
keiten (Kraftstoff, Hydrauliköl) können die Haut durch- under high pressure can penetrate the skin and cause
dringen und schwere Verletzungen verursachen. Daher heavy injuries. Therefore immediately consult a doctor as
sofort einen Arzt aufsuchen, da anderenfalls schwere otherwise heavy infections can be caused.
Infektionen entstehen können! 2. When searching leakages use appropriate auxiliary devices
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr because of the danger of accidents.
geeignete Hilfsmittel verwenden! 3. Before working at the hydraulic equipment, lower pressure
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt to zero and lower working arms of the rnachine.
drucklos machen und angebaute Geräte absenken! 4. When working at the hydraulic equipment, absolutely stop
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor motor and secure tractor against rolling away (parking brake,
abstellen und Traktor gegen Wegrollen sichern shim)!
(Feststellbremse, Unterlegkeil)! 5. When connecting hydraulic cylinders and motor pay attention
5. Beim Anschließen von Hydraulikzylindern und -motoren ist to correct connection of hydraulic flexible hoses.
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu 6. In case of exchanging the ports, the tunctions are vice versa
achten! (f. ex. lift-up/lower) - danger of accidents!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen 7. Check hydraulic flexible hoses regularly and replace them in
(z.B. Heben/Senken) - Unfallgefahr! case of dammage or wear! The new hose pipes must comply
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei with the technical requirements of the machine manufacturer!
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen Orderly disposal or recycling of oil, fuel and
des Geräteherstellers entsprechen! filters!

Öle, Kraftstoffe und Filter ordnungsgemäß

entsorgen!

008 910 36 BOMAG 615

13.4 Bosch Rexroth AG | Mobile Hydraulics
46 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel HD e.g HD

X - 10 bar

Einstellschraube - Regelbeginn / P
Set screw - begin of control
Vg min

G
X
Betriebsdruck /
Operating
pressure

~ P/2

1:2

M1

Stelldruck /
Control pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - HD Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Manometer "X" = 60 bar ● Pressure gauge "X" = 60 bar

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 10 bar Steuerdruck an X Example: 10 bar pilot pressure at X

Manometer an M1 beachten! Observe pressure gauge at M1!

Druckwert an X erhöhen bis an M1 die Hälfte Increase pressure value at X till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

616 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
47

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel EP e.g EP

Einstellschraube - Regelbeginn /
Set screw - Begin of control
P

Vg min

Betriebsdruck /
Operating pressure

~ P/2

1:2

M1

Stelldruck /
Control pressure

Sicherheitsbestimmungen beachten! Observe safety regulations!

Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - EP Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Magnet = Multimessgerät ● Solenoid = multi measuring device

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 200/400 mA Example: 200/400 mA

Manometer an M1 beachten! Observe pressure gauge at M1!

Strom erhöhen bis an M1 die Hälfte Increase current till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

008 910 36 BOMAG 617

13.4 Bosch Rexroth AG | Mobile Hydraulics
48 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg min - Vg max ) (Begin of regulation of Vg min - Vg max )
z.Beispiel HA z.Beispiel HA

