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00891153.j10 Bomag

bomag

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100% found this document useful (5 votes)

5K views

00891153.j10 Bomag

bomag

Uploaded by

carlos serna

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 1022

Service - Manual

Use only genuine BOMAG spare parts.

Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
These repair instructions are not subject of an updat-
ing service; for this reason we would like to draw your
attention to our additional "Technical Service Bulle-
tins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.

! Danger
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
* The applicable documents valid at the date of print-
ing are part of this manual.

10 BOMAG 008 911 53

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

l Use protective clothes like hard hat, safety boots

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

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

008 911 53 BOMAG 11

1.2 Safety regulations

l Start the extraction fan before starting work and gine oils contain potentially hazardous contaminants,
guide with the progressing work as required. which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
l Always isolate the burner when laying it down (re-
be provided.
move possible electrode residues).
l Wear protective clothes and safety gloves, if possi-
l Protect cables from being damaged, use cables
with insulated couplings. ble.
l If there is a risk of eye contact you should protect
l Ensure sufficient fire protection, keep a fire extin-
your eyes appropriately, e.g. chemistry goggles or
guisher at hand.
full face visor; a facility suitable for rinsing the eyes
l Welding work in areas where there is a risk of fire or should also be available.
explosion, must only be carried out with welding
permission.
l Avoid longer and repetitive contacts with oils. In
case of open incisions and injuries seek medical ad-
l Remove any combustible materials from the weld- vice immediately.
ing area or cover such items appropriately. l Apply protective cream before starting work, so that
l Name a fire watch during and after welding work. oil can be easier removed from the skin.
l Place welding rod holders and inert gas welding l Wash affected skin areas with water and soap (skin
guns only on properly insulated bases. cleansers and nail brushes will help). Lanolin con-
l Place the inert gas bottles in a safe place and se- taining agents will replace natural skin oils that were
cure them against falling over. lost.
l
Use a protective screen or hand shield with welding
l
Do not use gasoline, kerosene, diesel, thinner or
filter, wear welding gloves and clothes. solvents to wash the skin.
l
Switch the welding unit off before connecting weld-
l
Do not put oil soaked cloths into your pockets.
ing cables. l
Avoid clothes getting soiled by oil.
l
Check electrode holders and electric cables at reg- l
Overalls must be washed at regular intervals. Dis-
ular intervals. pose of non-washable clothes environmentally.
Behaviour in case of faults l
If possible degrease components before handling.
l
In case of faults on the welding unit switch of the
welding unit immediately and have it repaired by ex- Environment
pert personnel. It is strictly prohibited to drain off oil into the soil,
l
In case of failure of the extraction system switch the the sewer system or into natural waters. Old oil
system off and have it repaired by expert personnel. must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con-
Maintenance; waste disposal sult your local authorities.
l
Replace damaged insulating jaws and welding rod
holders immediately. Hydraulics
l
Replace the welding wire reels only in de-energized l Always relieve the pressure in the hydraulic system
state. before disconnecting any lines. Hydraulic oil escap-
ing under pressure can penetrate the skin and
What to do in case of accidents; First Aid
cause severe injury.
l
Keep calm. l
Always make sure that all screw fittings have been
l Call first air helpers. tightened properly and that hoses and pipes are in
l
Report the accident. mint condition before pressurizing the system
again.
l
In case of an electric accident: Interrupt the power
supply and remove the injured person from the
l Hydraulic oil leaking out of a small opening can
electric circuit. If breathing and heart have stopped hardly be noticed, therefore please use a piece of
apply reactivation measures and call for an emer- cardboard or wood when checking for leaks. When
gency doctor. injured by hydraulic oil escaping under pressure
consult a physician immediately, as otherwise this
may cause severe infections.
Old oils
l Do not step in front of or behind the drums, wheels
Prolonged and repetitive contact with mineral oils will or crawler tracks when performing adjustment work
remove the natural greases from the skin and causes in the hydraulic system while the engine is running.
dryness, irritation and dermatitis. Moreover, used en- Block drums, wheels or crawler tracks with wedges.

12 BOMAG 008 911 53

Safety regulations 1.2
Reattach all guards and safety installations after Synthetic rubber
all work has been completed.
Many O-rings, hoses, etc. are made of synthetic ma-
terial, a so-called fluorocarbon elastomer. Under nor-
Environment mal operating conditions this material is safe and does
It is strictly prohibited to drain off oil into the soil, not impose any danger to health.
the sewer system or into natural waters. Oil oil However, if this material becomes damaged by fire or
must be disposed of according to applicable envi- extreme heat, it may decompose and form highly
ronmental regulations. If in doubt you should con- caustic hydrofluoric acid, which can cause severe
sult your local authorities. burns in contact with skin.
l If the material is in such a state it must only be
Fuels touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
!Danger cable environmental regulations immediately after
use.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
l If the material has contacted the skin despite these
BOMAG. measures, take off the soiled clothes and seek
medical advice immediately. In the meantime cool
Follow the valid accident prevention instructions when and wash the affected area of skin over a sufficient
handling fuels. time with cold water or lime water.
The following notes refer to general safety precau-
tions for danger free handling of fuel. Poisonous substances
Fuel vapours not only are easily inflammable, but also Some of the fluids and substances used are toxic and
highly explosive inside closed rooms and toxic; dilu- must under no circumstances be consumed.
tion with air creates an easily inflammable mixture.
The vapours are heavier than air and therefore sink Skin contact, especially with open wounds, must be
down to the ground. Inside a workshop they may eas- avoided.
ily become distributed by draft. Even the smallest por- These fluids and substances are, amongst others,
tion of spilled fuel is therefore potentially dangerous. anti-freeze agents, hydraulic oils, fuels, washing addi-
tives, refrigerants, lubricants and various bonding
l Fire extinguishers charged with FOAM, CO2 GAS agents.
or POWDER must be available wherever fuel is
stored, filled in, drained off, or where work on fuel
systems is performed. Engine
l
The vehicle battery must always be disconnected,
BEFORE work in the fuel system is started. Do not Danger
!

disconnect the battery while working on the fuel Do not work on the fuel system while the engine is
system. Sparks could cause explosion of the fuel running. (Danger to life!)
fumes.
Once the engine has stopped wait approx. 5 min-
l Wherever fuel is stored, filled, drained off or where utes for the system to depressurize. The systems
work on fuel systems is carried out, all potential ig- are under high pressure. (Danger to life!)
nition sources must be extinguished or removed.
Keep out of the danger zone during the initial test
Search lights must be fire proof and well protected
rung. Danger caused by high pressure in case of
against possible contact with running out fuel.
leaks. (Danger to life!)
When performing work on the fuel system make
Hot fuels sure that the engine cannot be started uninten-
Please apply the following measures before draining tionally during repair work. (Danger to life!)
of fuel to prepare for repair work: l Maintenance and cleaning work on the engine must
l Allow the fuel to cool down, to prevent any contact only be performed with the engine stopped and
with a hot fluid. cooled down. Make sure that the electric system is
l
Vent the system, by removing the filler cap in a well switched off and sufficiently secured against being
ventilated area. Screw the filler cap back on, until switched on again (e.g. pull off ignition key, attach a
the tank is finally emptied. warning label).
l
Observe the accident prevention regulations for
electric systems (e.g. -VDE-0100/-0101/-0104/-

008 911 53 BOMAG 13

1.2 Safety regulations

0105 Electric precautions against dangerous con- In combination with the inspection, the refrigerant
tact voltages). collector must be visually examined two times per
year. Special attention must thereby be paid to
l Cover all electric components properly before wet
signs of corrosion and mechanical damage. If the
cleaning.
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
Air conditioning system erator or third parties against the dangers when
handling or operating pressure vessels.
! Caution l Secure pressure vessels against tipping over or roll-
Work on air conditioning systems must only be ing away.
carried out by persons who can provide sufficient l
Do not throw pressure vessels! Pressure vessels
evidence of their ability (proof of professionalism) may thereby be deformed to such an extent, that
and only with the appropriate technical equip- they will crack. The sudden evaporation and escape
ment. of refrigerant releases excessive forces. This ap-
l Always wear goggles and protective clothing when plies also when snapping off valves on bottles. Bot-
performing maintenance and repair work on air con- tles must therefore only be transported with the
ditioning systems. Refrigerant withdraws heat from safety caps properly installed.
the environment when evaporating, which can l Refrigerant bottles must never be placed near heat-
cause injury by freezing when in contact with skin ing radiators. Higher temperatures will cause higher
(boiling point of R134a -26,5 °C at normal pres- pressures, whereby the permissible pressure of the
sure). vessel may be exceeded.
l Perform maintenance and repair work on air condi- l
Do not heat up refrigerant bottles with an open
tioning systems only in well ventilated rooms! Es- flame. Excessive temperatures can damage the
caping refrigerant vapours will mix with the ambient material and cause the decomposition of refriger-
air and displace the oxygen required for breathing ant.
(danger of suffocating).
l
Do not overfill refrigerant bottles, since any temper-
l Smoking is prohibited when performing mainte- ature increase will cause enormous pressures.
nance and repair work on air conditioning systems!
Toxic breakdown products may be generated if re-
frigerant comes into contact with heat. Environment
It is strictly prohibited to release refrigerant into
l Refrigerant should always be extracted and re-
the atmosphere during operation, maintenance
moved by flushing with nitrogen before starting
and repair work and when taking air conditioning
welding or soldering work near components of the
systems into or out of service.
air conditioning system. The development of heat
may cause the refrigerant to develop toxic and high-
ly corrosive breakdown products. Battery
l Pungent smell! The toxic substances, which are re- l Always wear goggles and protective clothing to
sponsible for the pungent smell, must not be in- service or clean batteries! Battery acid can cause
haled, since this may cause damage to the severe injury by cauterization when coming in con-
respiratory system, the lung and other organs. Ex- tact with skin.
tract toxic breakdown products with a suitable ex- l Work only well ventilated rooms (formation of oxy-
traction system (workshop extraction system). hydrogen gas).
l
When blowing out components with compressed air l Do not lean over the battery while it is under load,
and when flushing with nitrogen the gas mixture es- being charged or tested (danger of explosion).
caping from the components must be extracted via l Keep ignition sources away from the battery. Burn-
suitable extraction facilities (workshop extraction ing cigarettes, flames or sparks can cause explo-
systems). sion of the battery
Handling pressure vessels
l
Use battery chargers etc. only in strict compliance
with the operating instructions.
l Since the fluid container is pressurized, the manu- l
After an accident with acid flush the skin with a suf-
facture and testing of these pressure vessels is gov-
ficient amount of water and seek medical advice.
erned by the pressure vessel directive. The
pressure vessels must be repetitively tested by an l Do not allow children access to batteries.
expert as specified in TRB 532 Inspection by Ex- l When mixing battery fluid always pour acid into wa-
perts, Repetitive Tests. In this case periodically re- ter, never vice-versa.
curring inspections consist of external
examinations, normally on containers in operation.

14 BOMAG 008 911 53

Safety regulations 1.2
Special safety regulations
l
Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
l The installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
l Unauthorized changes to the machine are prohibit-
ed for safety reasons.
l Do not perform any cleaning work while the engine
is running.
l If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine (danger of crushing!).
l
If tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
l
Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
l
Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
l
Always ensure an adequate supply of fresh air
when refuelling in closed rooms.
l
Dispose of used filters in accordance with applica-
ble environmental regulations.
l
When performing repair and maintenance work col-
lect oils and fuels in suitable containers and dispose
of in compliance with applicable environmental reg-
ulations.
l Do not heat up oils higher than 160 °C because they
may ignite.
l Wipe off spilled or overflown oil using suitable
cleaning means and dispose of in accordance with
applicable environmental regulations.
l
Dispose of old batteries according to applicable en-
vironmental regulations.
l
There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
engine and hydraulic system to cool down to a suf-
ficient level.
l
Do not exceed the max. permissible tire pressure.

008 911 53 BOMAG 15

1.3 General repair instructions

General Electrics
1.3 General repair instructions

l
Before removing or disassembling parts, assem- General
blies, components or hoses mark these parts for
easier assembly. Due to the fast technical development electric and
electronic vehicle systems become more intelligent
l Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly
or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle
surfaces as required and in compliance with the systems.
compatibility of materials.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).

General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l
Do not disconnect or connect battery or generator
while the engine is running.
l
Do not operate the main battery switch under load.
l
Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l
It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!

16 BOMAG 008 911 53

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

008 911 53 BOMAG 17

1.3 General repair instructions

Generator Starter motor

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

18 BOMAG 008 911 53

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

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

008 911 53 BOMAG 19

1.3 General repair instructions

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

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

20 BOMAG 008 911 53

General repair instructions 1.3
l If the air conditioning system had been opened for Notes on cleanliness for Common Rail
repair work, a new drier should be installed in the re- engines
frigerant circuit.
Special requirements with respect to cleanliness in
l After completion of repair work screw locking caps the fuel system do apply for commissioning, mainte-
(with seals) on all valve connections service con- nance and repair work, particularly for TEIRIII engines
nections. with the DEUTZ Common Rail System. Contamina-
l Before start up of the air conditioning system after a tion like dirt, welding residues or similar can lead to the
new filling: - Turn the compressor approx. 10 revo- failure of individual components and adversely affect
lutions by hand using the clutch or V-belt pulley of engine operation.
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle
speed and maximum cooling power.
l Never run the compressor with an insufficient
amount of refrigerant.

Fig. 1
l
Spare parts should be left in their original packaging
as long as possible and should only be unpacked
just before use.
l
When parts are unpacked any connections must be
closed with suitable plugs or caps, in order to pre-
vent (Fig. 1) contamination of hose connections. If
e.g. fuel hoses are connected to one side, while the
second side cannot yet be connected, there is a
danger of dirt entering into the system. The free
connection must in this case also be appropriately
closed.

Notes and measures to be applied before starting

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

008 911 53 BOMAG 21

1.3 General repair instructions

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

22 BOMAG 008 911 53

General repair instructions 1.3
l Remove loose parts (e.g. paint scales that may Fuel hoses
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
l Working means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.

Fig. 2

! Caution
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.

008 911 53 BOMAG 23

1.3 General repair instructions

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

Fig. 3
l
Lubricate the sealing lips (2) (Fig. 3) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.

i Note
If possible, use an assembly sleeve (1 (Fig. 3)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-

24 BOMAG 008 911 53

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

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

Fig. 5
l Clean and thoroughly examine the feather key.
l Deburr and thoroughly clean the edges of the key-
way with a fine file before reassembling.

Fig. 6
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.

008 911 53 BOMAG 25

1.3 General repair instructions

l Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between ball or roller
bearing and seats. Tightening torque
l Make sure that shaft and housing are free of burrs
before assembling the ball or roller bearing. !Caution
l Always mark the individual parts of separable ball or Tighten nuts or screws with the tightening tor-
roller bearings (e.g. taper roller bearings) to enable ques specified in the following tables of tighten-
correct reassembling. Never assemble the rollers to ing torques. Tightening torques deviating from
an outer race that has already been used, replace the ones in the table are specially mentioned in
the complete ball or roller bearing instead. the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
Fig. 7
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
!Caution
specified tightening torque you should first relieve
When assembling the ball or roller bearing to the by a quarter turn and then tighten to the correct
shaft load must only be applied to the inner race 1 torque.
(Fig. 7).
l Before tightening you should lightly oil the thread, in
When fitting the bearing into the housing load order to ensure low friction movement. The same
must only be applied to the outer race (2). applies for self-locking nuts.
l Make sure that no oil or grease will enter into blind
tapped bores. The hydraulic power generated when
turning in the screw could cause breakage of the ef-
fected part.

26 BOMAG 008 911 53

General repair instructions 1.3
Strength classes, metric screws Strength classes of metric nuts
The strength classes (from 3.6 to 12.9) are specified Nuts are differentiated by three load groups. Each
for all strength classes from a nominal diameter of load group has a special designation system for the
5mm. The corresponding identification can be found strength class assigned, so that the load group can be
where allowed for by the shape of the screw. clearly identified.

Nuts for screw joints with full load capability (4, 5,

6, 8, 10, 12)

Fig. 9 Identification of nuts

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

Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 8 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
l
The nominal tensile strength is 12 X 100 N/mm2 = 05)
1200 N/mm2.
The preceding "0" indicates that, due to their low
The second number specifies 10-times the ration be- height, nuts 2 (Fig. 9) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0,8 d (d = nominal dimension).

Nuts for screw joints without specified load factor

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
l The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.

i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.

008 911 53 BOMAG 27

1.3 General repair instructions

Identification in clock system Identification of UNF-threads

Fig. 10 Identification of nuts in clock system

For small nuts (Fig. 10) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
l
The strength class is identified by a dash (b).
Fig. 11

Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 11).

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

Studs and brake rods

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

28 BOMAG 008 911 53

General repair instructions 1.3
Cotter pins

Fig. 12
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.

008 911 53 BOMAG 29

1.4 Tightening torques

The values specified in the table apply for screws:

1.4 Tightening torques

l black oiled
l with surface protection A4C
l with surface protection DACROMET

i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.

Tightening torques for screws with metric unified thread1

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
1 Coefficient of friction μ tot. = 0,14

Tightening torques for screws with metric unified fine thread1

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
1 Coefficient of friction μ tot. = 0,14

30 BOMAG 008 911 53

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 2401 (copper paste)

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
1 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.

Tightening torques for wheel nuts (fine thread) 1 2

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

008 911 53 BOMAG 31

1.4 Tightening torques

The values specified in the table apply for screws:

l black oiled
l with surface protection A4C
l with surface protection DACROMET

i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.

Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
1 Coefficient of friction μ tot. = 0,14

Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050

32 BOMAG 008 911 53

Tightening torques 1.4
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
1 Coefficient of friction μ tot. = 0,14

008 911 53 BOMAG 33

1.4 Tightening torques

34 BOMAG 008 911 53

2 Technical data

008 911 53 BOMAG 35

2.1 Technical data

Fig. 13

Dimensions in A B B2 B3 D H H2 H4 K L
mm
BC 672 RB-2 3500 3800 3550 3775 1660 4120 3820 1950 600 8120
BC 772 RB-2 3500 3800 3550 3775 1660 4120 3820 1950 600 8120

1 BC 672 RB-2 BC 772 RB-2

Weights
Operating weight (CECE) kg 32100 36500
Front axle load (CECE) kg 15300 17400
Rear axle load (CECE) kg 16800 19100

Travel characteristics
Travel speed range I (forward/reverse) km/h 0 - 4,5 0 - 4,5
Travel speed range II (forward/reverse) km/h 0 - 12 0 - 12
Max. gradability (depending on soil) % 100 100

Engine
Engine manufacturer Deutz Deutz
Type TCD 2015 V06 TCD 2015 V06
Cooling Water Water
Number of cylinders 6 6
Rated power ISO 9249 kW 330 330
Rated power acc. to SAE J 1349 hp 442 442
Rated speed rpm 2100 2100
Electrical equipment V 24 24
Drive system hydrostatic hydrostatic
Driven compactor wheels 4 4

Compactor wheels
Width, front mm 1350 1350
Width, rear mm 1125 1125
Number of teeth, front 60 60
Number of teeth, rear 50 50

Brake
Service brake hydrostatic hydrostatic

36 BOMAG 008 911 53

Technical data 2.1
1
BC 672 RB-2 BC 772 RB-2
Parking brake mechanical mechanical
Emergency brake hydro-mechanical hydro-mechanical

Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydraulic hydraulic
Steering angle ±° 40 40
Oscillation angle ±° 15 15
Inner track radius mm 3090 3090

Dozer blade
Height adjustment above ground level mm 1200 1200
Height adjustment below ground level mm 120 120

Filling capacities
Fuel (diesel) l 500 500
Engine oil l 36 36
Coolant l approx. 50 approx. 50
Hydraulic oil l 350 350
1 Subject to technical alterations.

008 911 53 BOMAG 37

2.1 Technical data

Fig. 14

Dimensions in A B B2 B3 D H H2 H4 K L
mm
BC 772 RS-2 3875 3800 3550 3775 1660 4120 3820 1800 600 9275

1
BC 772 RS-2

Weights
Operating weight (CECE) kg 37300
Front axle load (CECE) kg 20800
Rear axle load (CECE) kg 16500

Travel characteristics
Travel speed range I (forward/reverse) km/h 0 - 4,5
Travel speed range II (forward/reverse) km/h 0 - 12
Max. gradability (depending on soil) % 75

Drive
Engine manufacturer Deutz
Type TCD 2015 V06
Cooling Water
Number of cylinders 6
Rated power ISO 9249 kW 330
Rated power acc. to SAE J 1349 hp 442
Rated speed rpm 2100
Electrical equipment V 24
Drive system hydrostatic
Driven compactor wheels 4

Compactor wheels
Width, front mm 1350
Width, rear mm 1125
Number of teeth, front 60
Number of teeth, rear 50

38 BOMAG 008 911 53

Technical data 2.1
1
BC 772 RS-2

Brake
Service brake hydrostatic
Parking brake mechanical
Emergency brake hydro-mechanical

Steering
Type of steering Oscill.-articul.
Steering operation hydraulic
Steering angle ±° 30
Oscillation angle ±° 15
Inner track radius mm 3750

Dozer blade
Height adjustment above ground level mm 5350
Height adjustment below ground level mm 50

Filling capacities
Fuel (diesel) l 750
Engine oil l 36
Hydraulic oil l 350
Coolant l approx. 50
1 Subject to technical alterations.

008 911 53 BOMAG 39

2.1 Technical data

Fig. 15

Dimensions in A B B2 B3 D H H2 H4 K L
mm
BC 672 EB-2 3500 3800 3550 3425 1580 4120 3820 1050 600 8120
BC 772 EB-2 3500 3800 3550 3775 1580 4120 3820 1050 600 8120

1
BC 672 EB-2 BC 772 EB-2

Weights
Operating weight (CECE) kg 28900 35300
Front axle load (CECE) kg 14100 17300
Rear axle load (CECE) kg 14800 18000

Travel characteristics
Travel speed range I (forward/reverse) km/h 0 - 4,5 0 - 4,5
Travel speed range II (forward/reverse) km/h 0 - 12 0 - 12
Max. gradability (depending on soil) % 100 100

Compactor wheels
Width, front mm 1175 1350
Width, rear mm 1125 1125
Number of teeth, front 50 60
Number of teeth, rear 50 50

Brake

40 BOMAG 008 911 53

Technical data 2.1
1
BC 672 EB-2 BC 772 EB-2
Service brake hydrostatic hydrostatic
Parking brake mechanical mechanical
Emergency brake hydro-mechanical hydro-mechanical

Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydraulic hydraulic
Steering angle ±° 40 40
Oscillation angle ±° 15 15
Inner track radius mm 3265 3090

Dozer blade
Height adjustment above ground level mm 1200 1200
Height adjustment below ground level mm 120 120

Filling capacities
Fuel (diesel) l 500 500
Engine oil l 36 36
Coolant l approx. 50 approx. 50
Hydraulic oil l 350 350
1 Subject to technical alterations, technical data may deviate for optional equipment

008 911 53 BOMAG 41

2.1 Technical data

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 800 - 850
High idle speed rpm 2100 - 2160
Specific fuel consumption g/kWh 225
Valve clearance intake mm 0,25
Valve clearance exhaust mm 0,3
Injection valves opening pressure bar Pump/nozzle
Starter power kW 6,6

Transfer box
Reduction ratio of travel pump drive 1,12
Reduction ratio of working pump 1,12
drive
Pressure setting PRV coolant circuit bar 25
(high idle)

Travel pump
Manufacturer Bosch-Rexroth
Type front A4 VG 71 DA
Type rear A4 VG 71 DG
System Axial piston/swash plate
Max. displacement cm3/rev. 71
Max. flow capacity l/min 156,2
High pressure limitation bar 480 - 20
Pressure override valve bar 420 ± 10
Charge pressure, high idle bar 30 ± 2
Pilot pressure control start at engine 6 bar at 1025 rpm
speed
_Absolute pressure at control start 50 bar at 1025 rpm
__Corresponds with pump speed rpm 1150 ± 50
Pilot pressure at control end 14 bar at 1700 rpm
_Absolute pressure at control end 400 bar at 1700 rpm

Travel motors
Manufacturer Bosch-Rexroth
Type A6VM 160 HA 2T
Quantity 4
System Axial piston – bent axle
Displacement (stage 1) cm3/rev. 160
Displacement (stage 2) cm3/rev. 50
Control start change-over bar 280 ± 5
Control end change-over bar 380 ± 10
Perm. leak oil rate l/min 7

Wheel drive
Manufacturer Bosch-Rexroth
Type GFT 110 R3
Reduction ratio 83

Wheel drive
from serial number 101 570 591 019 BC 672 RB-2
Manufacturer Bonfiglioli
Type 716 C 3B

Steering/working pump

42 BOMAG 008 911 53

Technical data 2.1
Type A10VO 71 DFR
System Axial piston/swash plate
Max. displacement cm3/rev. 71
Max. dozer plate pressure bar 230 + 10
Max. steering pressure bar 200 + 10
Stand-by pressure bar 30 ± 2

Valve block, working hydraulics

Type 2M6-22
Max. steering pressure bar 230 + 10
Max. dozer plate pressure bar 230 + 10
LS-pressure limitation bar 210 + 10
Tank pre-loading valve bar 18

Charge circuit filter micron 12

Return flow filter micron 80

008 911 53 BOMAG 43

2.1 Technical data

The following noise and vibration values according to the EC-directive for machines, edition (98/37/EEC)
and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vi-
bration switched on. The machine was standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is

sound pressure level at the work place of the operator (with cabin):
LpA =71,4 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is

guaranteed sound capacity level of the machine:

LWA = 110 dB(A)
LWA = 111 dB(A), BC 772 RS-2
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204
for sound pressure level (LpA) at the place of the operator.

Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:

Vibration of the entire body (driver’s seat)

The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2.

Hand-arm vibration values

The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.

44 BOMAG 008 911 53

3 Maintenance

008 911 53 BOMAG 45

3.1 General notes on maintenance

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

On diesel engines both combustion air and fuel injec-
When performing maintenance work always comply
with the appropriate safety regulations. tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
Thorough maintenance of the machine guarantees far gas quality of the engine.
longer safe functioning of the machine and prolongs
If your engine has to work permanently in "thin air" (at
the lifetime of important components. The effort need-
higher altitudes) and under full load, you should con-
ed for this work is only little compared with the prob-
sult the customer service of BOMAG or the customer
lems that may arise when not observing this rule.
service of the engine manufacturer.
The terms right/left correspond with travel direction
forward.
Notes on the cooling system
l Always clean machine and engine thoroughly be-
Prepare and check coolant with highest care, since
fore starting maintenance work.
otherwise the engine may be damaged by corrosion,
l For maintenance work stand the machine on level cavitation and freezing.
ground.
Coolant is prepared by adding an ethylene-glycol
l Always remove the main battery switch for all main- based anti-freeze agent with corrosion inhibiting prop-
tenance work. erties to the cooling water.
l Perform maintenance work only with the motor Mixing with cooling system protection agent is neces-
switched off. sary in all climatic zones. It prevents corrosion, lowers
the freezing point and raises the boiling point of the
l
Relieve hydraulic pressures before working on hy-
coolant.
draulic lines.
l
Before working on electric parts of the machine dis- Notes on the hydraulic system
connect the battery and cover it with insulation ma-
terial. During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
l
When working in the area of the articulated joint at- dirt or other contaminating substances can enter into
tach the articulation lock (transport lock). the system. Small particles can produce flutes in
valves, cause pumps to seize, clog nozzles and pilot
Environment bores, thereby making expensive repairs inevitable.
During maintenance work catch all oils and fuels l
If, during the daily inspection of the oil level the hy-
and do not let them seep into the ground or into draulic oil level is found to have dropped, check all
the sewage system. Dispose of oils and fuels en- lines, hoses and components for leaks.
vironmentally. l
Seal external leaks immediately. If necessary in-
Keep used filters in a separate waste container form the responsible customer service.
and dispose of environmentally. l
Do not store drums with hydraulic oil outdoors, or at
Catch biodegradable oils separately. least under a cover. Water can be drawn in through
the bunghole when the weather changes.
Notes on the fuel system l Always use the filling and filtering unit (BOMAG
The lifetime of the diesel engine depends to a great part-no. 007 610 01) to fill the hydraulic system.
extent on the cleanliness of the fuel. This unit is fitted with a fine filter to clean the hydrau-
lic oil, thereby prolonging the lifetime of the filter.
l Keep fuel free of contaminants and water, since this
will damage the injection elements of the engine.
l
Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
l Drums with inside zinc lining are not suitable to
store fuel.
l Do not leave the tank opening unnecessarily open,
but cover it so that nothing can fall in.
l When choosing the storage place for fuel make
sure that spilled fuel will not harm the environment.
Welding work on the refuse compactor
l Do not let the hose stir up the slurry at the bottom of
the drum.
l
Disconnect the main battery switch
l
The fuel drum must rest for a longer period of time
l Pull the plugs off all control units, engine control unit
before drawing off fuel. (EMR), travel control (ESX) and additional control
(DIOS).
l The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes.