Vg min X M1

Stelldruck /
Control
pressure
1:2

Einstellschraube - Regelbeginn / G
Set screw - Begin of control Betriebsdruck /
Operating
pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake)
Manometer 600 bar an G und M1 anschließen. Connect pressure gauge 600 bar at G and M1
Beispiel 1: Example 1:
Regelbeginn 200 bar, Begin of regulation 200 bar
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge at
Stelldruck Manometer M1 G = 200 bar
1 /2 des Betriebsdruckes = ca. 100 bar Positioning pressure gauge M1
♦ Regelbeginn 1/2 of the sevice pressure = approx. 100 bar.
Nachjustierung des Stelldruckes an ♦ Begin of control
Einstellschraube - Regelbeginn Readjust positioning pressure at set screw - start of control
Hinweis: Note:
Drehen im Uhrzeigersinn - Regelbeginn früher. Clockwise turning - begin of regulation earlier
Drehen gegen Uhrzeigersinn - Regelbeginn später. Anti-clockwise turning - begin of regulation later
Beispiel 2: Example 2:
Bei Anlagen mit zwei oder mehr Motoren z. B. Raupenfahrzeuge In systems with two or more motors, e.g. tracked vehicles,
kann folgende Einstellung zusätzlich erfolgen. the following setting may be carried out additionally.
Kontermutter von Einstellschraube Vgmin lösen - Remove safety cap from the setscrew Vg min - do not disturb
Einstellschraube nicht verdrehen. Maß X festhalten. setscrew.
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge is indicating
anzeigt. 200 bar at G.
Kontrolle: Einstellschraube Vg min "fest" (Steuerlinse wird gegen Verification: Vg min "fixed" (lens plate is pressed against setscrew).
die Einstellschraube gedrückt). Up from 200 bar service pressure the screw is becoming
Ab 200 bar Betriebsdruck wird die Schraube "lose" "movable".
(Steuerlinse schwenkt Richtung Vg max). (lens plate is stroking to direction Vg max).
♦ Regelbeginn ♦ Begin of control
Achtung! Attention
Einstellwert Vg min -Schraube nicht verändern. Do not modify setting data of Vg min screw.
Hinweis: Nachjustierung an Einstellschraube- Regelbeginn Note: Readjustment at the set screw - begin of regulation

618 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
49

Inbetriebnahme
Operating instruction

Einstellüberprüfung (Regelbeginn) G1
DA1/4, DA2,3,4,5,6 X3 Einstellschraube - Regelbeginn
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Stelldruck

Beispiel: Betriebsdaten nach Geräteblatt

Verstellbeginn Vg min - Vg max bei 20 bar Steuerdruck X3
und 220 bar Betriebsdruck

● Manometer G = 600 bar Betriebsdruck

● Manometer X3 = 60 bar Steuerdruck
● Manometer M1 = 600 bar Stelldruck G
Fahrzeug beladen, Straßengang, Fahren (max. Geschwindigkeit
= max. Steuerdruck)
Manometer M1 beobachten, anbremsen für Druckaufbau an
"G", ab 220 bar Betriebsdruck baut sich Druck an M1 ab.
♦ Regelbeginn P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 Betriebsdruck (Regelbeginn)

20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = Regelbeginn Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Einstellschraube - Regelbeginn - Drehen im Uhrzeigersinn - Regelbeginn später

nur 1/8 Umdrehung verstellen ♦ kontrollieren

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ® Vg max
20 bar 225 bar 0 bar = Vg max Stelldruck

008 910 36 BOMAG 619

13.4 Bosch Rexroth AG | Mobile Hydraulics
50 A6VM | RDE
Travel 91 604-01-R/03.03
motor A6VM/VE

Inbetriebnahme
Operating instruction

Setting test (Begin of Regulation) G1

DA1/4, DA2,3,4,5,6 X3
Setscrew - Begin of control
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Control
pressure
X3
Example: Operation data as to machine specification sheet
Begin of regulation Vg min - Vg max at 20 bar pilot pressure
and 220 bar service pressure
G
● Pressure gauge G = 600 bar service pressure
● Pressure gauge X3 = 60 bar pilot pressure
● Pressure gauge M1 = 600 bar positioning pressure
Load vehicle, travel mode, travel (max. speed = max. pilot pressure
Observe pressure gauge M1, declarate at "G" for pressure generation,
up from 220 bar service pressure pressure at M1 is dropping.
♦ begin of regulation P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 service pressure (begin of regulation)
20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = begin of regulation Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Setscrew - begin of regulation - turn clockwise - begin of regulation later

displace by 1/8 turn only ♦ verification

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ♦ Vg max
20 bar 225 bar 0 bar = Vg max Control
pressure

620 BOMAG 008 910 36

RDE 91 604-01-R/03.03
Travel motor A6VM/VE | A6VM Mobile Hydraulics | Bosch Rexroth AG 13.4
51