46 BOMAG 008 911 53

Fuels and lubricants 3.2
3.2 Fuels and lubricants

Engine oil
Quality
For use in DEUTZ engines the lubrication oils are
classified in DEUTZ Lubrication Oil Quality Classes
(DQC).
Use only oils complying with DQC III-05 or DQC IV-
05.
The list of approved lubrication oils is also available in
the Internet under the following address:

www.deutz.com
de >>SERVICE >> Fuels and lubricants and
diagnostics >> DeutzQualityClass >>
DQC-Release list
en >>SERVICE >> Fuels and lubricants and
diagnostics >> DeutzQualityClass >>DQC-
release list

Consult your local service station if in doubt.

l
Use winter grade engine oil for winter operation!

Oil viscosity
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo- Fig. 16
cation of the engine is of utmost importance when Optimal operating conditions can be achieved by us-
choosing the viscosity class (SAE-class) . ing the oil viscosity chart (Fig. 16) as a reference.
Too high viscosity can cause starting difficulties, too At ambient temperatures below -40 °C the lubrication
low ´viscosity can jeopardize the lubrication effect and oil must be pre-heated (e.g. by parking the machine
result in a high lubrication oil consumption. indoors).
The viscosity is classified acc. to SAE. Multi-purpose
oils should generally be used.

Oil change intervals

The longest permissible time a lubrication oil should
remain in an engine is 1 year. If the following oil
change intervals are not reached over a period of 1
year, the oil change should be performed at least once
per year, irrespective of the operating hours reached.
DQC III, DQC
IV = 500 operating hours

! Caution
When using fuels with a sulphur content of more
than 0,5% to 1% or under permanent ambient tem-
peratures below -10°C and when using biodegrad-
able diesel fuel the oil change intervals must be
halved.

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

008 911 53 BOMAG 47

3.2 Fuels and lubricants

sulphur content has a negative effect on the oil l pH-value too low
change intervals. Adding of caustic lye of soda or caustic potash so-
The fuel level should always be topped up in due time lution.
so that the fuel tank is never run dry, as otherwise filter l Total hardness or chlorides and/or sulphates too
and injection lines need to be bled. high:
Mixing with dehardened water (e.g. distilled water).
Quality
l Total hardness or carbonate hardness too low:
The following fuel specifications are permitted:
Mixing with hardened water (harder water is in most
l
EN 590 cases available in the form of drinking water).
l
DIN 51628
l
ASTM D975 Grade-No. 1-D and 2-D. !Caution
l
JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lu- Another analysis must be made after the fresh wa-
brication properties acc. to EN 590 ter has been prepared.
Winter fuel Cooling system protection agent
For winter operation use only winter diesel fuel, to As a protection against frost, corrosion and boiling
avoid clogging because of paraffin separation. At very point anti-freeze agents must be used under any cli-
low temperatures disturbing paraffin separation can matic conditions.
also be expected when using winter diesel fuel.
Coolant for fluid cooled engines is prepared by adding
In most cases a sufficient cold resistance can also be an ethylene-glycol based anti-freeze agent with corro-
achieved by adding flow enhancing fuel additives. sion inhibiting properties to the cooling water.
Consult the engine manufacturer.
We therefore highly recommend our BOMAG cooling
system protection agent (BOMAG part-no. 009 940
Coolant 08)..
For fluid cooled engines the cooling fluid must be pre- If our cooling system protection agent is not available
pared by admixing a cooling system protection agent for any important reasons, you may, in exceptional
to the fresh water and should be checked within the cases, use products that have been approved by the
specified maintenance intervals. engine manufacturer.
This prevents damage caused by corrosion, cavita- The list of approved cooling system protection agents
tion, freezing and overheating. can be found in the internet under www.deutz.com
Fresh water quality >>SERVICE >> Fuels and lubricants and diagnostics
>> Collig system protection >>Technical circular Cool-
The correct quality of water is highly important when ing System Protection Agents.
preparing coolant. Clear and clean water within the
boundaries of the following analysis values should Products of the same product group (see Deutz Tech-
generally be used. nical Circular Cooling System Protection Agents) can
be mixed with each other.
The BOMAG cooling system protection agent corre-
Fresh water analysis values
sponds with product group A.
pH-value at 20 °C 6.5 - 8.5
Chloride ion content (mg/l) (ppm) max. 100
Sulphate ion content (mg/l) max. 100 Caution
!
(ppm) Do not mix different coolants and additives of any
Total hardness [°dGH] 3 - 12 other kind.
corresponds with a potash ion 0.54 - 3.56
content (mmol/l) of Before changing the product you must clean the
Carbon hardness proportion of min. 3 entire cooling system.
the total hardness (°d) Consult your local service station if in doubt.
corresponds with a content of min. 53.4 To ensure proper corrosion protection you must use
CaCO3 (mg/l) (ppm) the cooling system protection agent all year around,
whereby the following concentration must not be fall-
Information concerning the water quality can be ob-
en short of or exceeded.
tained from the waterworks.
If the fresh water analysis values are unknown, these
must be determined with the help of a water analysis.
If the values of the analysis deviate, the water must be
treated accordingly.

48 BOMAG 008 911 53

Fuels and lubricants 3.2
Gear oil
Mixing ratio
Quality
Cooling sys- Fresh water Cold protec-
For the gearboxes use only ,ulti-purpose gear oils ISO
tem protection tion down to VG 220 of API-GL5-class with a minimum viscosity of
agent 20 mm2/s at 100 °C. We recommend BOMAG SAE
min. 35% 65% -22 °C 80W-140, TN 00992507.
40% 60% -28 °C
This is a hypoid lubricant of highest quality class for
max. 45% 55% -35 °C
extremely loaded transmissions.

! Caution The additives in this oil ensure low wear lubrication

under all operating conditions.
A proportion of more than 45% of cooling system
protection agent causes a drop in cooling power.
Lubrication grease
The use of corrosion protection oils as cooling
For lubrication purposes use an EP-high pressure
system protection agents is not permitted.
grease, lithium saponified (penetration 2), acc. to DIN
51502 KP 2G.
i Note
When working at temperature below -35 °C you
should consult our local service representative.

Environment
Coolant must be disposed of environmentally.

Mineral oil based 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

The hydraulic system can also be operated with a syn-
thetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Pan-
olin HLP Synth.46 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 lubrication oil service of the oil manufactur-
er for details.

! Caution
Check the filter more frequently after this change.
Perform regular oil analyses for content of water
and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.

008 911 53 BOMAG 49

3.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity

Summer Winter Attention

Observe the level marks

Engine

- Engine oil DQC III or IV approx. 36 litres

SAE 10W-40 (-20 °C to +40 °C)

SAE 10W/40 (-15 °C to +40 °C)

SAE 5W-40 (-30 °C to +40 °C)

SAE 5W-30 (-30 °C to +30 °C)

- Fuel Diesel Winter diesel fuel approx. 500 litres

- Coolant Mixture of water and anti-freeze agent approx. 50 litres

(see "Fuels and Lubricants - Colant")

Hydraulic system Hydraulic oil (ISO), HV46, kinem. Viscosity approx. 350 litres
46 mm2/s at 40 °C with viscosity index (VI) >150 or
biodegradable ester based hydraulic oil

Transfer box Gear oil SAE 80W-140, API GL-5 approx. 4.5 litres

Travel gear Gear oil SAE 80W-140, API GL-5 approx. 7,7 litres each
Gear oil SAE 80W-140, API GL-5 (Bonfiglioli)
approx. 6,5 Liter each (L +
S)

Central lubrication system High pressure grease (lithium saponified) approx. 2.0 kg, automatic
lubrication

Bucket High pressure grease (lithium saponified) as required

Air conditioning system Refrigerant R134a approx. 1850 g

Cabin heater (diesel)

- Oil bath air filter SAE 15W/40 (above 0 °C) SAE 10W/30 as required
(down to approx. -10 °C )
SAE 5W/30
(down to approx. -30 °C )

50 BOMAG 008 911 53

Running-in instructions 3.4
3.4 Running-in instructions
The following service work must be performed
when taking new machines into operation.

! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.

After a running time of 15 minutes retighten the V-

belts for generator and air conditioning compres-
sor.

every 2000 oper. hours

every 4000 oper. hours

every 6000 oper. hours

every 500 oper. hours
No. Maintenance work Comment

as required
5.44 Replace the glow plugs only by authorized X
service personnel
5.45 Clean, change the dry air filter car- when the air filter X
tridge warning light lights up
min. 1x per year
5.46 Clean the condenser X
5.47 Adjust scrapers and edge cutters X
5.48 Replace the wheel caps X
5.49 Check the condition of the cutting X
blades, replace the cutting blades if
necessary
5.50 Fill the provision tank for the wind- X
screen washer system
5.51 Drain off dirty fluids from front and X
rear frame
5.52 Tighten all bolted connections X
5.53 Conservation X
1 Running-in instructions: after 50 operating hours change the oil; oil change intervals depend on fuel quality (sulphur content); with a
fuel consumption of > 50 l/h the oil must be changed every 250 operating hours
2 Running-in instructions: oil change after 50, 500 and 1000 operating hours, then every 1000 operating hours
3 also after repairs in the hydraulic system.
4 oil change after 500 and 2000 operating hours, then every 2000 operating hours

54 BOMAG 008 911 53

4 Electrics

008 911 53 BOMAG 55

4.1 Understanding circuit diagrams

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

Structure
l Table of contents (Fig. 17)
l Function groups (Fig. 18)
l List of components (Fig. 20)

56 BOMAG 008 911 53

Understanding circuit diagrams 4.1
Table of contents (Fig. 17)
The table of contents lists all function groups.

Fig. 17 Table of contents

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

008 911 53 BOMAG 57

4.1 Understanding circuit diagrams

Function groups (Fig. 18)

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

Arrangement of current paths

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

Fig. 18 Function groups

Potential cross references

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

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

Relay cross reference

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

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

58 BOMAG 008 911 53

Understanding circuit diagrams 4.1
Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 19) (0 ..... 20).

Fig. 19 Current paths

008 911 53 BOMAG 59

4.1 Understanding circuit diagrams

List of components (Fig. 20)

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

Fig. 20 List of components

Component cross references

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

60 BOMAG 008 911 53

Designation of components in the wiring diagram 4.2
4.2 Designation of components in the wiring diagram
The designation of components in the wiring diagram groups several electrical parts of the machine in one
group. The components can be identified by the following table.

Component designa- Meaning

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

008 911 53 BOMAG 61

4.3 Terminal designations in wiring diagram

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

Terminal designation Meaning

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

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

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

31 Battery minus direct or ground

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

49 Input flasher relay

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

50 Starter, starter control

50a Battery changeover relay, output for starter control

53 Wiper motor input (+)

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

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

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

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

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

61 Generator control

75 Radio, cigarette lighter

76 Loudspeaker

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

62 BOMAG 008 911 53

Terminal designations in wiring diagram 4.3
Terminal designation Meaning
87a Relay contact on breaker and two-way contact, output 1 (breaker side)
87b Relay contact on breaker and two-way contact, output 2
87c Relay contact on breaker and two-way contact, output 3
87z Relay contact on breaker and two-way contact, input 1
87y Relay contact on breaker and two-way contact, input 2
87x Relay contact on breaker and two-way contact, input 3

88 Relay contact for maker

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

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

008 911 53 BOMAG 63

4.4 Circuit symbols in the circuit diagram

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

Fig. 1 Example: Circuit symbol

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

64 BOMAG 008 911 53

Battery ground and analog ground 4.5
4.5 Battery ground and analog 4.6 Current and voltage
ground
General
GND, battery ground If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the One simply compares electric current with water.
potential of "Zero" Volt and represents the reference
potential for operating voltages. Voltage
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.

Terminal designation for GND = terminale 31

AGND, analog ground

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

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

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

008 911 53 BOMAG 65

4.6 Current and voltage

The following statements concerning electric volt- Current

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

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

The electric amperage (I) is measured in Ampere

(A).

The technical flow direction is specified from

PLUS to MINUS.

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

Circuit

Fig. 3 Circuit
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring.
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).

66 BOMAG 008 911 53

Resistance 4.7
Types of current 4.7 Resistance
Direct current (D.C.)
Resistance and voltage drop
While current flows through a conductor the current
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance.

Fig. 1 Direct current (D.C.)

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

Fig. 2 Alternating current (A.C.)

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

Fig. 2 Potentiometer, infinitely adjustable resistor

The resistance can only be measured with a Multime-
ter.

Symbol, R

Unit, Ohm Ω

The electric resistance (R) is measured in Ohm Ω.

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

008 911 53 BOMAG 67

4.7 Resistance

l The cleaner the contacts, the better the current.

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

Unnecessary resistances
Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.

Bad

Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
Fig. 1 Screw-type terminals
keeps water away.
Copper wires are squashed and thus become faulty.

Better

Fig. 2 Spring clamps

Connecting clamps for flexible conductors Fig. 4 Balistol oil

BOMAG No. 057 565 72

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

68 BOMAG 008 911 53

Series / parallel connection 4.8
Sometimes the flanks of flat plugs bend open. If these 4.8 Series / parallel connection
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely Series connection
break sooner or later. It is better to place a small nail In a series circuit the resistors (consumers) are lined
under the bottom of the cable lug before bending. up one after the other and the same current (I) passes
through each of the consumers However, series con-
nection of consumers is not suitable in practice, as
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).

Fig. 1 Series connection

Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3

Voltage
The sum of all partial voltages is identical with the total
voltage.
Fig. 5
Utotal = U1 + U2 + U3
Hint for practice:
A tool you cannot buy. The pliers were converted, the Resistance
nail is permanently present. The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3

Series connection of batteries

Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.

008 911 53 BOMAG 69

4.8 Series / parallel connection

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

Fig. 3 Parallel connection

Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3

Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3

Resistance
The total resistance is less than the lowest individual
resistance.

Parallel connection of batteries

Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.

70 BOMAG 008 911 53

Ohm's law 4.9
l In parallel connection the plus pole of the first bat- 4.9 Ohm's law
tery is connected with the plus pole of the second
battery and the minus pole of the first battery with In a closed electric circuit voltage, current and resist-
the minus pole of the second battery. ance must always be considered in close relation.
l Plus and minus poles have the voltage of the single This relation is represented by Ohm's Law.
battery applied.
l The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.

Fig. 1
According to this law a voltage of 1V is required to let
1A (ampere) flow through a conductor with a resist-
ance of 1 (Ohm Ω).

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

Voltage U = I multiplied with R

Resistance R = U divided by I

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

008 911 53 BOMAG 71

4.10 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

72 BOMAG 008 911 53

Formula diagram 4.11
4.11 Formula diagram
Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate

Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere

Fig. 1 Formula diagram

Resistance, R Ohm Ω

Voltage, U Volt

Current, I Ampere

Power, P Watt

008 911 53 BOMAG 73

4.12 Metrology

4.12 Metrology Multimeter

This tester is a multimeter and can be used to meas-
Test lamps ure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
Test lamp frequency.

Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
l
the range selector switch must be correctly set for
the corresponding measurement.
! Caution l
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- l
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic l
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp l
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The l In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.

Fig. 2 Diode test lamp

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

74 BOMAG 008 911 53

Metrology 4.12
Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter

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

Fig. 3
The following information should be observed when
measuring resistance and continuity: Fig. 5 Voltage measurement
l The component to be measured must not be con- l
A measurement at the consumer measures the volt-
nected to the power supply during the measure- age drop at this component.
ment.
l At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
l Polarity is of no significance.

008 911 53 BOMAG 75

4.12 Metrology

Current measurement with the multimeter Clip-on measuring instrument

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

Fig. 6 Measuring current

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

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

Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.

76 BOMAG 008 911 53

Metrology 4.12
Magnet tester Power measurement
The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring of current and voltage.
However, there are also pure power meters with 4
connections available. The power meter has a electro-
dynamic measuring mechanism. The current circuit
must be opened for measuring. Take care when per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.

Fig. 1 Magnet tester

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

Fig. 2

008 911 53 BOMAG 77

4.13 Diodes, relays, fuses

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

Diodes

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

Fig. 2 Marking of the cathode

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

Fig. 3 Diode circuitry

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

78 BOMAG 008 911 53

Diodes, relays, fuses 4.13
Light emitting diodes Relays

Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
Fig. 4 LED
A free-wheeling diode prevents induction voltage from
The light emitting diode, also referred to as LED, is a
flowing back from the coil into the vehicle wiring sys-
semi-conductor diode, which generates (emits) light
tem, which would cause interference with electronic
during operation in forward direction. A semi-conduc-
components (control units).
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the With the possibility of using breaker - maker contacts
head. Light emitting diodes are available in various the effect of an information can be reversed.
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.

Fig. 2 Relay circuitry

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

008 911 53 BOMAG 79

4.13 Diodes, relays, fuses

85 = Ground supply for coil Fuses

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

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

Caution
!

Fuses must not be repaired or bridged.

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

80 BOMAG 008 911 53

Telemecanique switch 4.14
4.14 Telemecanique switch
Example of terminal designations

Fig. 1 Terminal designations

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

i Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.

008 911 53 BOMAG 81

4.14 Telemecanique switch

Disassembly

Fig. 2 Disassembly
l Lift up the interlock (5).

Fig. 4 Pulling out the front element

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

82 BOMAG 008 911 53

Telemecanique switch 4.14
Assembly

Fig. 5 Assembly
l Insert the front element (3) into the bore in the con-
trol panel.

Fig. 7 Assemble the switch block

l Clip on the switch block (4).

Fig. 6 Observe the marks.

i Note
Hook in the switch block at the bottom first (Fig. 7).
l Clip the fastening adapter (6) onto the front element
(3).

i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
l
Tighten the screw (1) with a tightening torque of 0.6
Nm.

008 911 53 BOMAG 83

4.15 Plug connectors

Duties and requirements
Electric plug connectors must provide a reliable con-
nection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
with different voltage potentials.
l
Excellent leak tightness against water and mois-
ture.

84 BOMAG 008 911 53

Magnetic coil plug 4.16
Magnetic coil plug with LED and suppres-
4.16 Magnetic coil plug

sor diode
The plug is equipped with a polarized function display
and a suppressor diode as protection against over-
voltages.

Fig. 8 Magnetic coil plug without LED and with-

The plug is polarized, it does not matter whether Pin1 out supressor diode
or Pin 2 is supplied with current, Pin 3 is not used. The
The plug has no LED and no suppressor diode as pro-
LED lights if voltage is applied to the solenoid valve.
tection against overvoltages.

Fig. 9

Fig. 10 Switching symbol in circuit diagram

008 911 53 BOMAG 85

4.16 Magnetic coil plug

Assembly of magnetic coil plugs

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

Fig. 13
l
Fasten the screw with a suitable screwdriver.

Fig. 11 Solenoid valve plug with pointed cable

Fig. 14
l
Press the plug firmly on again.

Fig. 12
l Connect the plug with the coil connection and press
it firmly onto the connecting housing.

Fig. 15
l Retighten the screw.

86 BOMAG 008 911 53

Deutsch plug, series DT and DTM 4.17
4.17 Deutsch plug, series DT and
DTM

General
Plug connectors DT and DTM have a wedge to hold
the pins and sockets in their position. This wedge can
be removed and replaced, without having to cut any
leads.

Fig. 16

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

Fig. 18 Crimp connections

Caution
!

Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
Fig. 17 Correctly installed plug without gap When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).

Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
l
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.

008 911 53 BOMAG 87

4.17 Deutsch plug, series DT and DTM

DT Series

Fig. 1 DT plug connection

Fig. 2 DT Series

Fig. 3 Sectional drawing

88 BOMAG 008 911 53

Deutsch plug, series DT and DTM 4.17
Installing DT contacts

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

Caution
!

Perform a pull test on each lead, each of the termi-

nals and connections must withstand a pulling
force of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

008 911 53 BOMAG 89

4.17 Deutsch plug, series DT and DTM

Disassembling DT contacts

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

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

90 BOMAG 008 911 53

Deutsch plug, series DT and DTM 4.17
DTM Series

Fig. 1 DTM plug connection

Fig. 2 DTM Series

Fig. 3 Sectional drawing

008 911 53 BOMAG 91

4.17 Deutsch plug, series DT and DTM

Installing DTM contacts

Fig. 4
l
Insert the contacts through the rubber grommet until
they click into place.
l
Insert the orange wedge, until it clicks into place.

Caution
!

Perform a pull test on each lead, each of the termi-

nals and connections must withstand a pulling
force of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

92 BOMAG 008 911 53

Deutsch plug, series DT and DTM 4.17
Disassembling DTM contacts

Fig. 5
i Note
l Pull the orange wedge (interlock) out with long nose Use the same method when assembling the socket.
pliers.
In this case the interlock disassembly tool (see special
l Slightly pull the lead and unlock the interlocking tools for electrics) serves as an aid to remove the
hook with a screw driver. wedges.
l Pull the contact out of the socket.

008 911 53 BOMAG 93

4.18 Plugs and terminals in spring clamping technology

General

Fig. 1

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

Connecting terminal for quick repairs

Fig. 2 That's how it works

BOMAG part-no.: 057 565 72

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

That's how it works

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

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

94 BOMAG 008 911 53

Plugs and terminals in spring clamping technology 4.18
Series clamp

Fig. 3 That's how it works

That's how it works

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

Caution
!

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

Measuring signals
On these terminal blocks the bridge slot is most suitable for tapping off and measuring signals. Here you may
directly insert a 4 mm test adapter (see special tools for electrics) for connecting a measuring lead. This test
adapter is standard in the central electrics of heavy equipment machines.

Fig. 4 Test adapter

008 911 53 BOMAG 95

4.18 Plugs and terminals in spring clamping technology

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

X-COM plug clamp

Fig. 5 That's how it works

That's how it works

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

Caution
!

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

Fig. 6 X-COM plug with measuring cable

l The most reliable measurements on the plug can be made when using the measuring and connecting cable
with 2mm plug (see special tools for electrics).

96 BOMAG 008 911 53

Plugs and terminals in spring clamping technology 4.18
Measuring signals

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

008 911 53 BOMAG 97

4.19 Batteries

4.19 Batteries Battery maintenance

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

Battery test in general

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

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

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

98 BOMAG 008 911 53

Batteries 4.19
Batteries with screw plugs Checking the electrolyte density

Checking the electrolyte level

Fig. 4
Fig. 3 The cells are filled with diluted sulphuric acid as elec-
1 Upper filling level mark trolyte (approx. 25 Vol% sulphuric acid in distilled wa-
ter), also referred to as accumulator acid, which has a
2 Lower filling level mark
density of 1.285 kg/dm3 at a temperature of +27° Cel-
l If the electrolyte level only reaches up to the lower sius. This means that one litre of electrolyte has a
filling level mark (2), fill distilled water into the corre- weight of 1.285 kg. As the cell is being discharged
sponding cells. lead sulphate (PbSO4) will form on both electrodes
and the electrolyte will increasingly change to water.
Since water has a lower specific 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.
With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead bat-
tery. The so-called electrolyte tester (densimeter) is
used for this purpose.

Fig. 5 Checking the electrolyte density:

1) correct
2) poor
3) poor

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

008 911 53 BOMAG 99

4.20 Battery service, check the main battery switch

Do not draw too much electrolyte into the pipe. 4.20 Battery service, check the
Make sure that the float is not obstructed in its move- main battery switch
ment and hold the electrolyte tester at eye level.
The electrolyte tester must be read at the highest
electrolyte level. Danger
!

l If the electrolyte temperature deviates from the Danger of cauterisation ! Danger of explosion!
electrolyte tester calibration temperature, the indi- When working on the battery do not use open fire,
cated value for the specific electrolyte weight must do not smoke!
be corrected acc. to the formula (reference) below.
The battery contains acid. Do not let acid come in
Reference contact with skin or clothes!
The specific weight varies slightly with temperature. Wear protective clothing!
To be exact, the specific weight drops by 0.0007 per 1 Do not lay any tools on the battery!
°C temperature increase (by 0.0004 per 1 °F) and in-
For recharging remove the plugs from the battery
creases by 0,0007 per 1 °C temperature reduction (by
to avoid the accumulation of highly explosive gas-
0,0004 per 1 °F) . If e.g. a temperature of 20 °C (68 °F)
es.
is used as reference, the indicated value of the specif-
ic weight must be corrected acc. to the following for-
mula. Environment
l Specific weight at 20 °C = measuring value + Dispose of the old batteries environmentally.
0,0007 × (electrolyte temperature: 20 °C)
l
Specific weight at 68 °F = measuring value + 0,0004
× (electrolyte temperature: 68 °F)
i Note
Maintenance free batteries also need care. Mainte-
Acid density at 27 °C in kg/dm3 nance free only means that the fluid level does not
l
1.25 -1.28, open-circuit voltage approx. 12.7 Volt. need to be checked. Each battery suffers under self-
Battery is charged. discharge, which may, in not checked occasionally,
even cause damage to the battery as a result of ex-
l
1.20 -1.24, open circuit voltage approx.12.4 to 12.5 haustive discharge.
Volt, is 50% discharged. Charging is necessary.
l
1.19 and less, open circuit voltage less than 12.3 The following therefore applies for the service life:
Volt. Battery is insufficiently charged. The battery l
Switch off all consumers (e.g. ignition, light, inside
needs to be recharged immediately. light, radio).
l
If there is a deviation of the specific weight of more l
Check open-circuit voltage of the battery at regular
than 0.05 between any of the cells, the battery intervals. At least once per month.
needs to be replaced.
Reference values: 12.6 V = fully charged; 12.3 V =
l
If the current consumption during charging is not 1/
50% discharged.
20 of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full recharging of the battery l Recharge the battery immediately after an open-cir-
results in a final electrolyte density of only 1.24 kg/ cuit voltage of 12.25 V or less is reached. Do not
dm3 or less, the battery shows normal wear by ag- perform quick charging.
ing. The battery was insufficient charging or ex- The open-circuit voltage of the battery occurs approx.
haustive discharge. 10 hours after the last charging process or one hour
after the last discharge.
l
After each charging process allow the battery to rest
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.

Caution
!

Exhausted batteries (batteries with formation of

sulphate on the plates are not covered under war-
ranty!

100 BOMAG 008 911 53

Battery service, check the main battery switch 4.20
Charging voltage recommendation Checking the main battery switch

Fig. 6 Fig. 8

! Caution
Pull out the main battery switch at the earliest 40
seconds after switching off the ignition, except in
cases of emergency.
With engine-independent air heating systems1 al-
low the heating to run for another 2 minutes.
l Turn the main battery switch (Fig. 8) to position "II"
and check by voltage measurement (ignition key
test) whether the batteries are disconnected from
the electric system of the machine.

Fig. 7
l Open the access cover in the floor in front of the
cabin door (Fig. 7).
l Clean battery poles and pole clamps and grease
them with pole grease (Vaseline).
l Retighten the pole clamps.
l
Check the fastening of the battery.
l
On serviceable batteries check the acid level, if nec-
essary top up to the filling mark with distilled water.

1 Optional equipment

008 911 53 BOMAG 101

4.21 Starting the engine with jump leads

4.21 Starting the engine with jump 4.22 Main battery switch
leads

!Caution
When using external starting aid two external bat-
teries are required, one for each on-board battery.
l Open the maintenance door to the battery compart-
ment.

Fig. 10

Main battery switch

Position "I" = Normal position, operation
Position "II" = Separates batteries from the on-
board electrics in case of cable fire
and fire in the engine compart-
ment as well as protection against
unauthorized use.
Fig. 9

!Caution !Caution
A wrong connection will cause severe damage in Pull out the main battery switch at the earliest 40
the electric system. seconds after switching off the ignition, except in
cases of emergency.
l
When starting with external batteries connect the
positive poles (Fig. 9) first and the negative poles With engine-independent air heating systems1 al-
(ground cable) after. low the heating to run for another 2 minutes.
l
Start as described under "Starting the engine".

i Note
The ignition switch is designed with a re-start lock. For
a new starting attempt the ignition key must first be
turned back to position "0".

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

! Caution
Run the engine warm for a short while before
starting work. Do not rev up a cold engine to high
idle speed/full load speed.
1 Optional equipment

102 BOMAG 008 911 53

Main fuse 4.23
4.23 Main fuse 4.24 Hydraulic oil temperature

Temperature sensor, R04

The sensor is installed inside the hydraulic oil tank.
The analog sensor is a variable resistance to ground.

Fig. 11

Main fuses for battery

(1) 250A = (F00) main fuse for battery
(2) 80A = (F48) Main fuse for pre-heating system
Fig. 12 Hydraulic oil tank
i Note
Temperature gauge, P02
The batteries with the main fuses are located inside
the battery compartment under the cover in front of This gauge shows the temperature of the hydraulic oil.
the driver's door.