008 910 36 BOMAG 621

13.4 Travel motor A6VM/VE

Brueninghaus Hydromatik GmbH

Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
[email protected]
www.boschrexroth.com/brm

© 2003 by Brueninghaus Hydromatik © 2003 by Brueninghaus Hydromatik

GmbH, 89275 Elchingen GmbH, 89275 Elchingen
All rights reserved. No part of this Alle Rechte vorbehalten. Kein Teil des
document may be reproduced or Werkes darf in irgendeiner Form ohne
stored, processed, duplicated or vorherige schriftliche Zustimmung der
circulated using electronic systems, in Brueninghaus Hydromatik GmbH
any form or by any means, without the reproduziert oder unter Verwendung
prior written authorization of Bosch elektronischer Systeme gespeichert,
Rexroth AG. In the event of verarbeitet, vervielfältigt oder verbreitet
contravention of the above provisions, werden. Zuwiderhandlungen
the contravening party is obliged to verpflichten zu Schadensersatz.
pay compensation. Die angegebenen Daten dienen allein
The data specified above only serve to der Produktbeschreibung. Eine
describe the product. No statements Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
given information does not release the werden. Die Angaben entbinden den
user from the obligation of own Verwender nicht von eigenen
judgement and verification. It must be Beurteilungen und Prüfungen. Es ist zu
remembered that our products are beachten, dass unsere Produkte einem
subject to a natural process of wear natürlichen Verschleiß- und
and aging. Alterungsprozess unterliegen.

Printed in Germany
RDE 91 604-01-R/03.03

622 BOMAG 008 910 36

13.5 Travel gear 705C3H10C80

008 910 36 BOMAG 623

13.5 Travel gear 705C3H10C80

624 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 625

13.5 Travel gear 705C3H10C80

626 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 627

13.5 Travel gear 705C3H10C80

628 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 629

13.5 Travel gear 705C3H10C80

630 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 631

13.5 Travel gear 705C3H10C80

632 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 633

13.5 Travel gear 705C3H10C80

634 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 635

13.5 Travel gear 705C3H10C80

636 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 637

13.5 Travel gear 705C3H10C80

638 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 639

13.5 Travel gear 705C3H10C80

640 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 641

13.5 Travel gear 705C3H10C80

642 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 643

13.5 Travel gear 705C3H10C80

644 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 645

13.5 Travel gear 705C3H10C80

646 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 647

13.5 Travel gear 705C3H10C80

648 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 649

13.5 Travel gear 705C3H10C80

650 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 651

13.5 Travel gear 705C3H10C80

652 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 653

13.5 Travel gear 705C3H10C80

654 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 655

13.5 Travel gear 705C3H10C80

656 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 657

13.5 Travel gear 705C3H10C80

658 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 659

13.5 Travel gear 705C3H10C80

660 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 661

13.5 Travel gear 705C3H10C80

662 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 663

13.5 Travel gear 705C3H10C80

664 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 665

13.5 Travel gear 705C3H10C80

666 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 667

13.5 Travel gear 705C3H10C80

668 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 669

13.5 Travel gear 705C3H10C80

670 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 671

13.5 Travel gear 705C3H10C80

672 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 673

13.5 Travel gear 705C3H10C80

674 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 675

13.5 Travel gear 705C3H10C80

676 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 677

13.5 Travel gear 705C3H10C80

678 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 679

13.5 Travel gear 705C3H10C80

680 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 681

13.5 Travel gear 705C3H10C80

682 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 683

13.5 Travel gear 705C3H10C80

684 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 685

13.5 Travel gear 705C3H10C80

686 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 687

13.5 Travel gear 705C3H10C80

688 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 689

13.5 Travel gear 705C3H10C80

690 BOMAG 008 910 36

Travel gear 705C3H10C80 13.5

008 910 36 BOMAG 691

13.5 Travel gear 705C3H10C80

692 BOMAG 008 910 36

13.6 Conveyor belt motor OMT

008 910 36 BOMAG 693

13.6 Conveyor belt motor OMT

694 BOMAG 008 910 36

Conveyor belt motor OMT 13.6

008 910 36 BOMAG 695

13.6 Conveyor belt motor OMT

696 BOMAG 008 910 36

Conveyor belt motor OMT 13.6

008 910 36 BOMAG 697

13.6 Conveyor belt motor OMT

698 BOMAG 008 910 36

Conveyor belt motor OMT 13.6

008 910 36 BOMAG 699

13.6 Conveyor belt motor OMT

700 BOMAG 008 910 36

Conveyor belt motor OMT 13.6

008 910 36 BOMAG 701

13.6 Conveyor belt motor OMT

702 BOMAG 008 910 36

Conveyor belt motor OMT 13.6

008 910 36 BOMAG 703

13.6 Conveyor belt motor OMT

704 BOMAG 008 910 36

Conveyor belt motor OMT 13.6

008 910 36 BOMAG 705

13.6 Conveyor belt motor OMT

706 BOMAG 008 910 36

Conveyor belt motor OMT 13.6

008 910 36 BOMAG 707

13.6 Conveyor belt motor OMT

708 BOMAG 008 910 36

Conveyor belt motor OMT 13.6

008 910 36 BOMAG 709

13.6 Conveyor belt motor OMT

710 BOMAG 008 910 36

13.7 Sprinkling pump

008 910 36 BOMAG 711

13.7 Sprinkling pump

712 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 713

13.7 Sprinkling pump

714 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 715

13.7 Sprinkling pump

716 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 717

13.7 Sprinkling pump

718 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 719

13.7 Sprinkling pump

720 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 721

13.7 Sprinkling pump

722 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 723

13.7 Sprinkling pump

724 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 725

13.7 Sprinkling pump

726 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 727

13.7 Sprinkling pump

728 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 729

13.7 Sprinkling pump

730 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 731

13.7 Sprinkling pump

732 BOMAG 008 910 36

Sprinkling pump 13.7

008 910 36 BOMAG 733

13.7 Sprinkling pump

734 BOMAG 008 910 36

14 Circuit diagrams

008 910 36 BOMAG 735

Circuit diagrams
l The circuit diagrams valid at the date of printing are
part of these repair instructions.

736 BOMAG 008 910 36

14.1 Wiring diagram

008 910 36 BOMAG 737

14.1 Wiring diagram

738 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 739

14.1 Wiring diagram

740 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 741

14.1 Wiring diagram

742 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 743

14.1 Wiring diagram

744 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 745

14.1 Wiring diagram

746 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 747

14.1 Wiring diagram

748 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 749

14.1 Wiring diagram

750 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 751

14.1 Wiring diagram

752 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 753

14.1 Wiring diagram

754 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 755

14.1 Wiring diagram

756 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 757

14.1 Wiring diagram

758 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 759

14.1 Wiring diagram

760 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 761

14.1 Wiring diagram

762 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 763

14.1 Wiring diagram

764 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 765

14.1 Wiring diagram

766 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 767

14.1 Wiring diagram

768 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 769

14.1 Wiring diagram

770 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 771

14.1 Wiring diagram

772 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 773

14.1 Wiring diagram

774 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 775

14.1 Wiring diagram

776 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 777

14.1 Wiring diagram

778 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 779

14.1 Wiring diagram

780 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 781

14.1 Wiring diagram

782 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 783

14.1 Wiring diagram

784 BOMAG 008 910 36

Wiring diagram 14.1

008 910 36 BOMAG 785

14.1 Wiring diagram

786 BOMAG 008 910 36

14.2 Hydraulic diagram

008 910 36 BOMAG 787

14.2 Hydraulic diagram

788 BOMAG 008 910 36

Hydraulic diagram 14.2

008 910 36 BOMAG 789

14.2 Hydraulic diagram

790 BOMAG 008 910 36