Fig. 13 Temperature gauge, old design

Fig. 14 Temperature gauge (z), new design

i Note
291 OHM ⇒40°C
36 OHM ⇒120°C

008 911 53 BOMAG 103

4.24 Hydraulic oil temperature

New version: If no temperature sensor is connected or Temperature switch, B20

the cable is broken, the temperature gauge will go out. The temperature switch is installed in the hydraulic oil
tank, it switches on at 96°C±3°C and off at 92°C±3°C.

Fig. 15 Hydraulic oil tank

Monitoring by ESX-control

i Note
The signal is evaluated by the ESX-control (Pin
X0:50) and displayed 10 seconds later in the display
module (Fig. 16) with code "574".
Code "575" appears after 2 minutes, the engine is
shut down and the wrning buzzer sounds.

Fig. 16 Display module in central electrics

104 BOMAG 008 911 53

Pressure switch, hydraulic oil filter 4.25
Hydraulic oil temperature warning light 4.25 Pressure switch, hydraulic oil
The switch contact connects the monitoring board filter
(A15, terminal X1:117) to ground. The hydraulic oil
temperature warning light 14 (Fig. 17) or q (Fig. 18)
lights up. Differential pressure switches, B21, B22,
B121, B122 and B42
The differential pressure switches B21, B22, B121
and B122 are installed in the charge circuit filters.

i Note
Differential pressure switches B121 and B122 are
only used in BC 972 RB-2.
The pressure switch B42 is installed in the filter of the
intermediate gearbox (ground switching).
The pressure switches B21, B22, B121 and B122 are
parallel connected with the monitoring board (A15)
(ground switching). The differential pressure switches
switch at a pressure differential of Δ 3.6 bar.
Fig. 17 Monitoring module, old design

Fig. 18 Monitoring module, new design

Fig. 1

Monitoring by ESX-control

i Note
The signals are evaluated by the ESX-control and dis-
played 10 seconds later in the display module (Fig. 2)
with code "572".

008 911 53 BOMAG 105

4.25 Pressure switch, hydraulic oil filter

Warning lamp for differential pressure switches,

B21, B22, B121 and B122
The switch contacts connect the monitoring board
(A15, terminal X1:119) to ground. The warning light
for the differential pressure switches 13 (Fig. 3) or u
(Fig. 18) lights up.

Fig. 2 Display module in central electrics

Fig. 3 Monitoring module, old design

Fig. 4 Monitoring module, new design

106 BOMAG 008 911 53

Pressure switch, hydraulic oil filter 4.25
Warning light for differential pressure switch, B42 Pressure switch in return flow filter block, B25
The switch contact connects the monitoring board Pressure switch 1(Fig. 7) is set to 3.5±0.5 bar and re-
(A15, terminal X1:120) to ground. The warning light ports excessive dynamic pressure before the primary
for the differential pressure switches 12 (Fig. 5) or p filter.
(Fig. 6) lights up.

Fig. 7
Fig. 5 Monitoring module, old design
Monitoring by ESX-control

i Note
The signals are evaluated by the ESX-control with a
delay of 120 seconds (timing relay K113) and dis-
played 10 seconds later in the display module (Fig. 8)
with code "580". The warning buzzer is activated at
the same time.

Fig. 6 Monitoring module, new design

Fig. 8

008 911 53 BOMAG 107

4.26 Magnetic sensor, hydraulic oil

Warning lamp for return flow filter block, B25 4.26 Magnetic sensor, hydraulic oil
The timer relay (K113) is activated via the switch con-
tact (ground switching). Magnetic sensor, B19
The monitoring board (A15, terminal X1:118) is con-
The magnetic sensor is in the return flow filter block.
nected to ground 120 seconds later. The return flow The sensor switches when sensor has picked up met-
filter warning light 15 (Fig. 9) or n (Fig. 10) lights up.
al chips.

Fig. 9 Monitoring module, old design Fig. 1

Monitoring by ESX-control

i Note
The signal is evaluated by the ESX-control and dis-
played 10 seconds later in the display module (Fig. 2)
with code "570".

Fig. 10 Monitoring module, new design

Fig. 2 Display module in central electrics

108 BOMAG 008 911 53

Pressure switch for brake 4.27
Warning light for magnetic sensor, B19 4.27 Pressure switch for brake
The switch contact connects the monitoring board
(A15, terminal X1:121) to ground. The warning light Pressure switch, B05
for the magnetic sensor 9 (Fig. 3) or w (Fig. 4) lights
up. At a pressure of less than15±1.5 bar the pressure
switch switches to ground.

Fig. 3 Monitoring module, old design

Fig. 4 Monitoring module, new design

Fig. 1

008 911 53 BOMAG 109

4.28 Level sensor in diesel tank (R03)

Parking brake warning light 4.28 Level sensor in diesel tank

The switch contact connects the monitoring board (R03)
(A15, terminal X1:122) to ground. The parking brake
warning light 10 (Fig. 2) or u (Fig. 3) lights up.

Fig. 2 Monitoring module, old design

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

Fuel level gauge

Fig. 3 Monitoring module, new design

The gauge shows the fuel level.

110 BOMAG 008 911 53

Level sensor in diesel tank (R03) 4.28

Fig. 2 Fuel level gauge, old design

Fig. 3 Fuel level gauge (j), new design

i Note
0 OHM ⇒ Tank full
81 OHM ⇒ Tank empty
New version: If no level switch is connected or the ca-
ble is broken, the fuel level gauge will go out.

008 911 53 BOMAG 111

4.29 Blower monitoring module A53

4.29 Blower monitoring module

A53

Fig. 1
The module is located in the right hand cabin flap.
The module has the function:
To make a connection from terminal 30 to terminal
87a after 20 seconds if the blower speed drops below
a certain limit (1300 rpm) and after 8 seconds if the
speed signal fails.

i Note
In deenerized condition there is no connection be-
tween Pins 30 and 87a.

Fig. 1 Blower monitoring module

Module description blower monitoring

This module protects the fresh air blower in case of
overloads (contamination) against damage and thus
the machine against subsequent damage.

Switch position Dropping resistor Signal frequency Blower speed

Low speed 22 Ohm 73 Hz 2190 rpm
Mean speed 10 Ohm 89 Hz 2670 rpm
Max.speed No dropping resistor 113 Hz 3390 rpm

112 BOMAG 008 911 53

Cab electrics 4.30

Fig. 1 Dashboard, old design 20 A65, control unit for air conditioning
1 P00, fuel gauge 21 S44, rotary switch for cabin fresh air ventilator
2 P12, Volt meter 24V 22 S119, travel pedal for throttle control
3 P03, engine RPM-meter with (P00) operating hour 23 S71, steering lever
meter
24 S03, push button for warning horn
4 P14, coolant temperature gauge
25 Air distribution nozzles
5 P02, hydraulic oil temperature gauge
6 S00, ignition switch
7 A15, fault indicator, engine functions
8 A15, fault indicator, machine functions
9 S70, lever for dozer blade / bucket control control
10 H04, warning light for engine control
11 H70, control light for water separator in fuel pre-fil-
ter
12 XS, socket 24V
13 S02, rotary switch, travel speed ranges
14 S31, travel lever (forward/0/reverse)
15 S04, rotary switch for parking brake
16 S25, rotary switch for seat heating
17 E20, cigarette lighter
18 S27, push button for central lubrication system
19 S01, Emergency stop switch

008 911 53 BOMAG 113

4.30 Cab electrics

Fig. 2 Dashboard, new design 21 S161, deceleration pedal with emergency braking
1 A15, instrument cluster left kick-down*
2 A15, instrument cluster right 22 S71, steering lever
3 S00, ignition switch 23 S03, push button for warning horn
4 Air distribution nozzles
5 S70, lever for dozer blade control
6 H04, warning light and diagnostic push button for
engine control
7 H70, warning light water in fuel filter
8 XS, socket 24V
9 S02, rotary switch, travel speed ranges
10 S31, travel lever
11 S04, rotary switch for parking brake
12 S25, rotary switch for seat heating
13 Cigarette lighter
14 S27, push button for central lubrication system
15 A65, control unit for air conditioning1
16 S44, rotary switch for cabin ventilator
17 S120, potentiometer for throttle control*
18 S160, rotary switch for activation of manual throt-
tle/deceleration pedal ON/OFF with indicator light*
19 S01, Emergency Stop switch
20 S119, travel pedal for throttle control
1 Optional equipment

114 BOMAG 008 911 53

Cab electrics 4.30

1 Wiring loom, electrics box - engine control unit 5 Wiring loom, electrics box - throttle pedal
(A48) 6 ESX, electronic control
2 Wiring loom, electrics box - ESX control 7 Wiring loom, electrics box - driversseat'
3 Wiring loom, electrics box - module cockpit
4 A48, engine control unit

008 911 53 BOMAG 115

4.30 Cab electrics

Dashboard, cabin
a = S20, toggle switch for front windscreen
wipers 1 A53, fan module for fresh air fan
b = S22, toggle switch for front washer 2 A57, pulse generator for windscreen wiper
c = S21, toggle switch/push button for rear 3 K32, relay for cabin
windscreen wiper/washer 4 U01, voltage transformer 24/12 Volt
d = S45, toggle switch for inside lights
e = S16, toggle switch for front working head
lights
f = S53, toggle switch for working head
lights, sides
g = S26, toggle switch for working head
lights, rear
h = S128, toggle switch for rear view mirror
heating
i = S38, toggle switch for flashing beacon
j = S137, toggle switch for engine compart-
ment illumination

Y138, solenoid valve for heating

1 A53, fan module

2 A57, pulse generator for windscreen wiper
3 K32, relay for cabin
4 U01, voltage transformer 24/12 Volt
E37, radial twin blower
A53, blower module for radial twin blower

116 BOMAG 008 911 53

Fuses 4.31
4.31 Fuses

B117, thawing thermostat

Fig. 3

Fuses

Terminal
X1:20 (15A) = (F50) Climatronic1
X1:21 (30A) = (F89) Cigarette lighter
B29, room temperature sensor
X1:22 = (F94) Spare, safety ventilation
B118, blow-off temperature sensor system
X1:23 (30A) = (F13) Ignition switch
X1:24 (25A) = (F93) EDC 7 Control, potential 30
X1:25 (30A) = (F05) Socket
X1:26 (10A) = (F84) Processor control
X1:27 (30A) = (F67) Power control
X1:28 = (F123) Spare, safety ventilation
system
X1:29 (15A) = (F24) Instruments
X1:30 (10A) = (F16) Central lubrication system
X1:31 (15A) = (F29) Driver’s seat
X1:32 (10A) = (F122) EDC 7 Control, potential
15
X1:33 (20A) = (F31) Cyclone separator
X1:34 (15A) = (F23) Warning horns
X1:35 (10A) = (F25) Driving and braking
X1:36 (10A) = (F33) Climatronic (option)

1 Optional equipment

008 911 53 BOMAG 117

4.32 Fuse, cabin

X1:37 = Spare 4.32 Fuse, cabin

Fig. 4
No. 1 = Fuse boxes, cabin

Danger
!

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

Fuse box F1 (top)

(1) 10A = (F27) Windscreen wiper, washer, front
(2) 10A = (F28) Windscreen wiper, washer, rear
(3) 10A = Spare
(4) 20A = (F85) 4 working headlights, front
(5) 15A = (F86) 2 working headlights, rear
(6) 10A = (F02) Fresh air fan
(7) 15A = (F99)2 headlight, engine compartment
light
(8) 15A = (F66) 2 working head lights left, right

Fuse box F2 (bottom)

008 911 53 BOMAG 125

4.34 Electronic control units

4.34 Electronic control units Modules

In the latest generation of machines BOMAG uses
Control units machine programmable modules. A module mainly
consists of a programmable microprocessor with ad-
Control units (ECU = electronic control unit or ECM =
ditional circuitry for inputs and outputs.
electronic control module) are electronic modules
which are mainly installed in places where something
needs to be controlled or regulated. Control units are
used in almost any electronic sector in the automotive
industry, but also to control machines, plants and oth-
er technical processes.
Control units generally work according to the IPO-
principle. IPO stands for Input-Processing-Output.
Sensors are available for input. Sensors determine a
physical characteristic like e.g. rotary speed, pres-
sure, temperature, etc. This value is compared with a
setpoint entered into or calculated in the control unit.
If the measured value does not match the stored val-
ue, the control unit regulates the physical process by
means of actors, so that the measured actual values
match the setpoint again. This means that the actors
correctively interfere with the ongoing process.

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

Fig. 1 Electronic control (ESX)

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

126 BOMAG 008 911 53

Electronic control units 4.34
Signals CAN-bus, Controller Area Network
Analog signals created by Bosch at the end of the eighties for auto-
mobile applications.
Process states are continuous (analog) when they
can be mapped by means of a real number, e.g. tem- Development objectives:
perature = 65.5 °C. The sensor converts a continuous Real-time critical, robust and low price communication
process status into an analog signal. If the control unit of control units, such as transmission and engine con-
needs the numerical value of the analog signal, an an- trol, but also less time critical applications in the field
alog-digital conversion is required. of convenience electronics, such as air conditioning.
Analog signals are needed to control, display or mon-
itor limit values. Checking the limit values of physical
quantities leads to the binary information: limit value
reached/not reached.

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

Fig. 3

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

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

Measuring on the CAN

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

008 911 53 BOMAG 127

4.35 Checking the voltage supply for the control unit

Power supply for a control unit, general

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

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

Fig. 4 Circuitry example

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

128 BOMAG 008 911 53

Checking the voltage supply for the control unit 4.35
Fault in current supply, general
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides
of control units are in most cases connected to the vehicle mains supply via several cables, so that several par-
allel current branches exist. Checking the power supply is therefore slightly more difficult than expected. Another
point is the fact that every current branch has several plug connections, which could corrode over the years.
Corroded points are transition resistances and thus cause undesired voltage drops. In case of undesired voltage
drops the control unit is supplied with a lower voltage. This can lead to faulty reactions or even failure of the
control unit.

Fig. 5 Circuitry example

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

008 911 53 BOMAG 129

4.35 Checking the voltage supply for the control unit

Measuring principle for line testing

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

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

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

Fig. 6 Pinbox for 68 pole ESX control

130 BOMAG 008 911 53

Checking the voltage supply for the control unit 4.35
General measuring setup to check a supply line (plus side)

Fig. 7 Measuring arrangement 12 Volt

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

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

008 911 53 BOMAG 131

4.35 Checking the voltage supply for the control unit

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

Fig. 8 Measuring arrangement 12 Volt

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

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

132 BOMAG 008 911 53

Checking the voltage supply for the control unit 4.35
Connection example to check the plus line between battery and plug pin 28

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

008 911 53 BOMAG 133

4.35 Checking the voltage supply for the control unit

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

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

134 BOMAG 008 911 53

Checking the voltage supply for the control unit 4.35
Test protocol for ESX
E lamp 12V / 21W in 12V vehicle network, to load the current branches.
E lamp 24V / 21W in 24V vehicle network, to load the current branches.
G01, battery
P multimeter, measuring range: DC

Plug pin Note Setpoints

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

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

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

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

008 911 53 BOMAG 135

4.36 Diagnostics concept

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

Fault description and questioning of the customer

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

Description of fault,
Questioning of customer

Visual inspection,
possible test drive

Interrogation of error log

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

Fig. 11

(1) Fault memorized in error log

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

136 BOMAG 008 911 53

Diagnostics concept 4.36
Line or component?

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

Sequence after the fault is found

Fault found

Replace component or
repair the connecting line

Delete the error log, test drive

Read out the error log again

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

Fig. 13

008 911 53 BOMAG 137

4.36 Diagnostics concept

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

Consideration, when the error log has not recorded a fault

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

138 BOMAG 008 911 53

5 Engine electrics

008 911 53 BOMAG 139

5.1 Engine control unit

! Caution
Pulling off the plug connectors of the control unit
while the control unit is working (i.e. with the pow-
er supply to terminal 15switched on) is not permit-
ted. Correct procedure: Switch off the electric
power supply (normally with the ignition key), wait
until the main relay has switched off (with a delay
of up to 15 seconds, listen for clicking sound),
then pull off the plugs from the control unit.
Sensors and actuators must not be connected to
external power sources for the purpose of testing,
but must only be operated on the EMR3. Other-
wise components may be permanently damaged.
The engine control unit is the central component of the
EMR3-system. It has the function of ensuring optimal
performance of the engine with the following goals
l excellent exhaust gas characteristics,
l low fuel consumption,
l smooth running of engine,
l long lifetime of engine,
l efficient servicing
under all operating conditions. For this purpose the
engine control unit uses the recorded measuring val-
ues and the parameters stored in its data memory to
run a number of calculations, which form the basis or
all the available functions. The most important func-
tions include:
l exact control of the injection process (among others
the number, start and duration of injections), Fig. 14
l
idle speed regulation, The EMR3-E (TCD 2015) (Fig. 14) engine control unit
is fitted with three sockets on the upper side of the
l regulation of exhaust gas recirculation,
housing:
l optimization of smooth running (by means of injec- l socket D2.1 to connect the vehicle wiring loom,
tion quantity correction),
l
socket D2.2 to connect the engine wiring loom for
l
engine monitoring,
sensors and actuators,
l system diagnose. l socket D2.3 to connect the engine wiring loom for
fuel metering unit and injection valves.

Main relay
When shutting down the engine, the ignition switch
isolates the electronic system from terminal 15. Meter
readings are saved in the non-volatile memory. After
approx. 10 seconds the internal main relay switches
off and disconnects the control unit from the power
supply. During this time the system must not be dis-
connected from terminal 30 (+Ubatt).

140 BOMAG 008 911 53

Engine control unit 5.1
Replacing the control unit

! Caution
It is not permitted to interchange control units
from one manufacturing series or against another
engine number. In this case the warranty will be-
come null and void.
Each control unit is clearly designated to the engine,
in accordance with the respective application. In case
of a replacement the control unit therefore needs to be
completed with the engine specific data set. When or-
dering a new control unit you must not only specify the
part-number, but also the engine serial number (see
sticker on EMR-control unit).

i Note
The Deutz part-number specified on the EMR-control
unit is the part number without software specific for
the engine. The correct part number can be found in
the spare parts catalogue.

008 911 53 BOMAG 141

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008 911 53 BOMAG 147

5.3 System faults indicated by flashing code

5.3 System faults indicated by If the fault log of the EMR3 engine control unit holds at
least one active system fault, an uniformly flashing (in
flashing code case of severe system faults) or a permanent light (in
case of minor system faults) will automatically inform
Engine protection function of the electric about this condition. In this case the output of the na-
engine controller EMR3 ture of the fault in the form of flashing codes (flashing
sequences in the pattern i x short flashing, j x long
Depending on the design of the monitoring function flashing, k x short flashing) can be started. The table
the EMR3in certain fault situations is able to protect of system faults shows which flashing codes exist and
the engine against damages by simply monitoring the what they mean.
compliance with important limit values during opera-
tion and by checking the correct function of system
components. Depending on the severity of the fault
the engine may continue its operation with certain re-
strictions, with the fault warning light permanently on,

Lamp light
or the fault warning light will be flashing to indicate a
severe system fault. In this case the engine should be
shut down, as soon as this is possible without risk.
Depending on the engine configuration the flashing
fault lamp can have the following meaning:
l Shut-down request for the operator
l
Attention: Loss of warranty if disregarded!
l
Automatic engine shut-down after a short pre-warn-
ing time, possibly in connection with a restarting
prevention.
l
Forced engine operation at low idle speed to cool
the engine, possible in connection with automatic
shut-down.
l
Start prevention.

Indication of system fault

The diagnostic button provides the possibility to read
out existing faults in form of flashing codes. The diag-
nostics button and the fault lamp are located on the
operatorsstandofthemachine.'

Fig. 16
The following steps are required to read out the flash-
Fig. 15 ing codes for saved system faults:
1 Diagnostics button, S118 l
Hold the diagnostics button depressed (1 to 3 sec-
2 Fault lamp, H04 onds), until the flashing light or the permanent light
3 EMR3 control unit of the fault lamp goes out.

148 BOMAG 008 911 53

System faults indicated by flashing code 5.3
l After approx. 2 s watch the flashing code or the first Deleting the fault log
or the next active fault.
The EMR3 engine control unit has two fault logs.Each
l Wait until the fault lamp shows the original flashing system fault is simultaneously saved in both logs.
or permanent light again after about 5 seconds. However, fault log 2 is only transmitted after switching
Example: 1x short flashing, 2x long flashing, 8 x short off the voltage via terminal 15 and the associated af-
flashing = flashing code 1-2-8; this flashing code indi- terrunning. Earlier switching off may result in the loss
cates an interruption or short circuit in the wiring of the of fault messages.
charge air temperature sensor. The following illustra- The diagnostics button enables you to delete passive
tion (Fig. 16) shows the temporal sequence of the faults from the first fault log. The second fault log can
flashing signals: only be cleared with SERDIA.
All active and passive system faults can be invoked by The following describes the steps for clearing fault log
repetitive execution of these steps. If this read-out 1:
process is continued after the last fault, the output will l Ignition OFF, press and hold the diagnostics button.
be restarted with the first fault.
l Switch the ignition on.

i Note l Only release the diagnostics button after approx. 10

seconds.
The light will go out after the fault has been rectified.
With some faults it is necessary to switch off the igni- l All passive faults in fault log 1 will be deleted.
tion, then wait for 30 seconds before switching the ig- l The deleting process is confirmed by three short
nition back on. flashing pulses.

008 911 53 BOMAG 149

5.4 Flashing code

Flashing code Function / component Fault

Short (0.4s) Long (0.8s) Short 0.4s
1 2 3 Output to coolant temperature Signal faulty, control unit over-
indicator lamp heating
1 2 6 Manual throttle control Signal faulty / implausible
1 2 8 Intake air temperature sensor Signal faulty
1 3 3 Gear oil temperature sensor Signal faulty
1 3 4 Rail pressure monitoring Signal implausible, pressure/
pressure deviation beyond per-
missible range
1 3 5 Output to lubrication oil pressure Signal faulty, control unit over-
warning lamp heating
Output to valve of fuel metering Signal faulty, control unit over-
unit heating
1 3 6 Air filter monitoring Air pressure after filter too low
1 3 7 Output to actuators Short-circuit to battery
1 3 8 Output to actuators Short-circuit against ground
1 4 2 Output to engine operation lamp Signal faulty, control unit over-
heating
1 4 3 Multiple stage switch 1 / 2 / 3 Signal faulty / implausible
1 4 4 Lubrication oil temperature sen- Signal faulty / implausible
sor
Monitoring of lubrication oil tem- Temperature outside nominal
perature range
1 4 5 Monitoring of override switch Signal implausible
1 4 6 Rail pressure limiting valve Valve open / pressure surge re-
quired / no opening after pres-
sure surge
1 4 7 Rail pressure sensor Signal implausible, pressure de-
viation beyond permissible
range
2 1 2 Monitoring of camshaft / crank- No camshaft signal, no crank-
shaft shaft signal
2 1 3 Monitoring of camshaft / crank- Discrepancy between camshaft
shaft and crankshaft signals
2 1 4 Motor protection Status of overspeed/override im-
plausible
2 1 6 Fuel low pressure sensor Signal faulty
Fuel low pressure monitoring Fuel low pressure outside nomi-
nal range
2 1 9 Output to actuator for exhaust Signal faulty, control unit over-
damper engine brake heating
2 2 2 Throttle pedal input 1 (PWM) PWM signal faulty
2 2 3 Charge air pressure sensor Signal faulty
Charge air pressure monitoring Charge air pressure outside
nominal range
2 2 4 Oil pressure sensor Signal faulty / implausible
2 2 5 Coolant temperature sensor Signal faulty / implausible in
comparison to oil temperature,
CAN-signal invalid
2 2 6 Input throttle pedal 1 (analog) Signal faulty / implausible
2 2 7 Fuel temperature sensor Signal faulty
2 2 8 Water level sensor in fuel filter Signal faulty
Fuel filter water level monitoring Max. water level exceeded
2 3 1 Monitoring of lubrication oil pres- Pressure outside the nominal
sure range
2 3 2 Monitoring of coolant tempera- Temperature above nominal
ture range

150 BOMAG 008 911 53

Flashing code 5.4
Flashing code Function / component Fault
Short (0.4s) Long (0.8s) Short 0.4s
2 3 3 Monitoring of intake air tempera- Temperature above nominal
ture range
2 3 5 Monitoring of coolant level Level below nominal range
2 3 7 Monitoring of fuel temperature Temperature outside nominal
range
2 3 8 Output to fan actuator 1 / 2 Signal faulty, control unit over-
heating
Monitoring of fan speed Speed outside nominal range
2 4 1 Monitoring of combustion Misfiring detected in one or sev-
eral cylinders
2 6 1 Monitoring of output to actuators Relay does not open or is de-
layed, short circuit to ground
2 6 3 Output to cold starting aid Signal faulty, relay defective,
jammed or incorrectly connect-
ed, short circuit
2 7 1 CAN-Bus Time-Out for one or several sent
messages, bus inactive
2 8 2 Sensor supply voltage 1 / 2 / 3 Voltage outside nominal range
2 9 2 Atmospheric pressure sensor Signal faulty / implausible
3 1 4 Hydraulic oil temperature sensor Signal faulty
Hydraulic oil temperature moni- Temperature outside nominal
toring range
3 1 8 Battery monitoring Voltage outside nominal range
3 2 8 Output to cold starting aid con- Signal faulty, control unit over-
trol lamp heating
4 1 4 Output to external exhaust gas Signal faulty
recirculation actuator
4 1 5 Output to external exhaust gas Signal faulty, control unit over-
recirculation actuator heating
4 1 6 Output to external exhaust gas Signal faulty
recirculation actuator
4 1 7 Lubrication oil wear time meter Critical time reached
5 1 2 Output to start relay Signal faulty, control unit over-
heating
5 1 3 Output to fault lamp Signal faulty, control unit over-
heating
5 1 4 Monitoring of terminal 15 No signal detected
5 1 5 Monitoring of terminal 50 Permanent signal detected
5 2 1 Speed measurement Travel speed implausible
5 2 8 Output to internal engine brake Signal faulty

008 911 53 BOMAG 151

5.5 Diagnose with SERDIA

SERDIA
With the diagnostics tool SERDIA and a hardware in-
terface one can read out / delete and save the error
log of the control unit.

EDC16
EMR3

Fig. 1 Service-Software TCD 2012 / 2013 Assignment of inputs/outputs

The SERDIA software is first choice for any diagnos- Display of the current input and output assignment of
tics task. the EMR-control.
SERDIA is a software program from Deutz which can
be used in connection with a laptop computer to per-
form more detailed fault analyses, especially reading
out of the error log.
This displays information on
l Location of fault (e.g. ’coolant temperature sensor’)
l Nature of fault (e.g. ’fallen short of bottom limit val-
ue’, ’sporadic fault’)
l Environmental data / operating data (speed and op-
erating hours at the time of the last fault occurrence)
l Number of fault locations and frequency of fault
l Fault status (active – fault present / passive- fault no
longer present)
l Fault messages for non-present / rectified faults can
be deleted with SERDIA.

Function test
The control outputs can be activated with the engine
shut down.

152 BOMAG 008 911 53

Diagnose with SERDIA 5.5
Representation of measuring values

Fig. 2
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).

008 911 53 BOMAG 153

5.5 Diagnose with SERDIA

Representation of fault log

Fig. 3
When looking for the cause of a fault in the EMR3-sys-
tem examining the fault log of the engine control unit
usually provides useful information.

154 BOMAG 008 911 53

Diagnose with CAN-bus 5.6
5.6 Diagnose with CAN-bus
The CAN-bus is used to transfer standard messages
of the SAE J 1939.
The display is a compact, robust and integratable
modules which enables the user to invoke engine data
and to display these in the following formats:
l Analog display
l
Digital data
l Multi data (a combination of analog and digital data)
l Alarm messages currently present
The different diagnostic screens enable detailed ex-
amination of the engine data flow

Fig. 1
Display for EMR control (Fig. 1).

008 911 53 BOMAG 155

5.7 Diagnostics interface

SerDia connection

Fig. 1 Control unit

Fig. 3 Diagnostic link

A = Battery plus (+)
B = Battery minus (-)
F = CAN2 low
G = CAN1 low
H = CAN1 high
Fig. 2 Diagnostic interface in electric switchbox K = K-Line
M = CAN2 high

156 BOMAG 008 911 53

Diagnostics interface 5.7
SERDIA connection CAN-bus display connection
Operation of the display is described in a separate op-
eration manual.

Fig. 5
Display for EMR control (Fig. 5).

BOMAG part-no.: 057 189 94

Fig. 4
The KWP-protocol with encrypted dataflow is used via
the K-line. For this purpose the PC or laptop (Fig. 4) is
connected to the diagnostic interface by means of a Fig. 6
special interface cable. The display is connected to the diagnostic interface by
Operation of SERDIA is described in a separate oper- means of a special cable.
ation manual. Wiring loom for display (Fig. 6)

BOMAG part-no.: 079 900 19

008 911 53
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300

18 / 730 / ArHt2.................................................................. 5 62 / 702 / Dummy2CD_SigNpl.........................................17 128 / 523611 / FrmMngTOTSC1VR................................ 29

19 / 676 / ArHtCD_NoLd.................................................... 5 69 / 2791 / EGRCD_Max .................................................17 131 / 523500 / FrmMngTxTO .......................................... 30
20 / 676 / ArHtCD_RlyErr .................................................. 5 70 / 2791 / EGRCD_Min ..................................................18 133 / 174 / FTSCD........................................................... 30
22 / 168 / BattCD ............................................................... 6 71 / 2791 / EGRCD_SigNpl..............................................18 134 / 174 / FTSCDSysReac ............................................ 30
23 / 168 / BattCDSysReac................................................. 6 72 / 2791 / EGRCDIntEGR ..............................................18 136 / 523618 / GOTSCD ................................................. 31
24 / 523561 / BIPCyl1........................................................ 6 74 / 923 / EngCDTrqCalcOut ...........................................19 137 / 523619 / GOTSCDSysReac................................... 31
25 / 523562 / BIPCyl2........................................................ 7 75 / 190 / EngMBackUp ...................................................19 138 / 29 / HdThrt ............................................................. 31
26 / 523563 / BIPCyl3........................................................ 7 76 / 190 / EngMCaS1.......................................................19 139 / 1638 / HOTSCD ..................................................... 32
27 / 523564 / BIPCyl4........................................................ 7 77 / 190 / EngMCrS1........................................................20 140 / 1638 / HOTSCDSysReac....................................... 32
28 / 523565 / BIPCyl5........................................................ 8 78 / 190 / EngMOfsCaSCrS.............................................20 141 / 523617 / HWEMonCom.......................................... 32
29 / 523566 / BIPCyl6........................................................ 8 79 / 190 / EngPrtSysReacFOC ........................................20 142 / 630 / HWEMonEEPROM........................................ 33
30 / 523567 / BIPCyl7........................................................ 8 80 / 190 / EngPrtSysReacORC........................................21 143 / 523612 / HWEMonRcyLocked ............................... 33
31 / 523568 / BIPCyl8........................................................ 9 81 / 703 / ESLpCD ...........................................................21 144 / 523612 / HWEMonRcySuppressed........................ 33

BOMAG
32 / 102 / BPSCD .............................................................. 9 82 / 1074 / ExFlCD...........................................................21 145 / 523612 / HWEMonRcyVisible ................................ 34
33 / 102 / BPSCDSysReac................................................ 9 83 / 975 / FanCD..............................................................22 146 / 523612 / HWEMonUMaxSupply............................. 34
37 / 111 / CLSCDSysReac .............................................. 10 85 / 1639 / FanCDEval.....................................................22 147 / 523612 / HWEMonUMinSupply.............................. 34
38 / 1323 / CmbChbMisfire1............................................ 10 86 / 523602 / FanCDSysReac .........................................22 149 / 105 / IATSCD ......................................................... 35
39 / 1324 / CmbChbMisfire2............................................ 10 87 / 97 / FlFCD.................................................................23 150 / 105 / IATSCDSysReac........................................... 35
40 / 1325 / CmbChbMisfire3............................................ 11 89 / 97 / FlFCD_WtLvl......................................................23 153 / 523350 / InjVlvBnk1A ............................................. 35
41 / 1326 / CmbChbMisfire4............................................ 11 90 / 94 / FlPSCD ..............................................................23 154 / 523351 / InjVlvBnk1B ............................................. 36
42 / 1327 / CmbChbMisfire5............................................ 11 91 / 94 / FlPSCDSysReac................................................24 155 / 523352 / InjVlvBnk2A ............................................. 36
43 / 1328 / CmbChbMisfire6............................................ 12 94 / 523239 / FrmMngDecV1...........................................24 156 / 523353 / InjVlvBnk2B ............................................. 36
44 / 1450 / CmbChbMisfire7............................................ 12 95 / 523240 / FrmMngFunModCtl ....................................24 157 / 523354 / InjVlvChipA.............................................. 37
45 / 1451 / CmbChbMisfire8............................................ 12 106 / 523212 / FrmMngTOEngPrt....................................25 158 / 523355 / InjVlvChipB.............................................. 37
46 / 1322 / CmbChbMisfireMul ........................................ 13 110 / 523216 / FrmMngTOPrHtEnCmd............................25 159 / 651 / InjVlvCyl1A .................................................... 37
47 / 1346 / CmbChbSysReac .......................................... 13 112 / 523218 / FrmMngTORxCCVS ................................25 160 / 651 / InjVlvCyl1B .................................................... 38
48 / 1109 / CoEngShOffDemIgr....................................... 13 113 / 523604 / FrmMngTORxEngTemp...........................26 161 / 652 / InjVlvCyl2A .................................................... 38
52 / 1072 / CRERCD ....................................................... 14 117 / 523238 / FrmMngTOSwtOut...................................26 162 / 652 / InjVlvCyl2B .................................................... 38
53 / 1081 / CSLpCD......................................................... 14 118 / 523222 / FrmMngTOTCO1 .....................................26 163 / 653 / InjVlvCyl3A .................................................... 39
54 / 704 / CTLpCD........................................................... 14 120 / 523605 / FrmMngTOTSC1AE.................................27 164 / 653 / InjVlvCyl3B .................................................... 39
55 / 110 / CTSCD ............................................................ 15 121 / 523606 / FrmMngTOTSC1AR.................................27 165 / 654 / InjVlvCyl4A .................................................... 39

DEUTZ AG, TE-CE, Fi Seite 1 Rev. 2.1, 22.10.2008

008 911 53
EMR3 List of fault codes
Sensors 5.9
5.9 Sensors

! Caution
Sensors and actuators must not be connected to
external power sources for the purpose of testing,
but must only be operated on the EMR3. Other-
wise components may be permanently damaged.
Sensors must under no circumstances be re-
paired, but must be replaced if they are defective.

Fig. 1
1 Oil pressure sensor
2 Fuel temperature sensor
3 Sensor for charge air temperature and charge air
pressure
4 Engine control unit
5 Coolant temperature sensor
6 Oil level sensor, option
7 Central plug
8 Rotary speed sensor for crankshaft
9 Rotary speed sensor for camshaft
10 Wiring loom connecting cable

008 911 53 BOMAG 229

5.9 Sensors

Fig. 2

Fig. 3

230 BOMAG 008 911 53

Oil pressure sensor 5.10
5.10 Oil pressure sensor

Pressure sensor, B88

Fig. 1

Fig. 2 Oil pressure sensor

008 911 53 BOMAG 231

5.10 Oil pressure sensor

Oil pressure monitoring Monitoring by ESX-control

EMR fault code

i Note
The signal is evaluated by the ESX-control (Pin
X0:52) and displayed 2 seconds later in the display
module (Fig. 4) with code "520".

Fig. 3
The operator is warned 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. 4 Display module in central electrics

permanent light = A fault message is present, the

engine can be started and the
refuse compactor is still operable
with limitations.
the control light flash-
es after 2 seconds= Severe fault, the engine cannot
be started.

232 BOMAG 008 911 53

Oil pressure sensor 5.10
Warning light, engine oil pressure Removing and installing the pressure sensor
If there is no oil pressure, the EMR-control (PIN
XD2.1.20, ground switching) switches, whereby the !Caution
coil of relay (K60) is excited. The switch contact of re-
Ensure absolute cleanliness when working in the
lay (K60) supplies the monitoring board (A15, terminal
lubrication oil system.
X1:88) with ground potential. The engine pressure
warning light 3 (Fig. 5) or c (Fig. 6) flashes. Thoroughly clean the area around the affected
component. Dry off wet locations with com-
pressed air.
Immediately close all connections and openings
with new and clean plugs/caps.
Only remove plugs/caps just before assembling.

Environment
Catch engine oil and dispose of environmentally.

Disassembling the pressure sensor

Fig. 5 Monitoring module, old design

3 red = Engine oil pressure too low.

Fig. 7
l Unlock and pull out the cable plug (Fig. 7).
l
Unscrew the oil pressure sensor with a socket
spanner.
l Check the component visually.

Fig. 6 Monitoring module, new design

c red = Engine oil pressure too low.

008 911 53 BOMAG 233

5.10 Oil pressure sensor

Installing the pressure sensor

Fig. 8
l Insert the oil pressure sensor with a new seal ring
and tighten.

i Note
Tightening torque: 20Nm

Fig. 9
l
Plug in the cable plug.

i Note
Delete the fault entry in the fault log of the engine con-
trol unit.

234 BOMAG 008 911 53

Fuel temperature sensor 5.11
Temperature senor, B126
5.11 Fuel temperature sensor

Fig. 1
l Temperature correction for injection quantity

Fig. 2

008 911 53 BOMAG 235

5.12 Charge air temperature - charge air pressure sensor

Charge air temperature - charge air pres-

5.12 Charge air temperature - charge air pressure sensor

sure sensor, B133

Fig. 1 now detects the temperature of the passing air flow.

This is used for the smoke limitation.

i Note
With a faulty pressure sensor the engine continues to
run with charge pressure simulation.
With a defective temperature sensor the engine also
carries on running.

Charge air temperature monitoring

The operator is warned if
l the temperature exceeds the warning limit and/or
l
the power is reduced by the EMR 3 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.

Fig. 2
This sensor unites two functions in one housing. The
one function measures the charge air pressure in the
and adapts the injection quantity in dependence on
the measured pressure. On the other hand the EMR

236 BOMAG 008 911 53

Charge air temperature - charge air pressure sensor 5.12
Disassembling and assembling the sen-
sor
Disassembling the sensor

Fig. 5
l Carefully insert the pressure/temperature sensor
(Fig. 5).
l Plug on the cable plug and engage the lock.
Fig. 3 l Tighten the screw (1).
l Unlock and pull out the cable plug (Fig. 3).
l Unscrew the screw. i Note
l Remove the pressure/temperature sensor. Delete the fault entry in the fault log of the engine con-
trol unit.
l Check the component visually.

Installing the sensor

Fig. 4
l Assemble a new O-ring (Fig. 4).
l
Slightly cover the O-ring with grease.

008 911 53 BOMAG 237

5.13 EMR coolant temperature sensor

5.13 EMR coolant temperature sen-

sor

Temperature sensor, B113

Fig. 1

Fig. 2
The coolant temperature has an effect on the calculat-
ed injection quantity and the preheating behaviour of
the glow plugs.

238 BOMAG 008 911 53

EMR coolant temperature sensor 5.13
Coolant temperature monitoring Monitoring by ESX-control

EMR fault code

i Note
The signal is evaluated by the ESX-control (Pin
X0:18) and displayed 30 seconds later in the display
module (Fig. 4) with code "522".

Fig. 3
The operator is warned 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. 4 Display module in central electrics

permanent light = A fault message is present, the

engine can be started and the
refuse compactor is still operable
with limitations.
the control light flash-
es after 2 seconds= Severe fault, the engine cannot
be started.

008 911 53 BOMAG 239

5.13 EMR coolant temperature sensor

Warning light, overheating of engine Removing and installing the temperature sensor
If the coolant temperature is exceeded the EMR-con-
trol (PIN XD2.1.39, ground switching) switches, Environment
whereby the coil of relay (K146) is excited. The switch
Catch running out fluids in a suitable vessel and
contact of relay (K146) supplies the monitoring board
dispose of environmentally.
(A15, terminal X1:87) with ground potential. The en-
gine overheating warning light 6 (Fig. 5) or f (Fig. 6)
flashes. i Note
Follow the corresponding documentation in the oper-
ating instructions to drain and fill the cooling system.

Disassembling the temperature sensor

Fig. 5 Monitoring module, old design

6 red = Coolant temperature too high.

Fig. 7
l Unlock and pull out the cable plug (Fig. 7).

Fig. 6 Monitoring module, new design

f red = Coolant temperature too high.

Fig. 8
l Unscrew the coolant temperature sensor (Fig. 8).
l
Check the component visually.

240 BOMAG 008 911 53

EMR coolant temperature sensor 5.13
Installing the temperature sensor

Fig. 9
l Tighten the coolant temperature sensor (Fig. 9).

i Note
Make sure that the seal rings are present .
Tightening torque: 22±2 Nm.

Fig. 10
l Push on the cable plug (Fig. 10).

i Note
Delete the fault entry in the fault log of the engine con-
trol unit.

008 911 53 BOMAG 241

5.14 Rotary speed sensor for crankshaft

Rotary speed sensor, B130

5.14 Rotary speed sensor for crankshaft

Fig. 1
l
Inductive sensor
l
Exact determination of engine speed
l Limp-home function in case of camshaft sensor fail-
ure

242 BOMAG 008 911 53

Rotary speed sensor for camshaft 5.15
Rotary speed sensor, B114
5.15 Rotary speed sensor for camshaft

Fig. 1
l
Inductive sensor
l
Determination of TDC
l
Limp-home function in case of crankshaft sensor
failure

008 911 53 BOMAG 243

5.16 Preheating system

Glow plugs, R02

The engines are fitted with glow plugs as cold starting
aids by standard.

Fig. 2 Solenoid valve Y02

Fig. 1 Glow plug R02

Once the preheating temperature is reached, a sole-
noid valve (Y02) directs fuel into the evaporation
zones of the glow plug. This generates a flame which
sustainably heats up the intake air and thus enables
reliably, comfortable and environmentally friendly
starting, also at low temperatures.

Fig. 3
1 Main battery fuse (F00), 250A
2 Fuse for preheating system (F48), 80A

Removing and installing the glow plug

! Caution
Follow the safety regulations and country specific
regulations concerning the handling of fuel.
Ensure absolute cleanliness when working in the
fuel system. Remove any existing paint and dirt
particles before disassembling. Thoroughly clean
the area around the affected component. Dry off
wet locations with compressed air.
Immediately close all connections and openings
with new and clean plugs/caps. Only remove
plugs/caps just before assembling.

Environment
Catch running out fluids in a suitable vessel and
dispose of environmentally.

244 BOMAG 008 911 53

Preheating system 5.16
Disassembling the glow plug

Fig. 4
l Remove the fuel lines 1 (Fig. 4).

Fig. 7
l Remove the seal 1 (Fig. 7).
l Check the component visually.

Fig. 5
l
Unscrew the nut 1 (Fig. 5).
l
Disconnect the cable.

Fig. 6
l
Loosen counter nut 1 (Fig. 6).
l Unscrew the glow plug.

008 911 53 BOMAG 245

5.16 Preheating system

Installing the glow plug

i Note
Tightening torque of counter nut 25 Nm

Fig. 10
l Push on the cable lug (Fig. 10).
l Install the washer.
l
Tighten the nut.

i Note
Tightening torque of nut = 5 Nm.

Fig. 8
l
Install the new gasket.
l
Screw in the glow plug.

i Note
Observe measurement (X) (Fig. 8).
Measurement (X) = 60 - 3 mm

Fig. 9
l
Install the fuel lines 1 (Fig. 9).
l Tighten the counter nut (2).

246 BOMAG 008 911 53

Checking the preheating system. Maintenance in case of frost. 5.17
5.17 Checking the preheating sys- Test step 2
tem. Maintenance in case of
frost. Danger
!

Danger of injury!

Danger
!
Keep clear of rotating parts.
Fire hazard! l Loosen the pipe fitting (2) on the glow plug for a few
turns.
When working on the fuel system do not use open
fire, do not smoke, do not spill any fuel.

Environment
Catch running out fuel.

Fig. 13
l
Press the button of the emergency stop switch in
(Fig. 13).
l
Hold the ignition key in position „I“, until the „pre-
heating“ control light goeas out.
Fig. 11
l
Turn the ignition key further to position "II" against
the resistance and crank the engine with the starter.
i Note
l
Fuel must run out of the loosened pipe fitting. Oth-
If the system works correctly suction pipe 3 (Fig. 11)
erwise have the system (solenoid valve) checked.
must become hand-warm near the glow plug (1) dur-
ing preheating. Otherwise perform the test in the fol-
lowing sequence: Test step 3
l
Remove the glow plug and connect the fuel line.
Test step 1 l Crank the engine with the starter, see test step 2.
l
Fuel must run out of the glow plug. Otherwise re-
place the clogged glow plug.
l
Reinstall the disassembled parts.

Fig. 12
l Turn the ignition key to position "I", the control light
"preheating" 1 (Fig. 12) mus flash.
Otherwise the glow plug is defective or the line is in-
terrupted.

008 911 53 BOMAG 247

5.18 Sensor, water in fuel

5.18 Sensor, water in fuel EMR fault code

Sensor, B124

Fig. 16

i Note
Fault light is permanently on.
permanent light = A fault message is present, the
engine can be started and the
refuse compactor is still operable
with limitations.

Fig. 14
1 Water separator sensor (B124)

Warning light water in fuel filter

In case of water in the fuel, the EMR-control will switch
(Pin XD2.1.38 ground) The water in fuel warning light
(Fig. 15) lights up.

Fig. 15
lights = Lights when the water content in the fuel
pre-cleaner reaches the sensor contacts.

248 BOMAG 008 911 53

Air filter vacuum switch 5.19
5.19 Air filter vacuum switch Monitoring by ESX-control

Vacuum switches, B03 and B116 i Note

The signal is evaluated by the ESX-control (Pin
X0:11) and displayed 2 seconds later in the display
i Note
module (Fig. 18) with code "526".
The signal is not monitored by the engine control unit.
The signal is monitored by the ESX-control.
The pressure switches are connected in parallel.

Fig. 18 Display module in central electrics

Air filter warning light

The vacuum switches operate at a vacuum of > 50
Fig. 17
mbar.
The switch contacts connect the monitoring board
(A15, terminal X1:86) to ground. The air filter warning
light 5 (Fig. 19) or g (Fig. 20) lights up.

Fig. 19 Monitoring module, old design

5 yellow = Air filter warning light
Lights when the combustion air filter is
contaminated.
Clean or replace, as necessary.

008 911 53 BOMAG 249

5.20 Coolant temperature sensor

Temperature sensor, B53

i Note
The temperature sensor is not monitored by the en-
gine control unit.
The temperature sensor is installed inside the engine.
The analog sensor is a variable resistance switched
rto ground.

Fig. 20 Monitoring module, new design

g yellow = Air filter warning light
Lights when the combustion air filter is
contaminated.
Clean or replace, as necessary.

Fig. 21 Diesel engine

Temperature gauge, P14

This gauge shows the temperature of the coolant.

250 BOMAG 008 911 53

Float switch, coolant tank 5.21
5.21 Float switch, coolant tank

Float switch, B55

i Note
The signal is not monitored by the engine control unit.
The signal is monitored by the ESX-control.

Fig. 22 Temperature gauge, old design

Fig. 23 Temperature gauge (y), new design

Fig. 1
i Note
Monitoring by ESX-control
480 OHM ⇒40°C
36 OHM ⇒120°C
i Note
New version: If no temperature sensor is connected or The signal is evaluated in the ESX-control (Pin
the cable is broken, the temperature gauge will go out. X0:19).
After 2 seconds the display module (Fig. 2) shows the
code "524".
Code "525" appears after 20 seconds, the engine is
shut down and the warning buzzer sounds.

008 911 53 BOMAG 251

5.22 Charge control light, engine RPM-meter

5.22 Charge control light, engine

RPM-meter

i Note
The generator is not monitored by the engine control
unit.

Fig. 2 Display module in central electrics

Coolant level warning light

The float switch switches if the coolant level is too low.
The switch contact connects the monitoring board
(A15, terminal X1:85) to ground. The coolant level
warning light 7 (Fig. 3) or d (Fig. 4) flashes.

Fig. 1 Generator
1 Terminal W
2 Terminal D+
3 Terminal B+

Charge control light

Charge control light, old design
If the battery is not being charged, a ground signal is
applied to D+ terminal 2 (Fig. 1). Current flows from
the monitoring board (A15) through the charge control
light to the D+ terminal. The charge control light 2, yel-
Fig. 3 Monitoring module, old design low (Fig. 2) lights up.

Fig. 4 Monitoring module, new design

252 BOMAG 008 911 53

Generator 5.23
5.23 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.

Terminal designations
l B61, L = charge control
l B+, B = battery plus, also with the designation "30"
l
B- = battery minus, also with the designation "31"
Fig. 2 Monitoring module, old design
l D+ = dynamo plus corresponds with terminal "61"
and "L"
Charge control light, new design
l D- = dynamo minus (this designation is only found
If the battery is not being charged, a ground signal is on D.C. generators or A.C. generators with regula-
applied to D+ terminal 2 (Fig. 1). The coil of relay tor removed)
(K61) is excited. Current flows from the monitoring
board (A15, Pin 10) through the coil of relay (K62) to
l DF = dynamo field (this designation is only found on
ground. The charge control light e, yellow (Fig. 3) D.C. generators or A.C. generators with regulator
lights up. removed). Note: The designation DF is also found
on older alternators with externally arranged regula-
tor on the connection of the exciting coil to the reg-
ulator or on the regulator itself
l
DF1 = dynamo field 1
l
DF2 = dynamo field 2
l
IG = "15" ignition switch

Fig. 3 Monitoring module, new design

Engine PRM-meter
Terminal "W" on the generator delivers a pulsating di-
rect voltage, which is utilized to determine the rotary
speed of the engine.

008 911 53 BOMAG 253

5.23 Generator

Three-phase generator 6 Brush holder

The AC-generator first of all produces AC-voltage / 7 Rectifier
AC-current. 8 Bearing cover
9 Rotor winding
Why does AC-current need to be rectified?
10Rotor
There are a few components for which can either be
operated with alternating current or direct current, be- 11V-belt pulley
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.
This includes :
l
Electric motors
l
Relays.
Fig. 5 Rotor with claw poles
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc- In the generator the armature windings are located in-
es work with alternating or three-phase current. side the stationary stator (Fig. 6), whereas the exciter
winding is arranged on the internally revolving rotor
This includes : (Fig. 5).
l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Design and function

Fig. 6 Stator
Fig. 4
The three stator windings (Fig. 6) are electrically offset
1 Fan to each other by 120°. The excitation of the magnetic
2 Holding plate field requires direct current, which is fed to the rotor
3 Stator core via two carbon brushes and slip rings.
4 Stator winding
5 Brush

254 BOMAG 008 911 53

Generator 5.23
Charge control light
The charge control light has two duties:
l Indication of the correct generator function
l External excitation of the generator during the start-
ing phase

Fig. 8 plus controlled charging regulator

Fig. 7 3-phase current
(Fig. 8) shows the current flow with the ignition
The wiring diagram (Fig. 7) shows the 3 windings in Y- switched on, engine stopped.
connection and the 6 associated rectifier diodes (D1
to D6).
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
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.

Fig. 9 plus controlled charging regulator

(Fig. 9) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.

008 911 53 BOMAG 255

5.23 Generator

Any other behaviour would indicate a defect on the Charge controller

generator (rectifier, carbon brushes, regulator) or a
The charge controller has the following functions
defect on the lamp, presumed the on-board battery is
not discharged. l To regulate the voltage generated by the generator
A far more important function of the lamp is the transi- l To protect against overloads caused by too high
tion and provision of field current. At standstill there is output current
no magnetic field in the de-energized generator. Since l Protection against reverse current
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak If the output voltage or the output current of the gen-
field can build up. erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.
The current flows from the ignition switch via the
charge control light through the generator winding Electronic charge regulator
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
tery is available or the battery is discharged, external
excitation is no longer possible at standstill and no
Fig. 10
voltage will be generated, even when the generator is
running. In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
With used, older generators a weak permanent mag-
tached electronic charge regulator. Together with the
netic field may have developed over the lifetime,
holder for the carbon brushes this regulator forms a
which does even exist when no voltage is applied.
unit, which transfers the field current to the sliprings of
This type of machines can even start without charge
the rotor.
control light and produce current during operation.
However, this is an unintended effect and you should The regulator compares the rectified actual current of
not presume that a generator without charge control the generator with the a stable reference voltage in
light or external excitation can be started up. the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
tion dependent internal resistance of the stator coils or
thermal monitoring.

256 BOMAG 008 911 53

Generator 5.23
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.

Fig. 11 plus controlled regulator

The following points allow to contain faults in the volt-
age supply within certain limits.
l Cable connections on the generator OK?
l V-belt OK?
l Generator ground (engine ground) OK?
l Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.

Fig. 12 minus controlled regulator

008 911 53 BOMAG 257

5.23 Generator

Checking the pre-exciter circuit, D+ generator

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

Fig. 13 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
l Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 13). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.

258 BOMAG 008 911 53

Generator 5.23
Checking the rotor Checking the stator

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

Fig. 14 Fig. 15
l Measure the resistance between the sliprings. l Use the resistance range of the continuity tester to
l If the resistance does not comply with the factory measure the resistance between the individual lines
specification, replace the rotor. of the stator winding.
l Use the resistance range of the continuity tester to
l If the measuring value does not comply with the fac-
check the continuity between slipring and core. tory specification, replace the stator.
l Replace the rotor if no infinite value is indicated.
l Use the resistance range of the continuity tester to
check the continuity between the individual stator
windings and the core.
i Note l Replace the stator if no infinite value is indicated.
Factory specification for resistance: 2.8 to 5 OHM.

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

008 911 53 BOMAG 259

5.23 Generator

Checking the bearings Checking the regulator voltage with the generator
tester
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.

Fig. 16
l Check whether the bearing rotates without obstruc-
tion.
l Replace the bearing if it does not rotate properly.
Fig. 17
The generator test assesses the regulator voltage and
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
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.

260 BOMAG 008 911 53

Generator 5.23
Checking the regulator voltage with the multime- Checking the regulator in disassembled state
ter On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator.

i Note
When testing the regulator one should be aware that
Fig. 18 there are 2 different types of regulators:
l All plug-and-socket connectors must be free of cor- l If the carbon brush is not connected to ground the
rosion and intermittent contact. regulator is a so-called minus controlled regulator.
l The generator ground connection must be OK. The exciter winding is positioned between D+ and
l
The battery should be in good condition – the idle DF, the regulator therefore regulates the exciter
voltage of the battery should be at least 12.6 Volt. winding on the ground side. The other carbon brush
is connected with the cathodes of the exciter di-
l
If possible switch off all consumers.
odes, terminal D+. This leaves one further terminal,
l
Perform the measurement at raised engine speed. this is DF.
l
The voltage (B+) should adjust itself at 13 to 14 Volt. D+ (vehicle wiring system)
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)

Fig. 19
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).

008 911 53 BOMAG 261

5.23 Generator

Replacing carbon brushes

l On a Bosch generator unscrew two fastening
screws for the regulator and lift the regulator off.
Pull out the carbon brushes from underneath. Their
minimum length is 5 mm, shorter carbon brushes
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
l
For replacing the carbon brushes in the Delco-
Fig. 20
Remy generator the generator needs to be disas-
E.g minus controlled regulator sembled and partly dismantled. The carbon brush
One connects the regulator (Fig. 20) with D+ and D- to holder is located inside the collector ring bearing.
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. 21

Fig. 22
The illustrations (Fig. 21) and (Fig. 22) show two dif-
ferent regulator types.

262 BOMAG 008 911 53

Replacing the voltage regulator 5.24
5.24 Replacing the voltage regula-
tor

Disassembling the regulator

Fig. 3
l Lift off the plastic protective cover using a screw-
driver (Fig. 3).
l Remove the protective cover.

Fig. 1
l Unscrew the hexagon nut M5 from terminal W (Fig.
1).
l Remove hexagon nut, washer and flat-pin plug.

Fig. 4
l Slacken the screws M3 (A) (Fig. 4).
l Loosen the screws M5 (B).
Fig. 2 l Remove the screws, lift off the voltage regulator.
l
Unscrew the fastening nuts M5 from the protective
cover (Fig. 2).

008 911 53 BOMAG 263

5.24 Replacing the voltage regulator

Assembling the voltage regulator

Fig. 1

i Note
Check the correct alignment of the gasket before plac-
ing it on the brush holder (Fig. 1).

Fig. 3
l Attach the voltage regulator (Fig. 3).

i Note
The gasket must be inserted into the rectifier plate.
l Tighten the screw M3 (A).- Tightening torque 0.7-
1.0 Nm.
l Tighten the screw M5 (B).- Tightening torque 3.5-
Fig. 2 4.5 Nm.

i Note
The gasket must be pushed fully against the brush
holder (Fig. 2). For easy assembly of the regulator the
gasket ribs may be wetted.

Fig. 4
l
Attach the protective cover and fasten it with wash-
ers and hexagon nuts 1(Fig. 4). Tightening torque
4.0-5.0 Nm.
l
Attach flat-pin plug, washer and hexagon nut to ter-
minal (W) and tighten.- Tightening torque 2.7-3.8
Nm.

264 BOMAG 008 911 53

Electric starter 5.25
5.25 Electric starter Directly acting electric starter
This shows the design of this starter. It consists of a
General
starter motor and a magnetic switch.
Combustion engines need to be started by means of
a special device, because they are not able to start by
themselves. Considerable resistances caused by
compression and friction must thereby be overcome.
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
l to accelerate the combustion engine to start speed
with lowest possible current consumption.
l establish the gear connection between starter and
combustion engine.
l to maintain this connection.
Fig. 5
l to switch on the starter current.
1 Magnetic switch
After starting the engine:
2 Armature
l
to return the starter pinion to initial position.
3 Actuating lever
l
to switch off the starter current.
4 Freewheeling clutch
5 Resetting spring
6 Brush
7 Exciting winding
8 Armature
9 Collector

Ignition switch in position "START"

Fig. 6 Magnetic switch open

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

008 911 53 BOMAG 265

5.25 Electric starter

5 Ignition switch Engine running

6 Actuating lever
7 Ring gear
8 Pinion
9 Freewheeling clutch
10(Battery

Pinion meshes with the ring gear

Fig. 8
Once the engine is running and drives the pinion (1)
via the ring gear (2), the freewheeling clutch (3) will
open and prevent the armature (4) from being driven
by the engine.
1 Pinion
2 (Ring gear
Fig. 7 Magnetic switch closed 3 Freewheeling clutch
When the pinion (3) meshes with the flywheel mount- 4 Armature
ed ring gear (4) and the magnetic switch (2) is closed,
a strong current flows from the battery (7) directly into Ignition switch released
the exciting winding (6) and the armature winding, but
not into the pick-up winding.
This causes the armature (5) to rotate with high speed
and drives the pinion, which in turn drives the ring gear
(4) with a speed of 200 to 300 rpm.
1 Pick-up winding
2 Magnetic switch
3 Pinion
4 Ring gear
5 Armature
6 Exciting winding
7 Battery

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

266 BOMAG 008 911 53

Electric starter 5.25
4 Resetting spring Magnetic switch
5 Magnetic switch
6 Ignition switch
7 Pinion
8 Ring gear
9 Battery

Fig. 10 Direct acting electric motor

Fig. 11 Geared motor

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

008 911 53 BOMAG 267

5.25 Electric starter

Freewheeling clutch Trouble shooting "Starter"

i Note
The most frequent fault is definitely a fully discharged
battery.
If the starter rotates too slowly, either the brushes
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
the magnetic switch is defect / soiled (dismantle and
clean))- the main contacts on the magnetic switch are
Fig. 12 Freewheeling clutch worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
The freewheeling clutch is designed in such a way,
armature and clean), cover cleaned, moveable parts
that the flow of force is automatically interrupted if the
with grease.
pinion (5) of the clutch rotates faster than the free-
wheeling ring (1) at higher engine speeds. Frequently a jammed return mechanism is the reason
for a starter failure.
This makes sure that the armature will only drive the
ring gear, but can never be driven by the engine. Occasionally worn contacts are found on the magnetic
return switch
1 Freewheeling ring
2 Roller Defects on the actual starter motor including pinion
and carbon brushes are very rare.
3 Roller spring
With a trouble shooting chart the faults in the starter
4 Splined shaft
system can be narrowed down. The starter system
5 Pinion can only work when many conditions are fulfilled at
6 Pinion 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?
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.

268 BOMAG 008 911 53

Electric starter 5.25
Testing and measuring the starter Continuity test for the magnetic switch

Function control with the starter removed

Caution
!

Fasten the starter to make sure that it will not

come loose during the test.

Fig. 15
l
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
l Replace the magnetic switch if no continuity is de-
tected.
Fig. 13
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

i Note
If the motor does not start, the starter is defective. Re-
pair or replace the starter.

Checking the magnetic switch

Fig. 14
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

i Note
If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.

008 911 53 BOMAG 269

5.25 Electric starter

270 BOMAG 008 911 53

6 Electronic control

008 911 53 BOMAG 271

Installation location ESX-control

Bild 16 BC 972/1172

272 BOMAG 008 911 53

6.1 ESX control

008 911 53 BOMAG 273

6.1 ESX control

Installation location ESX-control

Bild 17 BC 972/1172

274 BOMAG 008 911 53

ESX control 6.1

Service Training
Electrics
BC572, 672, 772
BC972 ,1172

00809729 Version 7.00

Status: 16.02.2007 Page 1 of 67

Author: T.Löw / TE
Dateiname: c:\dokumente und einstellungen\nickb\lokale einstellungen\temp\schulung elektrik bc972_v7.00_gb.doc

008 911 53 BOMAG 275

6.1 ESX control

Service Training Refuse Compactor

Table of contents
1 Document alteration list.....................................................................................................................3
2 selected fault reactions of the ESX control .......................................................................................5
3 Known faults......................................................................................................................................6
4 Functions of the ESX control.............................................................................................................7
4.1 Description of the Display Module .............................................................................................7
4.2 Input of code numbers ...............................................................................................................7
4.3 Driving against the closed brake................................................................................................8
4.4 Enabling without the engine running..........................................................................................8
4.5 Enabling floating position ...........................................................................................................9
4.6 Showing stored faults...............................................................................................................10
4.7 Delete all stored faults .............................................................................................................10
4.8 Setting the machine type .........................................................................................................11
4.9 Parameter adjustment 2nd speed range (only BC972) ...........................................................12
4.10 Parameter setting steering system ..........................................................................................13
4.11 Travel pedal monitoring parameter setting ..............................................................................14
4.12 Dozer blade characteristics parameter setting ........................................................................14
4.13 Engine speed signal parameter setting ...................................................................................15
5 Block diagram normal operation BC972, 1172 ...............................................................................17
6 Block diagram normal operation BC 572/672/772 ..........................................................................18
7 Block diagram override operation BC972, 1172 .............................................................................19
8 Block diagram override operation BC 572/672/772 ........................................................................20
9 Description of the signals on the ESX-control.................................................................................21
10 Description of signals on the DIOS module (only with optional bucket)......................................26
11 Fault codes of the ESX control ....................................................................................................28
11.1 Overview ..................................................................................................................................28
11.2 Description of fault reactions ...................................................................................................29
11.3 Detailed description of fault codes and their possible causes................................................30
12 Input Codes for ESX Control .......................................................................................................53
12.1 Travel system...........................................................................................................................53
12.2 Steering....................................................................................................................................54
12.3 Working hydraulics...................................................................................................................56
12.4 Test functions...........................................................................................................................57
12.5 Diesel engine ...........................................................................................................................58
12.6 System information ..................................................................................................................59
12.7 Hydraulics ................................................................................................................................59
12.8 Parameter change ...................................................................................................................61
12.9 Fault log ...................................................................................................................................62
12.10 Setting the machine type......................................................................................................63
13 Terminology in connection with ESX...........................................................................................64

Status:16.02.2007
Author: T.Löw / TE

276 BOMAG 008 911 53

ESX control 6.1

Service Training Refuse Compactor

1 Document alteration list

No. Date Description of changes resp.

1 25.04.01 Creation of version 1.00 Löw
2 29.06.01 Creation of version 2.00: Löw
Pin assignment for dozer blade joystick changed
Fault "Hydr.Level1" eliminated
Fault and display codes changed

3 02.07.01 Pin 10 (open bucket) and Pin 17 (pressure differential switch) Löw
exchanged.
4 22.08.01 Inclusion of column "known faults" Löw

5 23.08.01 Creation of version 3.00: Löw

Parameter input "variable speed specification" eliminated
Code input "enter machine type" added
Block diagrams BC772 added
Fault description "travel speed range valve" added
Input codes "travel speed range valve" added
Cross references to wiring diagram deleted.

6 27.08.01 Voltage limits for bucket joystick changed. Löw

actuated to left: high voltage,
actuated to right: low voltage
PIN 17 open bucket, PIN 34 close bucket
7 13.09.01 Input code for "enable float position“ added Löw
8 01.10.01 Further point added under "known faults" Löw
9 09.10.02 Fault 475 "Fault when initializing the DIOS module" added Löw
10 25.02.02 Fault and input codes for travel pedal monitoring added Löw
(530..534), "Travel pedal monitoring parameter setting" added, list
of known faults extended.
11 18.03.02 Description of input code 452 adapted: Löw
max. closing = 1000
max. opening = -1000
12 10.06.02 Creation of version 4.00: Löw
Input codes for machine type BC572 added
Default setting 2nd gear changed to "FAST"
13 10.07.04 Creation of version 5.00 Löw
Input codes 271 / 272 changed to "steering valve right"
Input codes 276 / 277 changed to "steering valve left"
Comment concerning saving faults on page 29 added.
Explanation for input code 515 corrected (factor 10 added)
Number of pulses / engine revolutions on page 20 corrected
Speed data for 2nd gear on page 13 changed
Fault codes 053 and 063 added
Fault codes 052 and 062 added
Fault codes 045 and 046 deleted
Fault codes 045 and 046 deleted
Further point added under "known faults"
14 26.10.04 Creation of version 5.01 Löw
Machine codes 766 and 767 added
Description "Parameter setting for dozer blade characteristics"
added
Input codes 650..654 added

Status:16.02.2007
Author: T.Löw / TE

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6.1 ESX control

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No. Date Description of changes resp.

15 24.01.06 Creation of version 6.0 Löw
Fault code 540 added
Input codes 540, 541, 685, 686, 687 added
Description "Parameter setting for engine speed signal" added

16 07.11.06 Creation of version 7.0 Löw

Item "4.10 Parameter setting steering system" extended,
Input codes 251, 252, 647, 648, 649 added,
Signal description X0:14 and X0:15 changed

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2 selected fault reactions of the ESX control

Reaction Symbol in fault Warning Warning Engine stop

message display
Signal Code output Code output Code output
without buzzer with buzzer with buzzer

Engine oil pressure

(from EMR) 520 - -
after 2s

Coolant temperature
(from EMR) 522 - -
after 30s
Coolant level
(B55) 524 - 525
after 2s after 20s

Engine air filter

right or left 526 - -
(B03 or B116) after 2min

Contamination sensor
(B19) 570 - -
after 10s

Pressure differential switch

filter charge pump 1..4
1 572 - -
(B121, B122, B21, B22) after 10s
or
filter intermediate gear
(B42)
Hydraulic oil
Excessive temperature 574 - 575
(B20) after 10s after 2min

Filling level hydraulic oil

(B24) 578 - 579
after 2s after 20s

Return flow filter

(B25)
- 580 -
after 10s

Brake pressure
(B05)
- - -

1
BC572/772: only 2 pressure differential switches
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3 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.

Behaviour of machine Possible cause

The ESX control detects several faults of engine Fault indicators without voltage supply (F24
and hydraulic system monitoring at the same time tripped). The ESX inputs are drawn to ground
(524, 526, 570,...). However, the control through the LEDs of the fault indicators. For the
lights in the two fault indicators do not light. The control this is the same as when a sensor (e.g. oil
lamp test of the fault indicators is also out of pressure) delivers a ground signal.
function.
) Check the voltage supply for the fault
indicators.
The control detects line breakage on all 4 wheel Missing / poor ground connection on ESX
drive motors (100, 105, 110, 115) (only on housing.
BC972).
) Check ground connection, renew if
Steering is very jerky, but no fault is detected. necessary.
All control lights in both fault indicators are Terminal 15 signal for control and override relay
permanently on. The engine can be started, but missing:
the machine will not move. The fault display of the
central electrics does not show a fault code. ) Check fuse F25

The fault code 514 (Input engine speed: Voltage is applied to input MD+ (PIN 36) on the
no pulses from the resolver, even though the ESX control, even though the engine is not
engine is running) is already displayed while the running. This may occur when the link between
engine is at rest. generator and central electrics is interrupted,
because in this case the potential at input MD+
will be raised to +24V through the resistor R10 or
the coil K61. The control then assumes that the
engine is running and thus expects pulses from
the speed sensor.
Machine is in override state and indicates fault Up to software version 2.01 this fault was
934. displayed in addition to fault code 514 (see
above).
This means, that the machine has switched to
override state when a fault occurred at the rotation
sensor. This fault is a software fault, that has been
eliminated with version 3.00.
Machine is in override state and indicates fault Intermittent contact on Pin 20, 42 or 43
960, 962. Fault has been eliminated with software version
4.03

Status:16.02.2007
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ESX control 6.1

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4 Functions of the ESX control

4.1 Description of the Display Module

The display module consists of a 3-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.

Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.

Display values are permanently displayed, whereby values from 0 0 0 ...9 9 9 are possible. Higher
values lead to the display "- - - ", negative values are indicated by the "minus dot" lighting up (see
illustration).

The following description describes the input of code numbers.

4.2 Input of code numbers

For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:

1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
)The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
3rd digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.

In order to terminate a display function you must either enter code number 0 0 0 or switch the ignition
off.

Status: 16.02.2007 Functions of the ESX control Page 7 of 67

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4.3 Driving against the closed brake

After entering code number 5 0 0 the brake will not be released. When opening the rotary switch
"Parking Brake" and actuating the travel lever, the travel pumps will be actuated in accordance with
the selected travel direction. At the same time a warning (fault code 5 0 0 ) appears on the display and
the warning buzzer is triggered, in order to keep the operator informed about the condition.

In order to terminate this function and release the brake you must either enter code number 5 0 I or
switch the ignition off.

Note: This function can only be activated / deactivated when the travel lever is in
neutral position.

4.4 Enabling without the engine running

The input of code number 5 0 2 simulates operation of the diesel engine, i.e. certain functions are
enabled which are normally only possible when the engine is running (power supply to brake valve,
wheel motors, steering valves etc.). For safety reasons the floating position cannot be enabled. For
this purpose an additional input code is required (see "Enabling floating position")

For safety reasons relay K22 (engine shut down) is energized when activating this function. This
results in the engine control unit (EMR) being switched off. The displays "Fault EMR", "Oil Pressure"
and "Excessive Temperature" will therefore light permanently.

Note: This function can only be activated / deactivated when the travel lever is in
neutral position.

NOTE! After the input of this function the starter can still be operated! However, the
engine will not start!

When actuating the travel lever a warning (fault code 5 0 2 ) appears on the display and the warning
buzzer is triggered, in order to keep the operator informed about the condition.

To terminate this function the ignition must be switched off.

NOTE! If the starter is to be actuated without starting the engine (e.g. during
commissioning of the hydraulic system), this can be accomplished by pressing
the EMERGENCY STOP button. In this condition the engine control unit EMR is
not supplied with voltage.

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4.5 Enabling floating position

This function is only available from software version 3.00!

NOTE: Since the dozer blade / bucket may drop down by its own weight when
activating the float position, the activation is only possible in normal operation
with the engine running.

By entering code 5 0 4 the float position can also be activated for testing without the engine running.
However, the input of this code is only possible after the input "Enable without engine running" (double
interlock).

ATTENTION: After the input of this code the dozer blade can be lowered, but not raised any
more (no hydraulic pressure without the engine running)! You must therefore
make sure that there are no persons in the vicinity of dozer blade or bucket!

Entercode number 5 0 2 . This code number activates the function "Enabling without engine
running“.

Entercode number 5 0 4 . This code number activates the function "Enabling float position“.

The display module now shows the flashing code 5 0 4 .

When float position is now activated (move joystick forward and press button), the two float position
valves will be energized and the warning buzzer will sound.

In order to cancel this function you must either enter code number 5 0 5 or switch the ignition off.

Status: 16.02.2007 Functions of the ESX control Page 9 of 67

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4.6 Showing stored faults

Switch on function "Show stored faults":
Entercode number 7 0 0 . This code number enables the function „Show stored faults“.

The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX the display remains dark.

Switch off function "Show stored faults":

Enter code number 7 0 I . This code number disables the function „Show stored faults“.

Note: Apart from the stored faults the current faults are also displayed.

4.7 Delete all stored faults

Execute the function "Delete all stored faults":
The engine must not be running!
Entercode number 7 1 0 .
Switch the ignition off and on again.

All stored faults are now deleted.

Note: The stored faults can only be deleted when the engine is not running.

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4.8 Setting the machine type

This function is only available from software version 3.00!

Since the same control is used for all refuse compactors with electronically controlled engine (EPA II),
it is necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
type adjustment is necessary, because these machines e.g. are fitted with different wheel drive motors
or are designed with different numbers of speed ranges, or are equipped with dozer blade or bucket.

For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module of the central electrics when switching the ignition on. It can also be checked by
entering code 720.

The following machine types can be adjusted:

Machine type Machine type code Available from software

BC972/1172 with dozer blade 760 1.00
BC672/772 with dozer blade 761 1.00
BC972 with bucket 762 Not available
BC672/772 with bucket 763 1.00
BC572 with dozer blade 764 4.00
BC572 with bucket 765 4.00
BC672 EB 766 5.00
BC672 EB with tilt function 767 5.00

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

Enter code number 7 2 5 . This code number activates the function "Adjusting machine type".

The display module now permanently shows the code 7 2 5 .

Select and enter the machine from the table above.

The display module now permanently shows the entered code. (e.g. 7 6 1 )

Enter code number 7 2 6 . This code number confirms the entered machine type.

After confirming the machine type the control switches off, the display module shows the flashing code
726.

Switch the ignition off and on again.

The display module shows the reading 8 8 8 for approx. 10 seconds. The new parameters are loaded
according to the machine type setting. Do not switch the ignition off during this time!

After this the newly adjusted machine type will be displayed for approx. 3 seconds.

Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!

New controls are delivered with the default machine type setting 7 6 0 .

Status: 16.02.2007 Functions of the ESX control Page 11 of 67

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4.9 Parameter adjustment 2nd speed range (only BC972)

This function enables to choose from three different final speeds for the second travel range.

Note: Parameter adjustments can only be performed when the engine is not running!
This parameter adjustment is only possible on machines of type BC972

Enter code number 6 6 0 . This code number activates the function "Parameter input 2nd gear“.

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

At this point the input of following codes is possible:

Code number 6 6 1 ) Speed in speed range 2 SLOW (approx. 5 km/h)

Code number 6 6 2 ) Speed in speed range 2 MEDIUM (approx. 6
km/h)
Code number 6 6 3 ) Speed in speed range 2 FAST (approx. 7 km/h)

Upon delivery of the machine the final speed is preset to 6 km/h.

Status: 16.02.2007 Functions of the ESX control Page 12 of 67

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4.10 Parameter setting steering system

This function enables the setting of various parameters for the steering system. A differentiation can
be made between e.g. electronic and mechanical end position damping.

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

Enter code number 6 4 0 . This code number activates the function "Parameter input steering“.

The display module now permanently shows the code 6 4 0 .

At this point the input of following codes is possible:

Code number 6 4 1 ) Steering joystick ON

Code number 6 4 2 ) Steering joystick OFF
Code number 6 4 3 ) Steering wheel ON
Code number 6 4 4 ) Steering wheel OFF
Code number 6 4 5 ) Arms rest contact ON
Code number 6 4 6 ) Arms rest contact OFF
Code number 6 4 7 ) mechanical end position damping OFF
Code number 6 4 8 ) mechanical end position damping ON
Code number 6 4 9 ) electronic end position damping OFF (see note!)

Note: The electronic end position damping is inactive after entering code 649. End
position damping is automatically reactivated when switching the ignition the
next time, in order to prevent the steering cylinders from being damaged!

ATTENTION During input make sure that at least one of the functions (steering wheel or
joystick) is active. If both are deactivated the control is no longer able to steer
the machine. This is indicated by the fault code 290. The control will then switch
to override condition. In this case enter one of the two code numbers (for
joystick or for steering wheel) and switch the ignition off and on again.

Status: 16.02.2007 Functions of the ESX control Page 13 of 67

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4.11 Travel pedal monitoring parameter setting

This function is only available from software version 3.00!

This function provides the possibility to set the reaction to a cable breakage in the travel pedal. In case
of a cable breakage the engine is operated with a fixed speed of 1500 rpm, so that the machine can
still be moved.

If the fault monitoring system is active, the engine will be shut down when this engine fault occurs for
the first time while the travel lever is not in neutral position. This assures that the machine will not start
to move by itself.

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

Enter code number 6 9 0 . This code number activates the function "Parameter input for travel
pedal monitoring“.

The display module now permanently shows the code 6 9 0 .

At this point the input of following codes is possible:

Code number 6 9 1 ) Monitoring ON Engine is shut down (see above)

Code number 6 9 2 ) Monitoring OFF Engine is not shut down (see above)

The machine is delivered with this function enabled.

4.12 Dozer blade characteristics parameter setting

With this function one can pre-select one of three characteristics for the dozer blade function, or to
deactivate this characteristics function.

Note: Parameter adjustments can only be performed when the engine is not running!
This parameter adjustment is only possible on machines of type EB!

Enter code number 6 5 0 . This code number activates the function "Parameter input for dozer
blade characteristics“.

The display module now permanently shows the code 6 5 0 .

At this point the input of following codes is possible:

Code number 6 5 1 ) Characteristic 1 (slightly progressive)

Code number 6 5 2 ) Characteristic 2 (more progressive)
Code number 6 5 3 ) Characteristic 3 (highly progressive)
Code number 6 5 4 ) No characteristic

On machines of type BC672EB and BC772 EB no characteristic is selected by default!

Status: 16.02.2007 Functions of the ESX control Page 14 of 67

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4.13 Engine speed signal parameter setting

This function is only available from software version 6.00!

On engines of TIER III and higher the speed signal from the engine control unit (EMR III) is evaluated.
On machines with EMR I and EMR II the signal from an additional BOMAG speed sensor was
evaluated instead. These two signals have different pulses per engine revolution.

The function described next will enable you to switch between the two signals.

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

Enter code number 6 8 5 . This code number activates the function "Parameter input for travel
pedal monitoring“.

The display module now permanently shows the code 6 8 5 .

At this point the input of following codes is possible:

Code number 6 8 6 ) Evaluation of EMR III sensor signal

Code number 6 8 7 ) Evaluation of BOMAG sensor signal

Upon delivery of the machine evaluation of the EMR III sensor is enabled.

Status: 16.02.2007 Functions of the ESX control Page 15 of 67

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008 911 53
ESX control

5 Block diagram normal operation BC972, 1172

Motorsteuergerät Fahren A rbeitshydraulik Lenkung NOT Aus

Fahrpedal Schwimpos.
1 2 3 N
Heben STOP
24 V
analog
EMR Zu Auf
Solldrehzahl Senken

Öldruck Übertemp. Fahrstufen Fahrtrichtung Bremse Joystick Joystick Lenkrad Armlehne

Kontrolleuchte
CENTRY

digital
EMR

digital
digital
analog
analog
digital
analog/digital
analog/digital
analog/digital
digital
Dieselmotor

Pulse
Drehzahl
Drehzahl
CAN Bus
ESX
Hydraulik

BOMAG
digital
Druckschalter,
Füllstand, usw.
888
F1 F2

DIOS Modul Fehleranzeige

digital (auf /zu)

digital (vorwärts)
digital (rückwärts)
PWM (0..600mA)
PWM (0..600mA)
PWM (0..600mA)
PWM (0..600mA)
PWM (0..1000mA)
PWM (0..1000mA)
PWM (0..1000mA)
PWM (0..1000mA)
digital (ein/aus)
PWM (0..1000mA)
PWM (0..1000mA)

links rechts heben senken Schwimmpos. öffnen schließen

Bremse Fahrpumpen Radmotoren Lenkung Arbeitshydraulik Schaufel

Status: 16.02.2007 Block diagram Page 17 of 67

Author: T. Löw / TE
6.1

291
292
6.1

Service Training Refuse Compactor Block diagram

6 Block diagram normal operation BC 572/672/772

Motorsteuergerät Fahren A rbeitshydraulik Lenkung NOT Aus

Fahrpedal
Schwimpos.
1 2 N
Heben 24 V
analog STOP
EMR Zu Auf
Solldrehzahl Senken

Öldruck Übertemp. Fahrstufen Fahrtrichtung Bremse Joystick Joystick Lenkrad Armlehne

Kontrolleuchte
CENTRY

digital
EMR

digital
digital
analog
analog
digital
analog/digital
analog/digital
analog/digital
digital
Dieselmotor

Pulse
Drehzahl
Drehzahl
CAN Bus
ESX

BOMAG
Hydraulik

digital
Druckschalter,
Füllstand, usw.
888
F1 F2

DIOS Modul Fehleranzeige

digital (auf /zu)

digital (vorwärts)
digital (rückwärts)
PWM (0..1000mA)
PWM (0..1000mA)
PWM (0..1000mA)
PWM (0..1000mA)
digital (ein/aus)
PWM (0..1000mA)
PWM (0..1000mA)

digital (langsam/schnell)
links rechts heben senken Schwimmpos. öffnen schließen

Bremse Fahrpumpen Fahrstufen Lenkung Arbeitshydraulik Schaufel

Status: 16.02.2007 Block diagram Page 18 of 67

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ESX control
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008 911 53
ESX control

7 Block diagram override operation BC972, 1172

Motorsteuergerät Fahren Arbeitshydraulik Lenkung NOT Aus

Fahrpedal Schwimpos.
1 2 3 N 24 V
Heben ST OP
analog
EMR Zu Auf
Solldrehzahl Senken

Öldruck Übertemp. Fahrstufen Fahrtrichtung Bremse Joystick Joystick Lenkrad Armlehne

Kontrolleuchte
CENTRY

digital
EMR

digital
digital
digital
digital
digital
Dieselmotor

Override Relais
Drehzahl

Hydraulik

BOMAG
Druckschalter,
Füllstand, usw.
888
F1 F2

Leistungs- DIOS Modul Fehleranzeige

widerstände

digital (auf /zu)

digital (vorwärts)
digital (rückwärts)
konst. (ca.500mA)
konst. (ca.500mA)
konst. (ca.500mA)
konst. (ca.500mA)

links rechts heben senken Schwimmpos. öffnen schließen

Bremse Fahrpumpen Radmotoren (Qmax) Lenkung Arbeitshydraulik Schaufel

Status: 16.02.2007 Block diagram Page 19 of 67

Author: T. Löw / TE
6.1

293
294
6.1

Service Training Refuse Compactor Block diagram

8 Block diagram override operation BC 572/672/772

Motorsteuergerät Fahren A rbeitshy drau lik Lenkung NOT Aus

Fahrpedal Schwimpos.
1 2 N 24 V
Heben ST OP
analog
EMR Zu Auf
Solldrehzahl Senken

Öldruck Übertemp. Fahrstufen Fahrtrichtung Bremse Joystick Joystick Lenkrad Armlehne

Kontrolleuchte
CENTRY

digital
EMR

digital
digital
digital
digital
digital
Dieselmotor

Override Relais
Drehzahl

BOMAG
Hydraulik

Druckschalter,
Füllstand, usw.
888
F1 F2

Leistungs- DIOS Modul Fehleranzeige

widerstände

digital (auf /zu)

digital (vorwärts)
digital (rückwärts)
konst. (ca.500mA)
konst. (ca.500mA)
konst. (ca.500mA)
konst. (ca.500mA)

links rechts heben senken Schwimmpos. öffnen schließen

Bremse Fahrpumpen Fahrstufen (Qmax) Lenkung Arbeitshydraulik Schaufel

Status: 16.02.2007 Block diagram Page 20 of 67

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ESX control
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008 911 53
ESX control

9 Description of the signals on the ESX-control

Notes:
1. Wherever the value of 24 V is mentioned in the following text it refers to the current battery
voltage under due consideration of voltage drops in the lines.

ESX terminal Signal description Nominal values (voltage / current)

X0:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X0:2 Output Override (emergency operation) Control in operation, emergency operation not active) 24 V
Digital output (max. 2,5 A) Control not in operation, emergency operation active) approx.0 V
X0:3 Output indicator light 2nd gear Indicator light ON ) 24 V
Digital output (max. 2,5 A) Indicator light OFF ) approx.2 V
X0:4 Interface RS 232 RxD, not used for normal operation. Measurement not possible!

X0:5 Interface RS 232 TxD, not used for normal operation. Measurement not possible!

X0:6 Input drive pedal position Travel pedal not operated: ) approx. 0.5 V
Analog input / voltage input 0..5 V Travel pedal operated: ) Voltage > 0,5 V

BOMAG
X0:7 Input selector switch Speed ranges Position speed range selector switch (measured against AGND)
BC972/1172: 1st speed range ) 1,80..2,40 V
BC972/1172: (Step switch, 3 steps) 2nd speed range ) 3,70..4,70 V
BC572/672/772: (Step switch, 2 steps) 3rd speed range ) 5,60..7,00 V
BC572/672/772: 1st speed range ) approx. 0 V
Analogue input / voltage input 0..8.5 V 2nd speed range ) 7,65..9,35 V

X0:8 Input steering joystick Position steering joystick (measured against AGND)
Analogue input / voltage input 0..8.5 V maximum left ) 6,70..8,60 V
Neutral position ) 3,60..4,60 V
maximum right ) 0,50..1,00 V
X0:9 Input steering wheel (option) Position steering wheel (measured against AGND)
Analogue input / voltage input 0..8.5 V maximum left ) 5,70..7,10 V
Neutral position ) 3,70..4,60 V
maximum right ) 1,70..2,20 V

Status: 16.02.2007 Signal Description ESX Control Page 21 of 67

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296
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ESX terminal Signal description Nominal values (voltage / current)

X0:10 Input Pressure differential switch filter charge pump 1..4, or 2 all filters ok )approx.5 V
and filter transfer box at least 1 filter soiled ) 0V
Digital input active low
X0:11 Input pressure differential switch engine air filter all air filters ok )approx.5 V
Digital input active low at least 1 filter soiled ) 0V
X0:12 Input push button float position Push button actuated ) 24 V
Digital input active high Push button not actuated )approx.2 V
X0:13 Input hydraulic oil return flow filter Return flow filter ok )approx.5 V
Digital input active low Return flow filter soiled ) 0V
X0:14 Input steering stop left Stop not reached ) 24 V
Digital input active high Stop reached )approx.2 V
X0:15 Input steering stop right Stop not reached ) 24 V
Digital input active high Stop reached )approx.2 V
X0:16 Input Diesel engine speed Transducer delivers square-wave pulses
Digital input active high 167 pulse / revolution or 129 pulses / revolution on BC572
X0:17 Input joystick bucket close (optional) Joystick actuated to the left ) 24 V

BOMAG
Digital input active high Joystick not actuated )approx.2 V
X0:18 Input excessive coolant temperature (from EMR) Temperature ok )approx.5 V
Digital input active low Temperature too high ) 0V
X0:19 Input coolant filling level Filling level ok )approx.5 V
Digital input active low Filling level too low ) 0V
X0:20 Output dozer blade up Dozer blade is moved ) 0,3..1 A
PWM digital output (max. 4 A) Dozer blade is not moved ) 0A
X0:21 Output travel pumps forward Travel pumps triggered ) 24 V
PWM digital output (max. 4 A) Travel pumps not triggered ) 0V
X0:22 Output travel pumps reverse Travel pumps triggered ) 24 V
PWM digital output (max. 4 A) Travel pumps not triggered ) 0V
X0:23 Output voltage supply for sensors Nominal voltage = 8,5 V
This output supplies steering joystick, travel speed range switch, etc. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override mode (emergency function).
X0:24 Output engine shut down Engine shut down inactive ) 0V
Digital output (max. 2,5 A) Engine shut down active ) 24 V

Status: 16.02.2007 Signal Description ESX Control Page 22 of 67

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ESX control
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008 911 53
ESX control

ESX terminal Signal description Nominal values (voltage / current)

X0:25 Output indicator light 1st speed range Indicator light OFF )approx.2 V
Digital output (max. 2,5 A) Indicator light ON ) 24 V
X0:26 Interface CAN-Bus Wire -, is used to trigger the fault display module. Measurement not possible!
On bucket option also to trigger the DIOS module.
X0:27 Interface CAN-Bus Wire +, is used to trigger the fault display module. Measurement not possible!
On bucket option also to trigger the DIOS module.

X0:28 Input potential terminal 15 Control switched on ) 24 V

Digital input active high Control switched off )approx.2 V
This signal must be present, so that the control can work.
X0:29 Input potentiometer speed range 2nd gear (optional) Position potentiometer (measured against AGND)
Analogue input / voltage input 0..8.5 V right hand stop ) 0,50..1,00 V (max. speed)
left hand stop ) 6,80..8,70 V (min. speed)
X0:30 Input joystick dozer blade up/down Position potentiometer (measured against AGND)
Analogue input / voltage input 0..8.5 V maximum up ) 6,70..8,60 V
Neutral position ) 3,60..4,60 V
maximum down ) 0,50..1,00 V

BOMAG
X0:31 Input joystick bucket open/close (optional) Position potentiometer (measured against AGND)
Analogue input / voltage input 0..8.5 V maximum close ) 6,70..8,60 V
Neutral position ) 3,60..4,60 V
maximum open ) 0,50..1,00 V
X0:32 Input selector switch travel direction Position selector switch (measured against AGND)
Analogue input / voltage input 0..8.5 V forward ) 4,10..5,20 V
neutral ) 5,70..7,20 V
reverse ) 3,20..4,10 V
X0:33 not used

X0:34 Input joystick bucket open (optional) Joystick actuated to the right ) 24 V
Digital input active high Joystick not actuated )approx.2 V
X0:35 Input joystick dozer blade up Joystick pulled back ) 24 V
Digital input active high Joystick not actuated )approx.2 V

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ESX terminal Signal description Nominal values (voltage / current)

X0:36 Input D+ generator Engine running / engine is started ) 24 V
Digital input active high Engine stopped ) 0V
X0:37 Input position arm rest (optional) Arm rest bottom position ) 24 V
Digital input active high Arm rest up )approx.2 V
X0:38 Input steering joystick left Joystick actuated to the left ) 24 V
Digital input active high Joystick not actuated )approx.2 V
X0:39 Input steering joystick right Joystick actuated to the right ) 24 V
Digital input active high Joystick not actuated )approx.2 V
X0:40 Input switch brake Open brake ) 24 V
Digital input active high Close brake )approx.2 V
X0:41 Input joystick dozer blade down Joystick pushed forward ) 24 V
Digital input active high Joystick not actuated )approx.2 V
X0:42 Output dozer blade down Dozer blade is moved ) 0,3..1 A
PWM digital output (max. 4 A) Dozer blade is not moved ) 0A
X0:43 Output wheel motor rear right permissible current range: approx. 0.. 0,6 A
PWM digital output (max. 4 A)

BOMAG
X0:44 Output warning buzzer Warning buzzer ON ) 24 V
PWM digital output (max. 4 A) Warning buzzer OFF )approx.2 V
X0:45 Input hydraulic oil level float Oil level ok )approx.5 V
Digital input active low Oil level too low ) 0V
X0:46 Output wheel motor front left permissible current range: approx. 0..0,6 A
PWM digital output (max. 4 A)
X0:47 Output wheel motor front right permissible current range: approx. 0..0,6 A
PWM digital output (max. 4 A)
X0:48 Output wheel motor rear left permissible current range: approx. 0..0,6 A
PWM digital output (max. 4 A)
X0:49 Output steering left Steering active ) 0,3..1 A
PWM digital output (max. 4 A) Steering not active ) 0A
X0:50 Input excessive hydraulic oil temperature Temperature ok )approx.5 V
Digital input active low Temperature too high ) 0V
X0:51 Input contamination sensor Filter ok )approx.5 V
Digital input active low Filter soiled ) 0V
X0:52 Input oil pressure (from EMR) Oil pressure ok )approx.5 V
Digital input active low Oil pressure too low ) 0V

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ESX terminal Signal description Nominal values (voltage / current)

X0:53 not used -

X0:54 Voltage supply for electronics Emergency stop not actuated ) 24 V

Emergency stop actuated ) 0V
X0:55 Ground connection electronics 0 V measured against ground

X0:56 Voltage supply for outputs approx. 24 V measured against ground

X0:57 Voltage supply for outputs approx. 24 V measured against ground

X0:58 Voltage supply for outputs approx. 24 V measured against ground

X0:59 Voltage supply for outputs approx. 24 V measured against ground

X0:60 Voltage supply for outputs approx. 24 V measured against ground

X0:61 Output brake Open brake ) 24 V

BOMAG
Digital output (max. 4 A) Close brake ) 0V
X0:62 Output travel ranges (only BC772) Travel speed range: 2nd gear ) 24 V
Digital output (max. 4 A) Travel speed range: 1st gear ) 0V
X0:63 Output float position Float position active ) 24 V
Digital output (max. 4 A) Float position not active ) 0V
X0:64 Output steering right Steering active ) 0,3..1 A
PWM digital output (max. 4 A) Steering not active ) 0A
X0:65 Mouse port Baby Boards approx. 0 V

X0:66 Mouse port Baby Boards approx. 0 V

X0:67 Mouse port Baby Boards approx. 0 V

X0:68 Mouse port Baby Boards approx. 0 V

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10 Description of signals on the DIOS module (only with optional bucket)

DIOS terminal Signal description Nominal values (voltage / current)

X0/1:1 Interface CAN-Bus Wire +, is used to communicate with the ESX- Measurement not possible!
control.
X0/1:2 Interface CAN-Bus Wire -, is used to communicate with the ESX- Measurement not possible!
control.
X0/1:3 Voltage supply for electronics Ignition ON: ) 24 V
Ignition OFF: ) 0V
X0/1:4 Ground connection (Coding node address) 0 V measured against ground

X0/1:5 Output close valve Close bucket active ) 0,3..1 A

PWM digital output (max. 1 A) Bucket not active ) 0A
X0/1:6 Output open valve Open bucket active ) 0,3..1 A
PWM digital output (max. 1 A) Bucket not active ) 0A
X0/1:7 not used

X0/1:8 not used

BOMAG
X0/1:9 Voltage supply for outputs Ignition ON: ) 24 V
Ignition OFF: ) 0V
X0/1:10 Voltage supply for outputs Ignition ON: ) 24 V
Ignition OFF: ) 0V
X0/1:11 Ground connection 0 V measured against ground

X0/1:12 not used

X0/1:13 not used

X0/1:14 not used

X0/1:15 not used

X0/1:16 not used

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BOMAG
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Service Training Fault codes of the ESX control

11 Fault codes of the ESX control

11.1 Overview

Fault code Fault description

00I - 199 Fault in travel system
200 - 299 Fault in steering system
300 - 499 Fault in working hydraulics
500 - 509 Warning messages input codes
510 - 549 Fault diesel engine
560 - 562 Fault sensor voltage supply / override relays
570 - 599 Fault hydraulic system
800 - 899 Fault message „severe software fault"
900 - 919 Error message "Communication via CAN bus disturbed"
920 - 999 Fault message "Severe internal fault in control"

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11.2 Description of fault reactions

Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Audible signal in 5 second intervals.2
Signal light in monitoring board lights in 5 second intervals.
2 Function affected, the faulty function is replaced by an emergency function.
Fault code is displayed.
Audible signal in 5 second intervals.
Signal light in monitoring board lights in 5 second intervals.
3 Partial function faulty, the partial function cannot be overridden by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Fault code is displayed.
Audible signal in 5 second intervals.
Signal light in monitoring board lights in 5 second intervals.

BOMAG
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
) the diesel engine is shut down.
Fault code is displayed.
Audible signal in 1 second intervals.
Signal light in monitoring board lights in 1 second intervals.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
The fault code is displayed, the signal light in the monitoring board is permanently on.
No audible signal!

Note: Errors with error reaction 1 are only warning messages and are NOT stored in the error log!

2
audible signal not with all faults (see page 3: "selected fault reactions of the ESX control")

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11.3 Detailed description of fault codes and their possible causes

Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
00I Output brake ) Wire breakage in current path X0:61 001 5
No or too low current flow out of this output ) Current path connected to +24 V
002 Output brake ) Short circuit to ground in the current path X0:61 001 5
The current flow from this output is too high ) ) Coil from brake valve burned out
output was switched off!
003 Output brake ) Current path connected to +24 V X0:61 001 5
Although the output is switched off, voltage is
present
004 Output brake ) Excessive current flow in current path, probably because of a X0:61 - 5
The output switch was switched off because of a defective coil or a short circuit to ground
too high temperature. As soon as the switch has
cooled down the output will be switched on

BOMAG
again.

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
021 Input travel direction switch ) Wire breakage in current path X0:32 021 5
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to switch
) Fuse FM 6 has tripped or wire breakage in voltage supply
current path
) Switch defective
022 Input travel direction switch ) Current path connected to +24 V / +8,5 V X0:32 021 5
The voltage applied to the input is above the ) Switch not connected to ground
specified range (see signal description). ) Switch defective

025 Input travel direction switch ) Poor contact of plug-in connection (intermittent contact) in X0:32 021 5
The voltage applied to the input is excessively current path or in supply lines
fluctuating. ) Switch defective
040 Input travel range switch (only BC972) ) Wire breakage in current path X0:7 040 2
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to switch

BOMAG
) Fuse FM 1 has tripped or wire breakage in voltage supply
current path
) Switch defective
041 Input travel range switch (only BC972) ) Current path connected to +24 V / +8,5 V X0:7 040 2
The voltage applied to the input is above the ) Switch not connected to ground
specified range (see signal description). ) Switch defective

042 Input travel range switch (only BC972) ) Poor contact of plug-in connection (intermittent contact) in X0:7 040 2
The voltage applied to the input is excessively current path or in supply lines
fluctuating. ) Switch defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
050 Output travel pumps forward ) Current path connected to ground X0:21 050 2
The voltage on this output is too low

051 Output travel pumps forward ) Current path connected to +24 V X0:21 050 2
The voltage on this output is too high

052 Output travel pumps forward ) Line breakage in current path X0:21 052 2
No current flow out of this output
053 Output travel pumps forward ) Current path connected to ground X0:21 052 2
Too high current flow out of this output ) Magnetic coil defective

060 Output travel pumps reverse ) Current path connected to ground X0:22 060 2
The voltage on this output is too low

061 Output travel pumps reverse ) Current path connected to +24 V X0:22 060 2

BOMAG
The voltage on this output is too high

062 Output travel pumps reverse ) Line breakage in current path X0:22 062 2
No current flow out of this output
063 Output travel pumps reverse ) Current path connected to ground X0:22 062 2
Too high current flow out of this output ) Magnetic coil defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
070 Output valve speed ranges (only BC772) ) Current path connected to ground X0:62 070 2
The voltage on this output is too low

071 Output valve speed ranges (only BC772) ) Current path connected to +24 V X0:62 070 2
The voltage on this output is too high

072 Output valve speed ranges (only BC772) ) Line breakage in current path X0:62 070 2
No current flow out of this output
073 Output valve speed ranges (only BC772) ) Excessive current flow in current path, probably because of a X0:62 - 2
The output switch was switched off because of a defective coil or a short circuit to ground
too high temperature. As soon as the switch has
cooled down the output will be switched on
again.

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
100 Output proportional solenoid (only BC972) ) Current path has short circuit to ground X0:46 100 2
Wheel motor front left ) Current path has non-permitted connection to another current 120
The specified current value is not reached path
) Current path is interrupted
) Interturn fault in proportional solenoid (measure resistance)
105 Output proportional solenoid (only BC972) ) Current path has short circuit to ground X0:47 105 2
Wheel motor front right ) Current path has non-permitted connection to another current 120
The specified current value is not reached path
) Current path is interrupted
) Interturn fault in proportional solenoid (measure resistance)
110 Output proportional solenoid (only BC972) ) Current path has short circuit to ground X0:48 110 2
Wheel motor rear left ) Current path has non-permitted connection to another current 120
The specified current value is not reached path
) Current path is interrupted
) Interturn fault in proportional solenoid (measure resistance)

BOMAG
115 Output proportional solenoid (only BC972) ) Current path has short circuit to ground X0:43 115 2
Wheel motor rear right ) Current path has non-permitted connection to another current 120
The specified current value is not reached path
) Current path is interrupted
) Interturn fault in proportional solenoid (measure resistance)

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
230 Input steering joystick ) One of the two switches is defective (permanently closed) X0:38, 230 2
Switch left / switch right ) Connection between both switches or inputs (probably a chafed X0:39
Plausibility problem on the switches; the signals through cable)
right and left were detected at the same time.
231 Input potentiometer steering joystick ) Steering joystick switch right defective (does not close) X0:8, 230 2
Input steering joystick switch right ) Wire breakage in current path for steering joystick switch right X0:39 231
The signal from the steering joystick switch right
was not detected, although the potentiometer is
actuated to the right
232 Input potentiometer steering joystick ) Steering joystick switch left defective (does not close) X0:8, 230 2
Input steering joystick switch left ) Wire breakage in current path for steering joystick switch left X0:38 231
The signal from the steering joystick switch left
was not detected, although the potentiometer is
actuated to the left
233 Input potentiometer steering joystick ) Current path connected to +24 V / +8,5 V X0:8 231 2
The voltage applied to the input is above the ) Potentiometer not connected to ground

BOMAG
specified range (see signal description). ) Potentiometer defective

234 Input potentiometer steering joystick ) Wire breakage in current path X0:8 231 2
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse FM 4 has tripped or wire breakage in voltage supply
current path
) Potentiometer defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
240 Input steering wheel (optional) ) One of the two switches is defective (permanently closed) X0:14, 240 2
Switch left / switch right ) Connection between both switches or inputs (probably a chafed X0:15
Plausibility problem on the switches; the signals through cable)
right and left were detected at the same time.
241 Input steering wheel potentiometer (optional) ) Steering wheel switch right defective (does not close) X0:9, 240 2
Input steering wheel switch right ) Wire breakage in current path steering wheel switch right X0:15 241
The signal from the steering wheel switch right
was not detected, although the potentiometer is
actuated to the right
242 Input steering wheel potentiometer (optional) ) Steering wheel switch left defective (does not close) X0:9, 240 2
Input steering wheel switch left ) Wire breakage in current path for steering wheel switch left X0:14 241
The signal from the steering wheel switch left
was not detected, although the potentiometer is
actuated to the left
243 Input steering wheel potentiometer (optional) ) Current path connected to +24 V / +8,5 V X0:9 241 2

BOMAG
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective

244 Input steering wheel potentiometer (optional) ) Wire breakage in current path X0:9 241 2
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse FM 3 has tripped or wire breakage in voltage supply
current path
) Potentiometer defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
271 Output proportional solenoid ) Current path has short circuit to voltage supply X0:64 271 2
Steering right ) Current path has non-permitted connection to another current 272
Output current too low. path
) Current path is interrupted
272 Output proportional solenoid ) Current path has short circuit to ground X0:64 271 2
Steering right ) Current path has non-permitted connection to another current 272
Output current too high. path

273 Output proportional solenoid ) Current path is interrupted X0:64 271 2

Steering right ) Current path has impermitted connection to another current path 272
Fault when calibrating the valve / ground

276 Output proportional solenoid ) Current path has short circuit to voltage supply X0:49 276 2
Steering left ) Current path has non-permitted connection to another current 277
Output current too low. path
) Current path is interrupted

BOMAG
277 Output proportional solenoid ) Current path has short circuit to ground X0:49 276 2
Steering left ) Current path has non-permitted connection to another current 277
Output current too high. path

278 Output proportional solenoid ) Current path is interrupted X0:49 276 2

Steering left ) Current path has short circuit to ground 277
Fault when calibrating the valve ) Current path has impermitted connection to another current path
/ ground

290 Incorrect parameter setting for steering ) Steering wheel AND steering joystick were both deactivated. - - 5
see description "parameter setting steering" (page 13)

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
400 Input dozer blade joystick ) One of the two switches is defective (permanently closed) X0:35, 400 2
Switch up / switch down ) Connection between both switches or inputs (probably a chafed X0:41
Plausibility problem on the switches; the signals through cable)
up and down were detected at the same time.
401 Input potentiometer for dozer blade joystick ) Dozer blade joystick switch up defective (does not close) X0:30, 400 2
Input dozer blade joystick switch up ) Wire breakage in current path dozer blade joystick switch up X0:35 401
The signal from the dozer blade joystick switch
up was not detected, although the potentiometer
is actuated to direction up
402 Input potentiometer for dozer blade joystick ) Dozer blade joystick switch down defective (does not close) X0:30, 400 2
Input dozer blade joystick switch down ) Wire breakage in current path dozer blade joystick switch down X0:41 401
The signal from the dozer blade joystick switch
down was not detected, although the
potentiometer is actuated to direction down
403 Input potentiometer for dozer blade joystick ) Current path connected to +24 V / +8,5 V X0:30 401 2

BOMAG
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective

404 Input potentiometer for dozer blade joystick ) Wire breakage in current path X0:30 401 2
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse FM 5 has tripped or wire breakage in voltage supply
current path
) Potentiometer defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
411 Output proportional solenoid ) Current path has short circuit to voltage supply X0:20 411 2
Dozer blade up ) Current path has non-permitted connection to another current 412
Output current too low. path
) Current path is interrupted
412 Output proportional solenoid ) Current path has short circuit to ground X0:20 411 2
Dozer blade up ) Current path has non-permitted connection to another current 412
Output current too high. path

413 Output proportional solenoid ) Current path is interrupted X0:20 411 2

Dozer blade up ) Current path has impermitted connection to another current path 412
Fault when calibrating the valve / ground

421 Output proportional solenoid ) Current path has short circuit to voltage supply X0:42 421 2
Dozer blade down ) Current path has non-permitted connection to another current 422
Output current too low. path
) Current path is interrupted

BOMAG
422 Output proportional solenoid ) Current path has short circuit to ground X0:42 421 2
Dozer blade down ) Current path has non-permitted connection to another current 422
Output current too high. path

423 Output proportional solenoid ) Current path is interrupted X0:42 421 2

Dozer blade down ) Current path has impermitted connection to another current path 422
Fault when calibrating the valve / ground

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
430 Output float position valve ) Wire breakage in current path X0:63 430 2
No or too low current flow out of this output ) Current path connected to +24 V
431 Output float position valve ) Short circuit to ground in the current path X0:63 430 2
The current flow from this output is too high ) ) Coil from brake valve burned out
output was switched off!
432 Output float position valve ) Current path connected to +24 V X0:63 430 2
Although the output is switched off, voltage is
present
433 Output float position valve ) Excessive current flow in current path, probably because of a X0:63 - 2
The output switch was switched off because of a defective coil or a short circuit to ground
too high temperature. As soon as the switch has
cooled down the output will be switched on
again.

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
450 Input bucket joystick (optional) ) One of the two switches is defective (permanently closed) X0:17, 450 2
Switch open / switch close ) Connection between both switches or inputs (probably a chafed X0:34
Plausibility problem on the switches; the signals through cable)
open and close were detected at the same time.
451 Input potentiometer bucket joystick (optional) ) Bucket joystick switch open defective (does not close) X0:31, 450 2
Input bucket joystick switch open ) Wire breakage in current path bucket joystick switch open X0:34 451
The signal from the bucket joystick switch open
was not detected, although the potentiometer is
actuated to direction open
452 Input potentiometer bucket joystick (optional) ) Bucket joystick switch close defective (does not close) X0:31, 450 2
Input bucket joystick switch close ) Wire breakage in current path bucket joystick switch close X0:17 451
The signal from the bucket joystick switch close
was not detected, although the potentiometer is
actuated to direction close
453 Input potentiometer bucket joystick (optional) ) Current path connected to +24 V / +8,5 V X0:31 451 2
The voltage applied to the input is above the ) Potentiometer not connected to ground

BOMAG
specified range (see signal description). ) Potentiometer defective

454 Input potentiometer bucket joystick (optional) ) Wire breakage in current path X0:31 451 2
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) Fuse FM 7 has tripped or wire breakage in voltage supply
current path
) Potentiometer defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
461 Output proportional solenoid ) Current path has short circuit to voltage supply DIOS 461 2
Open bucket (optional) ) Current path has non-permitted connection to another current X0/1:6 462
Output current too low. path
) Current path is interrupted
462 Output proportional solenoid ) Current path has short circuit to ground DIOS 461 2
Open bucket (optional) ) Current path has non-permitted connection to another current X0/1:6 462
Output current too high. path

463 Output proportional solenoid ) Current path is interrupted DIOS 461 2

Open bucket (optional) ) Current path has impermitted connection to another current path X0/1:6 462
Fault when calibrating the valve / ground

471 Output proportional solenoid ) Current path has short circuit to voltage supply DIOS 471 2
Close bucket (optional) ) Current path has non-permitted connection to another current X0/1:5 472
Output current too low. path

BOMAG
) Current path is interrupted
472 Output proportional solenoid ) Current path has short circuit to ground DIOS 471 2
Close bucket (optional) ) Current path has non-permitted connection to another current X0/1:5 472
Output current too high. path

473 Output proportional solenoid ) Current path is interrupted DIOS 471 2

Close bucket (optional) ) Current path has impermitted connection to another current path X0/1:5 472
Fault when calibrating the valve / ground

475 DIOS module dozer blade ) Wire breakage in CAN bus lines - 2
Fault when initializing the module ) Short circuit between CAN bus lines
) One or both CAN bus line(s) has (have) connection to +12V or
ground
) DIOS module without voltage supply
) DIOS module defective

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Service Training Refuse Compactor Description of fault codes of the ESX control

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ESX control

Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
500 Warning „Drive against brake“ With the input of code 5 0 0 the function „Driving against brake“ - - 1
was activated. This messages is intended to remind you of this
condition. The function „Driving against brake“ can be disabled by
switching the ignition off and entering code 5 0 I .
502 Warning “Enable without the engine running” With the input of code 5 0 2 the function „Enable without engine - - 4
running” was activated. This messages is intended to remind you of
this condition. The function „Enable without engine running“ can be
disabled by switching the ignition off.
504 Warning „Enable float position“ With the input of code 5 0 4 the function „Enable float position” was - - 1
activated. This messages is intended to remind you of this
condition. The function „Enable float position“ can be disabled by
switching the ignition off and entering code 5 0 5 .

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
510 Output engine shut down ) Current path connected to +24 V X0:24 510 2
Although the output is switched off, voltage is
present
511 Output engine shut down ) Short circuit to ground in the current path X0:24 510 2
Although the output is switched on, no voltage is
present
512 Output engine shut down ) Wire breakage in current path X0:24 510 2
Although the output is switched off, a voltage of
approx. 0.8 V is present.
513 Engine stalled or shut down by engine control ) Engine overloaded - - 2
unit (EMR)
514 Engine speed input: ) Wire breakage in current path X0:16 514 1
Although the engine is running, no pulses from ) Current path has short circuit to ground 515
the rotation sensor ) Wire breakage in current path for voltage supply 516
) Engine speed sensor B92 defective / incorrectly assembled

BOMAG
) see also under : "Known faults" on page 6
517 Input D+ generator ) Wire breakage in current path X0:36 517 1
Although the engine is running there is no ) Current path has short circuit to ground
voltage present at input D+ ) V-belt broken
) Connections on generator faulty
) Generator defective

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ESX control

Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
520 Input engine oil pressure ) The engine control unit has measured a too low oil pressure. The X0:52 520 1
Engine control unit (EMR) delivers signal „no engine may be shut down.
engine oil pressure“
Should this message be displayed even though the engine is not
running, the following faults should be examined:
) Current path has short circuit to ground
) No voltage supply to EMR
521 Input engine oil pressure ) see fault code 5 2 0 X0:52 520 4
Fault 5 2 0 is present longer than 10 seconds
) Engine is shut down
522 Input coolant temperature )This message shows that the coolant temperature is too high. X0:18 522 1
Engine control unit (EMR) delivers signal The diesel engine control unit may reduce the engine power in
„excessive coolant temperature“ order to avoid a further temperature increase or may even shut
the engine down.

Should this message be displayed even though the coolant

BOMAG
temperature is in a non-critical range (e.g. machine is cold), you
should check the following faults:
) Current path has short circuit to ground
) No voltage supply to EMR
523 Input coolant temperature ) see fault code 5 2 2 X0:18 522 4
Fault 5 2 2 is present longer than 120 seconds
) Engine is shut down

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
524 Input coolant level float ) This message shows that the coolant level is too low. X0:19 524 1

Should this message be displayed even though the coolant level

is not critical, the following faults should be examined:
) Current path has short circuit to ground
) Float defective

525 Input coolant level float ) see fault code 5 2 4 X0:19 524 4
Fault 5 2 4 is present longer than 20 seconds
) Engine is shut down
526 Input pressure differential switch air filter diesel ) This message indicates that at least one of the two air filters is X0:11 526 1
engine dirty. (time delay 2 minutes)

Should this message be displayed even though both filters are

clean, the following faults should be examined:

BOMAG
) Current path has short circuit to ground
) Pressure switch defective

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ESX control

Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
530 Input travel pedal potentiometer ) Wire breakage in current path X0:06 530 1
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) No voltage supply for engine control unit (EMR)
) Potentiometer defective
531 Input travel pedal potentiometer ) Current path connected to +24 V / +5 V X0:06 530 1
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective

532 Input travel pedal potentiometer see Fault 5 3 0 / 5 3 1 X0:06 530 4

A travel pedal fault has occurred and the engine
runs with a speed of more than 1000 rpm, i.e. in
emergency mode the engine runs with a fixed
speed. Apart from that, the travel lever was NOT
in Neutral when the fault occurred.

BOMAG
) Engine is shut down
533 Input travel pedal potentiometer see Fault 5 3 0 / 5 3 1 X0:06 530 1
A travel pedal fault has occurred and the engine
runs with a speed of more than 1000 rpm, i.e. in
emergency mode the engine runs with a fixed
speed.

540 Engine speed signal ) Selection of incorrect parameter for "Engine speed signal X0:16 540 1
The engine speed is outside the permissible source"
range ) Speed sensor incorrectly installed
) Intermittent contact in current path
) Speed sensor defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
560 Output sensor voltage supply ) Current path connected to +24 V X0:23 560 5
The voltage applied to the output is higher than
10V.
561 Output sensor voltage supply ) Current path connected to ground X0:23 560 5
The voltage applied to the output is lower than
5V.
562 Output Override (emergency operation) )Fuse F67 has tripped or wire breakage in current path for X0:2 562 5
A voltage of 24V should be present at the output, voltage supply to control (56 - 60)
however, the measured voltage is lower than 5V. ) Current path has short circuit to ground

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -
ESX control

code on ESX code for reaction

diagnose
570 Input hydraulic oil contamination sensor ) This message shows that the hydraulic oil is contaminated. X0:11 570 1
(Time delay 10 seconds)

Should this message be displayed even though this is not true,

the following faults should be examined:
) Current path has short circuit to ground
) Sensor defective

571 Input hydraulic oil contamination sensor see fault code 5 7 0 X0:11 570 4
Fault 5 7 0 is present longer than 120 seconds
) Engine is shut down
572 Input pressure differential switch hydraulic filter ) At least one of the pressure differential switches shows a X0:10 572 1
charge pumps and intermediate gears pressure differential.

Should this message be displayed even though no differential

pressure has been measured, the following faults should be
examined:

BOMAG
) Current path has short circuit to ground
) one of the pressure switches are defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
573 Input pressure differential switch hydraulic filter see fault code 5 7 2 X1:13 572 4
charge pumps and intermediate gears
Fault 5 7 2 is present longer than 120 seconds
) Engine is shut down
574 Input excessive hydraulic oil temperature ) This message is a warning, giving the operator enough time to X0:50 574 1
move the machine out of the danger area before the engine is
automatically shut down after 120 seconds.

Should this message be displayed even though the hydraulic oil

temperature is ok (e.g. machine is cold), you should check the
following faults:
) Current path has short circuit to ground
) one of the 5 pressure switches is defective
575 Input excessive hydraulic oil temperature see fault code 5 7 4 X0:50 574 4
Fault 5 7 4 is present longer than 120 seconds

BOMAG
) Engine is shut down
578 Input hydraulic oil filling level ) This message shows that the hydraulic oil level is too low. X0:45 578 1
) This message is a warning, giving the operator enough time to
move the machine out of the danger area before the engine is
automatically shut down after 20 seconds.

Should this message be displayed even though the hydraulic oil

level is ok, the following faults should be examined:
) Current path has short circuit to ground
) Float defective

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008 911 53
ESX control

Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
579 Input hydraulic oil filling level see fault code 5 7 9 X0:45 578 4
Fault 5 7 9 is present longer than 20 seconds
) Engine is shut down
580 Input hydraulic oil return flow filter ) The return flow filter is dirty X0:13 580 1

Should this message be displayed even though no pressure has

been measured, the following faults should be examined:
) Current path has short circuit to ground
) Pressure switch defective
581 The warning 5 8 0 was present for longer than )This message indicates that a pressure differential was detected X0:13 580 4
120 seconds, the engine was then automatically at the filter which lasted longer than 120 seconds (see message
shut down. 5 8 0 ) and the engine was therefore automatically shut down.

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
800 Fault message "severe software fault in control" - - - 5
- The machine can only be moved in emergency
899 mode. The control has automatically switched off.
This fault cannot be rectified on the machine. The
control must be immediately replaced.
900 Error message "Communication via CAN bus ) Wire breakage in CAN bus lines X0:26 - 2
- disturbed" ) Short circuit between CAN bus lines X0:27
919 The modules (DIOS module for bucket control) ) One or both CAN bus line(s) has (have) connection to +12V or
controlled via the CAN bus cannot be addressed ground
by the main control (ESX). The respective ) DIOS module without voltage supply
machine functions (e.g. bucket control) are not ) DIOS module defective
available

920 Fault message "Severe internal fault in control" - - - 5

- The machine can only be moved in emergency

BOMAG
999 mode. The control has automatically switched off.
This fault cannot be rectified on the machine. The
control must be immediately replaced.
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X0:26 - -
control. ) Short circuit between CAN bus lines X0:27
) One or both CAN bus line(s) has (have) connection to +12V or
ground

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12 Input Codes for ESX Control
ESX control

12.1 Travel system

Input code Description of display function Display values

000 All display functions disabled. -
00I brake Display value / 10 = voltage in V
Show voltage on brake output.
003 brake 0 0 0 ) Switch position "brake OPEN"
Shows condition of brake switch 0 0 I ) Switch position "brake CLOSED"
020 Selector switch travel direction 1 0 0 ) actuated forward
Shows the travel direction. 0 0 0 ) Neutral position
0 0 I ) actuated to backward

021 Selector switch travel direction Display value / 100 = voltage in V

Shows the potentiometer voltage.
040 Selector switch travel speed range Display value / 100 = voltage in V
Shows the voltage on the input.

BOMAG
041 Selector switch travel speed range 0 0 I ) 1st gear
Shows the travel speed range. 0 0 2 ) 2nd speed range
0 0 3 ) 3rd speed range (only BC972)
050 Travel pump Display value / 10 = voltage in V
Show voltage on output “travel pump forward”
052 Travel pump Display value *10 = current in mA1
Show voltage on output “travel pump forward”
060 Travel pump Display value / 10 = voltage in V
Show voltage on output “travel pump reverse”
062 Travel pump Display value / 10 = current in mA1
Show current on output “travel pump reverse”

1
Current measurement with factor 10 only available from software version 4.03
(Up to and incl. version 4.02 the current output took place without this factor, i.e. only max. 999mA could be displayed)

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Input code Description of display function Display values

070 Speed range selector valve (only BC772) Display value / 10 = voltage in V
Shows the voltage on the output.
100 Wheel motor front left 3(only BC972) Display value = current in mA
Shows actual current value of proportional solenoid.
105 Wheel motor front right 1 (only BC972) Display value = current in mA
Shows actual current value of proportional solenoid.
110 Wheel motor front left 1 (only BC972) Display value = current in mA
Shows actual current value of proportional solenoid.
115 Wheel motor rear right 1 (only BC972) Display value = current in mA
Shows actual current value of proportional solenoid.
120 Wheel motors (only BC972) Display value = current in mA
Shows the current values.

12.2 Steering

BOMAG
Input code Description of display function Display values
230 Steering joystick I00 ) Switch left actuated
Shows the condition of the switches. 0 0 0 ) no switch actuated; neutral position
00I ) Switch right actuated
I0I ) Switches left and right actuated fault ) Fault
231 Steering joystick Display value / 100 = voltage in V
Shows the potentiometer voltage.
232 Steering joystick Value range: 1000...-1000
Shows the standardized position 1000 = max. actuation left
0 = zero position
-1000 = max. actuation right
Note: Due to the abilities of the display module only values from
9 9 9 . . . - 9 9 9 can be displayed. (See also description of
display module)

3
due to measuring inaccuracies the display values fluctuate slightly, e.g. actual current value 1st speed range: 0..15 mA

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Input code Description of display function Display values

240 Steering wheel (optional) I00 ) Switch left actuated
Shows the condition of the switches. 0 0 0 ) no switch actuated; neutral position
0 0 I ) Switch right actuated
I 0 I ) Switches left and right actuated fault ) Fault
241 Steering wheel (optional) Display value / 100 = voltage in V
Shows the potentiometer voltage.
242 Steering wheel (optional) Value range: 1000...-1000
Shows the standardized position 1000 = max. actuation left
0 = zero position
-1000 = max. actuation right
Note: Due to the abilities of the display module only values from
9 9 9 . . . - 9 9 9 can be displayed. (See also description of
display module)
250 Arm rest (optional) 0 0 0 ) Arm rest top position (joystick steering inactive)
Shows position determined by position switch 0 0 1 ) Arm rest bottom position
251 Limit switch steering left (only electronic end position damping) 0 0 0 ) End position reached
Shows position determined by position switch 001 )

BOMAG
252 Limit switch steering right (only electronic end position damping) 0 0 0 ) End position reached
Shows position determined by position switch 001 )
271 Steering valve right Display value = current in mA
Shows specified current value of proportional solenoid left.
272 Steering valve right Display value = current in mA
Shows actual current value of proportional solenoid left.
276 Steering valve left Display value = current in mA
Shows specified current value of proportional solenoid right.
277 Steering valve left Display value = current in mA
Shows actual current value of proportional solenoid right.

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12.3 Working hydraulics

Input code Description of display function Display values

400 Dozer blade joystick I00 ) Switch up actuated
Shows the condition of the switches. 0 0 0 ) no switch actuated; neutral position
0 0 I ) Switch down actuated
I 0 I ) Switches up and down actuated ) Fault
401 Dozer blade joystick Display value / 100 = voltage in V
Shows the potentiometer voltage.
402 Dozer blade joystick Value range: 1000...-1000
Shows the standardized position 1000 = max. actuation up
0 = zero position
-1000 = max. actuation down
Note: Due to the abilities of the display module only values from
9 9 9 . . . - 9 9 9 can be displayed. (See also description of
display module)
411 Valve up Display value = current in mA
Shows specified current value of proportional solenoid for lifting.

BOMAG
412 Valve up Display value = current in mA
Shows actual current value of proportional solenoid for lifting.
421 Valve down Display value = current in mA
Shows specified current value of proportional solenoid for lowering.
422 Valve down Display value = current in mA
Shows actual current value of proportional solenoid for lowering.
425 Push button float position 0 0 0 ) joystick not operated
Shows condition of push button 0 0 1 ) operated
426 Status float position 0 0 0 ) not active
0 0 1 ) active
430 Valve float position Display value / 10 = voltage in V
Shows the voltage on the output “float position”.

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Input code Description of display function Display values

450 Bucket joystick I00 ) Switch closing actuated
Shows the condition of the switches. 0 0 0 ) no switch actuated; neutral position
0 0 I ) Opening switch actuated
I 0 I ) Switches open and close actuated ) Fault
451 Bucket joystick Display value / 100 = voltage in V
Shows the potentiometer voltage.
452 Bucket joystick Value range: 1000...-1000
Shows the standardized position 1000 = max. actuation close
0 = zero position
-1000 = max. actuation open
Note: Due to the abilities of the display module only values from
9 9 9 . . . - 9 9 9 can be displayed. (See also description of
display module)
461 Valve open Display value = current in mA
Shows specified current value of proportional solenoid open.
462 Valve open Display value *100 = current in mA
Shows actual current value of proportional solenoid open.

BOMAG
471 Valve close Display value = current in mA
Shows specified current value of proportional solenoid close.
472 Valve close Display value *100 = current in mA
Shows actual current value of proportional solenoid close.

12.4 Test functions

Input code Description of display function Display values

500 Switch on function „Against brake“ see adjustment instructions (page 8 )!
50I Switch off function „Drive against brake“ see adjustment instructions (page 8 )!
502 Function “Enable without engine running” see adjustment instructions (page 8 )!
504 Switch on function „Enable float position" see adjustment instructions (page 9 )!
505 Switch off function „Enable float position" see adjustment instructions (page 9 )!

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12.5 Diesel engine

Input code Description of display function Display values

510 Engine shut down Display value / 10 = voltage in V
Shows the voltage on the output engine shut down.
511 Status diesel engine 0 0 0 ) Engine OFF
Shows the status of the diesel engine. Status is derived from MD+, oil 0 0 I ) Engine ON
pressure and engine speed. Running of engine is sensed if at least 2
signals are present.
514 Engine speed sensor Display value x 10 = engine speed in rpm
Shows the engine speed.
515 Engine speed sensor Display value x 10 = frequency in Hz
Shows the frequency at engine speed input.
516 Engine speed sensor Number of pulses; display jumps from 9 9 9 back to 0 0 0
Shows number of pulses on engine speed input.
517 D+ generator 0 0 0 ) MD+ not applied (input to ground)
Shows status of input MD+. 0 0 I ) MD+ present (input connected to +24 V)
520 Engine oil pressure 0 0 0 ) No engine oil pressure

BOMAG
Shows status of input engine oil pressure. 0 0 I ) Engine oil pressure OK
522 Coolant temperature 0 0 0 )Coolant temperature too high
Shows status of input coolant temperature. 0 0 I ) Coolant temperature OK
524 Coolant filling level 0 0 0 ) Filling level too low
Shows status of input coolant level. 00I ) Filling level OK
526 Air filter soiled 0 0 0 ) at least 1 filter soiled
Shows status of input air filter pressure differential switch. 00I ) both filters OK
530 Travel pedal potentiometer Display value / 100 = voltage in V
Shows the potentiometer voltage.
531 Travel pedal potentiometer Value range: 0..1000
Shows the standardized potentiometer voltage. Display value / 10 = voltage in % of the reference voltage from
EMR control unit (5 V)
532 Travel pedal potentiometer 0 0 I ) ok
Shows status. 0 0 2 ) Fault

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Input code Description of display function Display values

540 Engine speed measuring source 0 0 0 ) Evaluation of DEUTZ speed signal
You may either evaluate the speed signal provided by the DEUTZ 0 0 I ) Evaluation of BOMAG speed signal
engine control unit, or the signal from the BOMAG speed sensors.
541 Pulses / revolution engine speed signal 0 6 0 )DEUTZ speed signal
Number of pulses per revolution of the evaluated speed signal. 1 2 9 I )BOMAG speed signal (only BC572)
1 6 7 )BOMAG speed signal

12.6 System information

Input code Description of display function Display values

555 Software Version 3-digit version number
Shows the software version number.
560 Supply voltage 8.5V Display value / 100 = voltage in V
Shows the voltage value
56I Supply voltage 24 V Display value / 10 = voltage in V
Shows the voltage value

BOMAG
562 Override Display value / 10 = voltage in V
Shows the voltage on the output “override”.

12.7 Hydraulics

Input code Description of display function Display values

570 Hydraulic contamination sensor 000 ) Hydraulic oil contaminated
Shows status of input contamination sensor. 00I ) Hydraulic oil OK
572 Hydraulic oil filter 0 0 0 ) at least 1 hydraulic filter soiled
Shows the condition of input hydraulic oil filter for charge pumps and 00I ) all hydraulic oil filters OK
intermediate gear.
574 Hydraulic oil temperature 000 ) Temperature too high
Shows status of input oil temperature. 00I ) Temperature OK
578 Hydraulic oil filling level 0 0 0 ) Filling level too low

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Input code Description of display function Display values

Shows status of input hydraulic oil level float. 00I ) Filling level OK
580 Hydraulic return flow filter 0 0 0 )Hydraulic oil filter soiled
Shows status of input hydraulic return flow filter. 0 0 I ) Hydraulic oil filter OK

BOMAG
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12.8 Parameter change
ESX control

Input code Description of display function Display values

640 Activates function "parameter input steering" Display value 6 4 0
641 Activation of option "steering joystick" see adjustment instructions (page 13 )!
642 Deactivation of option "steering joystick" see adjustment instructions (page 13 )!
643 Activation of option "steering wheel" see adjustment instructions (page 13 )!
644 Deactivation of option "steering wheel" see adjustment instructions (page 13 )!
645 Activation of the arm rest initiator see adjustment instructions (page 13 )!
646 Deactivation of the arm rest initiator see adjustment instructions (page 13 )!
647 Deactivation of mechanical end position damping see adjustment instructions (page 13 )!
648 Activation of mechanical end position damping see adjustment instructions (page 13 )!
649 Deactivation of electronic end position damping see adjustment instructions (page 13 )!
650 Switch on function "parameter input setting dozer blade function" (only Display value 6 5 0
EB machines).
651 Activation "characteristic 1 (slightly progressive)" see adjustment instructions (page 14 )!
652 Activation "characteristic 2 (more progressive)" see adjustment instructions (page 14 )!
653 Activation "characteristic 3 (highly progressive)" see adjustment instructions (page 14 )!

BOMAG
654 Activation "no characteristic 1" see adjustment instructions (page 14 )!
660 Activates „parameter input 2nd speed range” (only BC972) Display value 6 6 0
661 Activation "slow speed" for 2nd speed range (only BC972). see adjustment instructions (page 12 )!
662 Activation "medium speed" for 2nd speed range (only BC972). see adjustment instructions (page 12 )!
663 Activation "high speed" for 2nd speed range (only BC972). see adjustment instructions (page 12 )!
685 Activation of "Parameter input diesel engine speed signal" see adjustment instructions (page 15 )!
686 Activation "DEUTZ engine speed signal" see adjustment instructions (page 15 )!
687 Activation "BOMAG engine speed signal" see adjustment instructions (page 15 )!
690 Activation "parameter input travel pedal monitoring" see adjustment instructions (page 14 )!
691 Activation "Monitoring ON" see adjustment instructions (page 14 )!
692 Activation "Monitoring OFF" see adjustment instructions (page 14 )!

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12.9 Fault log

Input code Description of display function Display values

700 Switch on function „Show stored faults“ see adjustment instructions (page 10 )!
701 Switch off function „Show stored faults“ see adjustment instructions (page 10 )!
710 Delete all stored faults see adjustment instructions (page 10 )!

BOMAG
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12.10 Setting the machine type

Input code Description of display function Display values

725 Switches on function „Set machine type“ see adjustment instructions (page 11 )!
726 Confirms entered machine type see adjustment instructions (page 11 )!
760 Pre-select machine type BC 972 dozer blade version see adjustment instructions (page 11 )!
761 Pre-select machine type BC 672/772 dozer blade version see adjustment instructions (page 11 )!
762 Pre-select machine type BC 972 bucket version see adjustment instructions (page 11 )!
763 Pre-select machine type BC 672/772 bucket version see adjustment instructions (page 11 )!
764 Pre-select machine type BC 572 dozer blade version see adjustment instructions (page 11 )!
765 Pre-select machine type BC 572 bucket version see adjustment instructions (page 11 )!
766 Pre-select machine type BC 672 EB see adjustment instructions (page 11 )!
767 Pre-select machine type BC 672 EB with tilt function see adjustment instructions (page 11 )!

BOMAG
Status: 16.02.2007 Description of Control Input Codes Page 63 of 67
Author: T. Löw / TE
6.1

337
6.1 ESX control

Service Training Refuse Compactor

13 Terminology in connection with ESX

Short circuit
A direct, unwanted connection between two different cables or between machine and
cables.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.

Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:

Line:
torn (not necessarily visible from outside)
chafed
chafed mostly in connection with a short circuit to ground

Terminal, cable lug

loosened, slipped off
broken off,
corroded,
socket / plug faulty

Status: 16.02.2007 Terminology Page 64 of 67

Author: T.Löw / TE

338 BOMAG 008 911 53

ESX control 6.1

Service Training Refuse Compactor

Short circuit to ground

Line, terminal has direct connection to vehicle ground, often in connection with wire
breakage

Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)

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

Status: 16.02.2007 Terminology Page 65 of 67

Author: T.Löw / TE

008 911 53 BOMAG 339

6.1 ESX control

Service Training Refuse Compactor

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

Closed loop control

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

Marking Closed loop control Control

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

Status: 16.02.2007 Terminology Page 66 of 67

Author: T.Löw / TE

340 BOMAG 008 911 53

ESX control 6.1

Service Training Refuse Compactor

Current and voltage measurement

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

Override / emergency operation

In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 18, "")

GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)

PWM – digital output

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

Status: 16.02.2007 Terminology Page 67 of 67

Author: T.Löw / TE

008 911 53 BOMAG 341

6.1 ESX control

342 BOMAG 008 911 53

7 Trouble shooting

008 911 53 BOMAG 343

7.1 Notes on trouble shooting

General notes on trouble shooting in hy- Progressive tests drawn up in the trouble shooting di-
7.1 Notes on trouble shooting

draulic systems agram lead to the detection of faults and their rectifi-
cation by trained personnel.
The following description of trouble shooting steps
contains a small selection of possible faults that may
l Ensure strict cleanliness, clean ports and fittings
occur during the operation of the machine. The fault before disconnecting.
lists are by no means complete, but the fault tables l Cover all openings and ports or close with plugs.
were compiled according to the experience gathered
by our central customer service, i.e. faults that have
l Check the hydraulic oil level before and after the
occurred in the past have almost all been included. work.
l Use only clean oil according to specification.
Procedure:
l
Check the hydraulic system for leaks, find and rec-
On machines with electronic control (ESX) you should
tify the cause.
first of all check the CAN-Bus module, to find out if
there is a error code and thus an electric fault present. l Ensure strict cleanliness, clean ports and fittings
If a fault code is present, continue trouble shooting by before disconnecting.
following the description of the ESX-control. l Fill new hydraulic units with hydraulic oil before
If no fault code is present, the fault may still be caused starting operation.
by an electrical problem or an operating error. The l After changing a component thoroughly flush and
control will only report a fault if the current/voltage val- bleed the hydraulic system.
ues are out of the nominal range. If e.g. a contact in a
switch is defective, the control will not always recog-
l As far as possible conduct all measurements at op-
nize this. For this reason one can have the incoming erating temperature 40 ... 50 °C.
and outgoing signals for the control displayed by the l
After changing a component check charge and high
CAN-Bus module to compare these with the table of pressure, if necessary check the rotational speed.
nominal values.
Hydraulic hoses
Important points for trouble shooting and
fault rectification Danger
!

Danger of injury
Danger
! Hydraulic hoses must be visually inspected at
Danger of injury! regular intervals.

Do not touch rotating parts of the engine. Hydraulic hoses must be immediately replaced if:

When working on the travel pump and performing

l
the outer layer is damaged down to the inlay (e.g.
tests in the travel circuit block the wheels with chafing, cuts, cracks, etc.)
suitable wheel chocks. l the outer layer is brittle (formation of cracks in the
Hydraulic oil escaping under pressure can pene- hose material)
trate the skin and cause severe injury. You should l the hose shows deformations in pressurized and
therefore relieve the pressure in the system be- depressurized condition, which do not comply with
fore disconnecting any lines. Before repressuriz- the genuine shape of the hydraulic hose
ing the system make sure that all line connections
and ports are in perfect condition.
l
the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, formation of
When being injured by hydraulic oil consult a phy- blisters
sician immediately, as otherwise this may cause
severe infections.
l the hose is leaking
l the hydraulic hose has separated from the fitting
Caution
! l the fitting shows corrosion that impairs both function
It is not recommended to open or repair hydraulic and strength
units and components without comprehensive l
the fitting is deformed in a way that both function
knowledge. and strength are affected
Risk of damage to pressure gauges if incorrectly l the storage time and utilization period has expired.
connected.
When performing trouble shooting it is assumed that
the machine is correctly equipped and connected, that
connections and hoses are free of faults and that set-
screws have not been deadjusted without permission.

344 BOMAG 008 911 53

The machine drives with the travel lever in „NEUTRAL“ 7.2

The machine drives with the travel lever in „NEUTRAL“

Check the control current to the solenoids

- Pull the plugs off the magnets
on the control, one after the other

Perform
Machine yes trouble shooting
stops? in the electrical
system

Check the zero position of the pump

- Connect control chamber ports X3 and X4 on
one pump with a hose
- Start the engine
- Repeat this test on all
other pumps

no
Machine
stops?

yes

7.2 The machine drives with the travel lever in „NEUTRAL“

008 911 53 BOMAG 345

7.2 The machine drives with the travel lever in „NEUTRAL“

Adjust the mechanical 0-position

- Connect control chamber ports X3 and X4
with a hose
- Connect 600 bar pressure gauges to
MA and MB.
- Check which pump is delivering
- On this pump adjust the 0-position so that the pressure
reading is below 60 bar
- Repeat this test until the lowest pressure value is reached
- Remove the connecting hose, repeat the pressure test

Check the control unit

- Remove the control unit
- Check the smooth movement of the control piston

no
Control unit Replace the
OK? control unit

yes

Replace/repair
the travel
pump

346 BOMAG 008 911 53

The machine does not drive 7.3
7.3 The machine does not drive

The machine does not drive

Read fault code and proceed appropriately

Check the emergency stop switch
- Check whether the emergency stop switch was pressed
Note:
If necessary select the travel direction again after unlocking or op-
erate the brake

no Unlock the emergency stop switch, replace if nec-

Emergency
stop switch essary
OK?
yes

Check the electric control

- Input module, enter PIN-CODE.
- Switch the ignition on and select the desired travel direction
- Check the voltage
Nominal value:
24V

no Perform trouble shooting

Voltage in electric system
OK?

yes

008 911 53 BOMAG 347

7.3 The machine does not drive

Check the solenoid

- Pull the plug off the solenoid
- Connect the adapter cable and measure the current draw
Nominal value: approx. 2A

no
Current draw Replace the
OK? magnet

- Pull the plug off the solenoid
- Connect the adapter cable and measure the current draw
Nominal value: approx. 2A

Replace the
no magnet
Current draw
OK?

yes

008 911 53 BOMAG 349

7.4 Machine travels to one direction only or to one travel direction

Check the high pressure relief valve

- Interchange the high pressure relief valves

yes Replace the corresponding high pressure relief valve

Travel direction
changes

Checking the swash time nozzles

- Unscrew the nozzles from ports X1 and X2 and check for block-
age

no
Nozzles Clean/replace the nozzles
OK?

yes

350 BOMAG 008 911 53

Machine travels to one direction only or to one travel direction 7.4

Replace the control

Travel direction
changes?

Replace/repair the travel pump

008 911 53 BOMAG 351

7.5 Hydraulic oil overheating

Hydraulic oil overheating

Check the engine cooling system

- Check the hydraulic oil cooler for dirt
- Check the engine cooling fan
- Inspect the air intake box on the cabin roof for dirt

no Clean the radiator or repair the cool-

Cooler ing system
OK?

yes

Check the high pressure limitation

- Pull the plug off the brake solenoid valve
- Start the engine
- Actuate the travel lever
- Select 2nd travel speed range
- Start the engine and run it with max. speed
- Check whether the high pressure relief valves heat up
- Repeat this test to the opposite direction.

Check the pressure setting of high pressure relief valves and

pressure override, adjust or replace as necessary
Valve no
heating up?

yes
Check the thermostat
- Run the machine up to operating temperature (hydraulic oil
temperature55°C).
- Check, whether the hose to the hydraulic oil cooler warms up
at an hydraulic oil temperature of more than 70°C or becomes
warmer than the direct hose from the thermostat to the tank

Thermostat no Replace the thermostat

OK?

352 BOMAG 008 911 53

Insufficient travel power, max speed is not reached 7.6
7.6 Insufficient travel power, max speed is not reached

Insufficient travel power, max speed is not reached

Pressure and speed test

- Run the machine warm to operating tempera- - Connect 600 bar pressure gauges high pressure sides of the
ture (approx. 50°C hydraulic oil temperature) travel pumps (pos. 1 to 4)
- Input module, enter PIN-CODE. - Connect 60 bar pressure gauges for pilot pressure (Pos.7 and 8)
- Connect 60 bar pressure gauges for charge pressure (Pos. 5
and 6)
- Start the engine, select 2nd speed range and switch to the de-
sired travel direction
- Watch the pressure gauges and accelerate the engine slowly up
to maximum speed
Nominal values:
Engine speed min. 2100 rpm; charge pressures must not drop,
min. 25 bar in idle speed, increasing to 30 bar; control chamber
pressures must increase evenly; high pressure must increase
evenly up to approx. 430 bar.

no
Perform
Rated speed
engine
OK?
trouble shooting
yes

no
Charge pres-
sure
in idle speed

yes

008 911 53 BOMAG 353

7.6 Insufficient travel power, max speed is not reached

Check the brake - Releasing the brake

- (only if pressure of left hand pump drops below 10 - Check charge pressure at idle speed
bar)
- Input module, enter PIN-CODE.

yes*
Charge pressure
OK?

no*

- * Inform the service department of

BOMAG

Check the charge pump

- Close the outlet port of the respective pump with a 200 bar
pressure relief valve
- Connect a 600 bar pressure gauge
- Crank the engine with the starter (pull the plug off the engine
shut-down solenoid)
Nominal value: 200 bar

yes
Pressure Replace
OK? charge pump

no*

354 BOMAG 008 911 53

Insufficient travel power, max speed is not reached 7.6

Check the individual components

- Disconnect the high pressure hoses from one pump
- Close the pump ports with plugs
- Repeat the pressure test
- Perform this test also on the other pump

yes Replace/repair the corresponding

Charge pres- travel motor
sure

Replace/repair the corre-

sponding travel pump

Pilot pressure no
OK?

yes

Check and adjust the DA-control valve

- Unscrew and check the DA-control valve, re-
place it if necessary
- Adjust the DA-control valve
Nominal value: 1220 rpm engine speed
150 bar high pressure
1890 rpm engine speed
390 bar high pressure
Pilot pressure evenly increasing

Pilot pressure
OK?

008 911 53 BOMAG 355

7.6 Insufficient travel power, max speed is not reached

Checking the pressure override

- Turn the adjustment screw completely in (block).
- Repeat the pressure test
Attention: Operate against high pressure relief valves
for max. 3 seconds!

Pilot pressure
OK?

Replace/repair the travel

pump

no
High pressure
OK?

yes

-
- Mechanical damage in travel motors
Checking the swash time nozzles
- Engine power too low
- Unscrew the swash time nozzles
from X1 and X2 and check them

356 BOMAG 008 911 53

Insufficient travel power, max speed is not reached 7.6

no
Nozzles Clean/replace the nozzles
OK?

yes

Check the individual components

- Disconnect the high pressure hoses from one
pump
- Close the pump ports with plugs
- Repeat the pressure test
- Perform this test also on the other pump

Replace/repair the travel pump with the too low

no pressure
High pressure
OK?

yes

Replace/repair the corresponding

travel motor

008 911 53 BOMAG 357

7.7 No steering function / steering stiff, end stops are not reached

No steering function / steering stiff, end stops are not reached

Read fault code and proceed appropriately

Check the steering/dozer blade pump
- Connect a 600 bar pressure gauge to the high pressure test
port.
- Start the diesel engine and turn the steering wheel against an
end stop
- Read the pressure gauge
Nominal value:
230 bar
Stand-by:
30 bar

yes Replace the flow

High pressure booster
OK?

Check the load signal to the steering/dozer blade pump

- Connect a 600 bar pressure gauge to pressure test port X on the
pump
- Operate the steering while the engine is running and read the
pressure gauge. Depending on the load the pressure should in-
crease up to 210 bar

LS-signal yes Replace/repair the steering/dozer blade

OK? pump

Replace/repair the valve

block

358 BOMAG 008 911 53

Failure of central lubrication system (grease emerges from re- 7.8
7.8 Failure of central lubrication system (grease emerges from relief valve)

Central lubrication system not working

(lubricant emerging from the relief valve)

Check the grease pump

- Remove the lubrication hose
- Connect a 600 bar pressure gauge
- Close the lubrication hose with a plug
- Switch the pump on and press the push button several times
Nominal value:
Raise the pressure to approx. 350 bar, grease emerging from the
relief valve

no
Pressure
OK?

yes

Check the pressure relief valve

no
valve Replace the pres-
OK? sure relief valve

yes

Replace the lubrica-

tion pump

008 911 53 BOMAG 359

7.8 Failure of central lubrication system (grease emerges from re-

Check the main distributor

- Loosen the top and bottom lubrication hoses,
- Reconnect the lubrication hose one after the other
- Connect a grease gun to the grease nipple and - The hose from which grease comes flowing out
apply a pressure of 200 bar indicates in which branch the blockage can be
found
- Reconnect the hoses

none top
Changing/cleaning the main Grease emerging
distributor

bottom

Check the sub-divider in the Check the sub-distribu-

front frame tor in the rear frame
- Generate a pressure of 200 bar - Generate a pressure of
with the grease gun and loosen 200 bar with the grease
the lubrication hoses one after gun and loosen the lubri-
the other. The hose from which cation hoses one after
grease comes flowing out indi- the other. The hose from
cates the blockage. which grease comes
flowing out indicates the
blockage.

Replace, clean no yes

Repair the respective bearing
the respective Grease emerging
location
sub-distributor

360 BOMAG 008 911 53

Trouble shooting travel system 7.9
Travel drive
7.9 Trouble shooting travel system

The following trouble shooting chart lists electrical, but also mechanical and hydraulic faults.
The specified numbers in the table indicate the probability of the fault cause and thus the recommended trouble
shooting sequence, based on our previous experience.

Machine moves with travel direction switch in neutral

Machine does not travel (forward and reverse)

Left or right hand side blocked in 1 direction

Machine travels to one direction only

Max. travel speed is not reached

Trouble shooting

Travel drive

Hydraulic oil overheating

1 wheel blocked
Symptoms

Possible cause
Emergency stop push button 1
Brake switch open/defective/wiring 1
(fault code?)
ESX-control / electrics defective/wir- 2 2 3 2
ing (fault code?)
Travel direction switch defective/wir- 1 1 3
ing (fault code?)
Travel speed range selector switch 1
position/defective/wiring (fault code?)
Pump control (electric (fault code?) / 2 1 1 2
hydraulic)
Control start / DA-valve cartridge 3 2 1
dirty/deadjusted/defective
Pressure override / high pressure re- 2 2
lief valves in travel pump dirty/dead-
justed/defective
Charge pump(s) / charge pressure re- 3 3
lief valve(s) dirty/seized/defective
Travel pump(s) defective 3 2 1 1 2
Coupling / transfer box defective 3
Control start of travel motor deadjust- 2
ed
Travel motor flushing valve stuck 3
Travel motor(s) defective 1 2
Brake (mechanical/hydraulic) 2 3 2
Planetary wheel drive defective 2
Hydraulic oil cooler soiled (internally/ 1
externally)
Thermostat (hydraulics) dirty/seized/ 3
defective
Diesel engine 1

008 911 53 BOMAG 361

7.9 Trouble shooting travel system

362 BOMAG 008 911 53

Trouble shooting working hydraulics 7.10
7.10 Trouble shooting working hydraulics

Working hydraulics
The following trouble shooting chart lists electrical, but also mechanical and hydraulic faults.
The specified numbers in the table indicate the probability of the fault cause and thus the recommended trouble
shooting sequence, based on our previous experience.

No steering function (dozer blade/bucket function OK)

Dozer blade/bucket function only to one direction

individual work functions too slow / fast / jerky

No dozer blade/bucket function (steering OK)

No steering and dozer blade/bucket function

all work functions too slow / fast / jerky

Steering function only to one side
Trouble shooting

Working hydraulics
Symptoms

Possible cause
Steering joystick defective/wiring 1 3 1 2
(fault code?)
Dozer blade/bucket control lever de- 1 3 1 2
fective/wiring (fault code?)
ESX-control defective/wiring (fault 3 3 1 2 2 1* 2
code?)
Valve block defective/spool seized/ 2 2 3 1 1 1 1
wiring (fault code?)
Steering cylinders defective 3 3 3
Dozer blade/bucket cylinder defective 3 3 3
Pressure/flow control valve out of ad- 1 2
justment/dirty/defective
Working pump(s) defective 2 3

*Control in override mode

008 911 53 BOMAG 363

7.10 Trouble shooting working hydraulics

364 BOMAG 008 911 53

8 Installed components / connection overview

008 911 53 BOMAG 365

8.1 List of installed components

BC 672/772 RB-2
8.1 List of installed components

Fig. 1
(M) Diesel engine
1 Transfer box
2 Travel pump front right
3 Travel pump rear right
4 Charge pump right
5 Travel pump front left
6 Travel pump rear left
7 Charge pump left
8 Working pump
9 Control valve block for dozer blade
10 electric steering unit
11 Steering cylinder, right
12 Steering cylinder, left
13 Dozer blade cylinder
14 Central lubrication system
15 Hydraulic return flow filter
16 Hydraulic charge oil filter
17 Engine oil filter
18 Travel motor front right with planetary gear
19 Priority valve (steering priority over dozer blade)
20 Return flow filter from transfer case
21 Fuel pre-filter
22 Fuel pre-filter

366 BOMAG 008 911 53

List of installed components 8.1
BC 772 RS-2

Fig. 2
(M) Diesel engine
1 Transfer box
2 Travel pump front right
3 Travel pump rear right
4 Charge pump right
5 Travel pump front left
6 Travel pump rear left
7 Charge pump left
8 Working pump
9 Valve block steering / bucket
10 Electric steering unit
11 Steering cylinder, right
12 Steering cylinder, left
13 Bucket tipping cylinder
14 Central lubrication system
15 Hydraulic return flow filter
16 Hydraulic charge oil filter
17 Engine oil filter
18 Travel motor front right with planetary gear
19 Dozer blade lifting cylinder
20 Return flow filter from transfer case
21 Fuel pre-filter
22 Fuel filter

008 911 53 BOMAG 367

8.2 Measuring and adjustment points on tandem travel pump unit

Measuring and adjustment points

8.2 Measuring and adjustment points on tandem travel pump unit

Fig. 3

368 BOMAG 008 911 53

Measuring and adjustment points on tandem travel pump unit 8.2

Pos. Designation Pos. in elec- Pos. in hy- Measuring value

tric wiring di- draulic dia-
agram gram
1 Port A, high pressure reverse, driven pump 08A, 11A
2 High pressure relief valves, driven pump 480 -20 bar
3 PS-line, pilot pressure supply to pressure over-
ride
4 Port A, high pressure reverse, dragged pump 09A, 12A
5 High pressure relief valves, dragged pump 480 -20 bar
6 Port B, high pressure forward, dragged pump
7 Plug T2, dragged pump T2
8 Port B, high pressure forward, driven pump B
9 Plug T2, driven pump T2
10 Plug a, solenoid valve forward Y 16 a 0 / 24V
11 Port T1, leak oil to return flow filter, driven pump, T1
with magnetic plug
12 Test port X1, control chamber pressure reverse M6, M16, X1 0 - 14 bar, **)
13 Port T1, leak oil to return flow filter, dragged T1
pump, with magnetic plug
14 Test port G, charge pressure M7, M17, G3 0 ± 2 bar in high idle
speed***)
15 Test port X2, control chamber pressure forward M5, M15, X2 0 - 14 bar **)
16 Port S, charge pressure from hydraulic oil filter
17 Plug b, solenoid valve reverse Y 17 b 0 / 24V
18 Charge pressure relief valve, driven pump 30 ± 2 bar in high idle
speed***)
19 DA-control valve *)
20 Pressure override, driven pump 430 +10/-20 bar
21 Test port MB, high pressure forward, driven M2, M12, MB 430 +10/-20 bar
pump
22 Charge pressure relief valve, dragged pump 30 ± 2 bar in high idle
speed***)
23 Pressure override, dragged pump 430 +10/-20 bar
24 Test port MB, high pressure forward, dragged M4, M14, MB 430 +10/-20 bar
pump
25 Port S1, suction connection charge pump from
tank
26 Port P, charge pump pressure port to filter
27 Test port MA, high pressure reverse, dragged M3, M13, MA 430 +10/-20 bar
pump
28 Test port MA, high pressure reverse, driven M1, M11, MA 430 +10/-20 bar
pump

), ), ); see adjustment instructions

008 911 53 BOMAG 369

8.3 Connection overview

Fig. 1 16 By-pass filter element

1 Port L, leak oil to return flow filter 17 Leak oil port from travel pump, front left
2 Port X, load signal to control valve block 18 Magnetic plug, wheel motor, rear right
3 Setscrew for flow control valve (88 l/min) 19 Leak oil port, wheel motor, rear right
4 Setscrew for pressure control valve (230 bar) 20 Leak oil port, wheel motor, rear left
5 Port S, suction line from tank 21 Leak oil port, steering/working pump
6 Test port for stand-by pressure, 18 bar; high pres- 22 Magnetic plug, steering/working pump
sure 200 bar
23 Leak oil port, wheel motor, front left
7 Port B, high pressure
24 Leak oil port, wheel motor, front right
8
25 Magnetic plug, wheel motor, front right
9
26 Leak oil port from travel pump, rear left
10
27 Non-return valve (3 bar), to tank
11
28 Connection to cooler
12
29 Thermostat (55°C...70°C)
13
30 Connection to tank
14
31 Connection from solenoid valve for brake/travel
15 Active filter element direction selector

370 BOMAG 008 911 53

Connection overview 8.3
32 Test port for case pressure 42 Plug, travel range selector
33 Pressure switch (3 bar), normally open 43 Plug, brake
34 Contamination sensor 44 Charge pressure switch (5 bar), right hand tan-
35 Magnetic plug, wheel motor, rear left dem pump, normally closed
36 Magnetic plug, wheel motor, rear right 45 Connection from left hand charge pump
37 Leak oil port from travel pump, rear right 46 Charge pressure switch (5 bar), left hand tandem
pump, normally closed
38 Leak oil port from travel pump, front right
47 Filter outlet, to the charge oil supply port on left
39 Filter outlet, to solenoid valve
hand tandem pump
40 Pressure switch, filter contamination indicator (2.5
48 Port X, pilot pressure
bar)
49 Port G, synchronous control
41 Pilot pressure connection, travel range selector
50 Port T, leak oil

008 911 53 BOMAG 371

8.4 Measuring and adjustment points on control valve block

Measuring and adjustment points

8.4 Measuring and adjustment points on control valve block

Fig. 2 Control valve block

372 BOMAG 008 911 53

Measuring and adjustment points on control valve block 8.4

Pos. Designation Pos. ii electric wir- Pos. in hydraulic Measuring

ing diagram diagram value
1 Proportional solenoid, steering right Y92 0 - 1000 mA
1a Proportional solenoid, steering left Y93 0 - 1000 mA
2 Switching solenoid, float position Y102 0 / 24V
2a 2. Switching solenoid, float position Y102 0 / 24V
3 Proportional solenoid, blade down Y109 0 - 1000 mA
3a Proportional solenoid, blade up (on opposite Y108 0 - 1000 mA
side)
4 Pressure test port, pilot pressure steering left Ma 20 -30 bar
4a Proportional solenoid, pilot pressure steering Mb 20 -30 bar
right (on opposite side)
5 Pressure test port, pilot pressure blade up Ma 10 -30 bar
5a Proportional solenoid, pilot pressure blade Mb 10 -30 bar
down (on opposite side)
6 Pressure test port, tank pre-tensioning valve Mt 10 -15 bar
7 Pressure test port, working pressure Mp 0 -230 +10
bar
8 LS-pressure limitation 0-210 + 10
bar
9 Tank pre-loading valve 15 bar (dozer
blade in top
position, drop
with floating
position)
10 Pressure test port, steering left M18 0 -230 +10
bar
11 Pressure test port, steering right M19 0 -230 +10
bar
12 Pressure test port, blade down M31 0 -230 +10
bar
13 Pressure test port, blade up M32 0 -230 +10
bar
14 mechanical endstop
15 Shock valve 260 bar

008 911 53 BOMAG 373

8.4 Measuring and adjustment points on control valve block

374 BOMAG 008 911 53

9 Air conditioning system

008 911 53 BOMAG 375

9.1 Physical basics

9.1 Physical basics A - heat absorption

In order to understand the working principle of an air B- Heat dissipation

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.

1. gaseous (invisible)

2. vaporous

3. liquid

4. solid

Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.

Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.

376 BOMAG 008 911 53

Physical basics 9.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.

Fig. 4 Pressure - Temperature Diagram

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

008 911 53 BOMAG 377

9.1 Physical basics

Excerpt from the wet steam table 1 R134a

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

378 BOMAG 008 911 53

Refrigerant R134a 9.2
9.2 Refrigerant R134a Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
General lowing trade marks.
The evaporation and condensation process is the H-FKW 134a
method commonly used in mobile air conditioning sys- SUVA 134a
tems. The system in this case works with a substance KLEA 134a
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and Colour:
under a steam pressure of 1 bar. Refrigerant in form of vapour or liquid is colourless as
Although the refrigerant circuit is a hermetically closed water. The gas is invisible. Only the bordering layer
loop, the system loses approx. 100g of refrigerant between gas and liquid is visible. (Fluid level in rising
over the course of 1 year by diffusion through hoses, pipe of filling cylinder or bubbles in inspection glass).
pipes and seals, even though the system is free of In the inspection glass the liquid refrigerant R134a
leaks. If too much refrigerant is lost the cooling power may appear coloured (milky). This turbidity results
of the system will drop. from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Physical data of the refrigerant R134a

Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous
CH2F-CF3 or CF3-CH2F refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
Chemical designation: sure and is frequently referred to as steam pressure.
Tetrafluoroethane The steam pressure is independent from the temper-
ature.

Boiling point at 1 bar:

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
-101.6 °C
ation oils, e.g. PAG-oils (polyalkylene glycol oils).

Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.

Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the

008 911 53 BOMAG 379

9.3 Compressor oil / refrigeration oil

liquid container has absorbed approx. 8 gr. of water, 9.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.

380 BOMAG 008 911 53

Working principle of the air conditioning system 9.4
9.4 Working principle of the air 9.5 Monitoring devices
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating
The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because
for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu-
tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig-
pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.

008 911 53 BOMAG 381

9.5 Monitoring devices

Monitoring chain

Fig. 2 Monitoring chain consisting of:

l 1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact
l 5 High pressure switch contact
l
6 Relay
l
7 Connection for magnetic clutch
l
8 Pressure switch

382 BOMAG 008 911 53

Description of components 9.6
9.6 Description of components

Compressor

Fig. 1 Refrigerant compressor Oil: PAG SP-20 (H14-003-404)

The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
the function of the system. Coupling and decoupling is
accomplished by an electromagnetically controlled
mechanical clutch (Y15), which is integrated in the V-
belt pulley of the compressor.
The refrigerant compressor is a 7-cylinder compres-
sor in swash plate design.
The gaseous refrigerant enters into the compressor
through the cylinder heads at the end of the compres-
sor and is delivered to the condensers in desnified
state.
The oil sump of the compressor is filled with refrigera-
tion oil up to level of the filler and level inspection bore.
An internal gear pump at the end of the drive shaft de-
livers this oil to the bearing locations inside the com-
pressor for lubrication.

Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr

008 911 53 BOMAG 383

9.6 Description of components

Fig. 2 Compressor mounting, bottom view

Pos. Designation Pos. ii electric wiring diagram Measuring value

1 Pressure side filling
port
2 Suction side filling
port
3 Plug connection X14 0-24 Volt
4 Magnetic clutch Y15 24 Volt, 1.75 Amp.

The service valves are installed directly on the com- oil lost by exchanging the components, must be
pressor. These are used to e.g. evacuate and fill the replaced with fresh oil.
system. The actual quantity depends on the amount of oil
Two manual shut-off valves are also installed here. that may have been lost in connection with the
These valves can be used e.g. in case of a compres- possible replacement of other components.
sor failure. The compressor can be replaced after
closing the valves. After completion of all repair work
Environment
the valves must be reopened, so that the system is
ready for operation without the need of refilling. Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.

! Caution The following table shows how much compressor oil /

refrigeration oil will be lost in connection with various
The compressor oil level must be checked after
types of work on the air conditioning system.
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration

384 BOMAG 008 911 53

Description of components 9.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve

! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1 Condensers
To avoid excessive oil in the A/C-system and thus The 2 condensers are mounted on a foldable frame in
a poor cooling effect, the oil level in the A/C-sys- front of the combustion air intake opening on the
tem must be adjusted accordingly. ROPS. They dissipate heat energy from the system
The quantity depends on the amount of oil that into the surrounding air and liquefiy the gaseous re-
may have been lost in connection with the possi- frigerant.
ble replacement of other components.
The compressor oil quantity must be 10% of the i Note
refrigerant quantity in the complete system. The fins must be free of dirt and damage.
With a refrigerant filling of 1100 gr. the system re-
quires a compressor oil / refrigerant oil filling of ! Caution
100 gr.
When replacing a heat exchanger, e.g. evaporator
Procedure: or condenser, any compressor oil lost by ex-
Drain and measure the compressor oil from the changing the components, must be replaced with
old compressor. fresh oil.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.

i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.

008 911 53 BOMAG 385

9.6 Description of components

Dryer / filter / fluid container / inspection Safety valve

glass

Fig. 2

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

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

Installation position: However, incorrect evacuation or filling may also be

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

386 BOMAG 008 911 53

Description of components 9.6
i Note Pressure switch
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.

! Danger Fig. 1
In case of mechanical damage or corrosion on After a minimum pressure is reached in the low pres-
this pressure container this collector unit must be sure side or a maximum pressure in the high pressure
replaced, to avoid bursting and further damage. side, the pressure switch (B75) will switch of the mag-
netic clutch of the compressor, thus to avoid destruc-
tion of system components by excessive pressure or
drawing in external gases and foreign matter as a re-
sult of too low pressure.
Working pressure:
Low pressure off: 1,5 ±0,5 bar
Low pressure on: 3.5 bar
Overpressure off: 25,0 ±1,5 bar
Overpressure on: 18,0 ±1,5 bar

008 911 53 BOMAG 387

9.6 Description of components

Expansion valve Evaporator

Fig. 1 Expansion valve Fig. 1 Evaporator

The expansion valve (1) is located inside the cab on The evaporator is located inside the cab in the blower
the blower box. The expansion valve always allows a box. It consists of a heat exchanger (inside air - refrig-
small amount of the high pressure liquefied refrigerant erant), with refrigerant flowing to a pipe system with
to flow into the evaporator, which has a much lower cooling flanges.
pressure. This lower pressure causes these liquid re- As with the condenser, correct operation of all fans
frigerant to expand and to evaporate to gaseous state. and cleanliness of the fins must be assured.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup- Air conditioning systems have a circulation air filter
plied to the refrigerant. This is the so-called cooling mounted in the air flow in front of the evaporator,
effect. which should be cleaned or changed by the operator,
depending on the amount of dirt.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.

i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in- Fig. 2 Changing the circulation air filter
let.+ l
Remove the slotted cover from the console behind
the driver’s seat.
l Remove both circulation air filters and insert the
new circulation air filters (Fig. 2) .
l Fasten the slotted cover to the console.
A condensation water filter is mounted in the air flow
after the evaporator. This filter has the function to col-
lect the water that has condensed from the air in the
evaporator block and to discharge this water into the
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.

388 BOMAG 008 911 53

Description of components 9.6
! Caution Defroster thermostat
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.

Fig. 1 Defroster thermostat

The feeler of a defroster thermostat (B117) to switch
off the magnetic clutch in case of icing up or to switch
the clutch back on after defrosting, is mounted on the
evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
should be checked during maintenance.
Switching point on: + 1°C (± 1°C)
Switching point off: + 5,5°C (± 1°C)

i Note
It is very important that the feeler is mounted down-
stream of the evaporator, but before the pressure sen-
sor, in countercurrent direction, with full length and
insulated against the outside temperature.

008 911 53 BOMAG 389

9.6 Description of components

Blower with rotary speed module Solenoid valve, heating

The heating valve (Y138) is a black/white valve and is
opened by the Climatronic control with 24V. When the
voltage supply is switched off, the applied water pres-
sure will close the valve as a pilot controlled valve. It
is thus very important to maintain the prescribed flow
direction (arrow on housing).

Fig. 1 Radial twin blower

The radial twin blower (E37) draws in air from inside
the cabin through the circulation air filter. The drawn in
air is cooled down in the evaporator fins and guided
through air ducts and nozzles back into the cabin.
The rotary speed module (blower module, A53) is Fig. 2
mounted on the blower housing. This module serves
Intended intermediate positions are realized via tem-
the purpose of converting the PWM current signals
poral cycling. The length of the total interval is approx.
from the Climatronic control into corresponding volt-
10 seconds. The temporal proportion of "open" is be-
age signals for the blower motor. The fan voltage
tween 30-100%.
complies with the fan speed shown in the display.

Fig. 3 Solenoid valve for heating Y138

390 BOMAG 008 911 53

Description of components 9.6
Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.

Recommended tightening torques for O-ring

sealed fittings

Thread Spanner width Torque

5/8“ 17 or 19 13,6 - 20,3 Nm
3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
1 1/16“ 32 40,7 - 47,5 Nm
M30X2 36 105,0 - 115,0 Nm
M36X2 41 165,0 - 175,0 Nm
Bending radii for air conditioning hoses

Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW10 min. 65 mm
GH 134 NW12 min. 75 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

008 911 53 BOMAG 391

9.7 Climatronic control

The Climatronic control is integrated in the housing of
the control unit.

Fig. 3 Sensors
The two sensors are technically identical, they only
differ by their colour identification:
Room temperature sensor (B29): blue colour mark,
Fig. 1 Front view of Climatronic control
Blow out temperature sensor (B119): yellow colour
mark.
These sensors are NTC-elements, i.e. the electric re-
sistance drops with increasing temperature.

Designation Measuring value

Blow out tempera- B118 55kΩ at -10°C
ture sensor 32kΩ at 0°C
19kΩ at +10°C
Fig. 2 Backside with connection terminal
12kΩ at +20°C
When the ignition is switched on the Climatronic con-
10kΩ at +25°C
trol is supplied with vehicle voltage via terminal X26:1
Room temperature B29 55kΩ at -10°C
and can be switched on.
sensor 32kΩ at 0°C
As long as the engine is not running, no signal is ap-
plied to terminal X26:4 on the control. After a period of 19kΩ at +10°C
10 minutes without the engine running the Climatronic 12kΩ at +20°C
limits the blower speed to 30% to prevent unneces-
10kΩ at +25°C
sary discharging of the battery.
In automatic mode the control regulates the cabin
temperature. This is accomplished with the help of the
two sensors:
l Room temperature sensor B29 (Fig. 3) under the
circulation filters.
l
Blow out temperature sensor B118 (Fig. 3).
The two sensor signals are fault monitored, i.e. in
case of cable breakage, short circuit or disconnected
sensors a fault will be displayed and the Climatronic
will be out of servise.
The digital output signals for:
l the magnetic clutch of the compressor (Y15) and
l the solenoid valve for heating (Y138)
as well as the analog PWM-signal
l for the blower speed module
are generated from the sensor signals.

392 BOMAG 008 911 53

Climatronic control 9.7
Various functions of control logic
This point deals with special control steps, which are
not self explanatory, and with technical backgrounds
of Climatronic functions, which are worth knowing.

Automatic operation

Fig. 4
(LED under the hand 7 (Fig. 4) off, nominal tempera-
ture in display). In this position the Climatronic control
regulates the blower speed in dependence on the
temperature difference between nominal and actual
room temperature. Furthermore, heating valve and
compressor clutch (only in air conditioning operation)
are automatically switched on or off as required, in or-
der to achieve the desired room temperature. If the
engine is still cold while heating is required, the control
recognizes this fact by the blow out temperature on
the heater box; the control will then limit the blower
speed until the engine is warm, thus preventing that
too much cold air is blown into the cabin.

Fig. 5
Air conditioning operation: In order to achieve a
cooling effect, the compressor outlet of the control
must be manually released also in automatic opera-
tion by pressing button 3 (Fig. 5). (LED below crystal
(5) on!). The compressor outlet is in this case not per-
manently supplied with current (except REHEAT op-
eration), but only when the control supplies the output
(X26:8) due to the difference between nominal and
actual temperature. The compressor can only start
running when the thermostat (B117) and the pressure
switch (B75) are closed.

008 911 53 BOMAG 393

9.7 Climatronic control

Manual operation of heating Manual blower speed setting

Fig. 6 Fig. 7

The automatic control of the heating valve can be Automatic blower speed control can be disabled with
switched off with push button 12 (Fig. 6) (manual heat- button 10 (Fig. 7) (LED below hand (7) lights), temper-
er operation, the display shows ’H’ and the LED below ature is still displayed). However, the temperature
the hand lights). The automatic blower control is control remains active as long as air conditioning op-
switched off at the same time. In manual heater oper- eration and heater operation remain switched on. In
ation the heating valve is set to a opening interval as this operating mode the +/- buttons are used to set the
shown in the bar graph (13), which can be changed blower speed manually.
with the +/- buttons (2,4). The number of displayed
bars indicates the opening time in percent (e.g.
4 bars = 40%: approx. 4 seconds valve energized/
open, approx. 6 seconds valve dead/closed etc).
When operating the blower button (10) the ’H’ will dis-
appear in the display, the nominal temperature will ap-
pear, the LED below the hand stays on (as with
manual blower speed setting, see below), however,
the manual heating operation remains active. Manual
heater operation can only be switched over to auto-
matic heater operation by pressing the button (12)
again. In manual heater operation the compressor
control remains active, i.e. in summer the system will
continue to try to achieve the nominal temperature.

394 BOMAG 008 911 53

Climatronic control 9.7
REHEAT function (dehumidification function) Circulation air operation

Fig. 8 Fig. 9
When pressing button 11 (Fig. 8), the blower is fixed Button 9 (Fig. 9) can theoretically be used to toggle
to maximum speed and the compressor output is per- between circulation and fresh air operation, the button
manently switched (however, the compressor is is - except the LED display - ineffective, the machines
switched off by the thermostat if there is a risk of the are only prepared for this function electrically, but not
evaporator icing up). The display shows ’rH’. Howev- the air guidance.
er, the heater control function remains active in order
to maintain the previously set nominal temperature, if
this should be necessary. The REHEAT function is
mainyl used to dehumidify the cabin (steamed up win-
dows).

008 911 53 BOMAG 395

9.7 Climatronic control

Error messages Faulty blow out temperature sensor

Faulty room temperature sensor

Fig. 11
’F1’ flashes in the display. The Climatronic is unable
Fig. 10
to work without the blow out temperature value and is
’F0’ flashes in display. The Climatronic is unable to therefore out of function when this error message is
work without the actual temperature value and is displayed. The Climatronic is only operable again af-
therefore out of function when this error message is ter this fault (cable breakage, short circuit, sensor not
displayed. The Climatronic is only operable again af- connected) has been rectified.
ter this fault (cable breakage, short circuit, sensor not
connected) has been rectified.

396 BOMAG 008 911 53

Measuring the compressor oil level 9.8
9.8 Measuring the compressor oil 9.9 Checking the magnetic clutch
level l Measure the voltage.

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

Fig. 1

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

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

Fig. 2 Measuring the air gap

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

008 911 53 BOMAG 397

9.10 Inspection and maintenance work

i Note 9.10 Inspection and maintenance

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

398 BOMAG 008 911 53

Servicing the air conditioning 9.11
9.11 Servicing the air conditioning Checking the refrigerant level
l
Start the engine.
The air conditioning unit is attached to the ROPS
and can be access from outside for service work.

! Caution
Under very dusty conditions clean every day in or-
der to maintain the cooling power of the air condi-
tioning system.

Danger
!

Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Fig. 6

Clean the condenser

l Switching on the control unit (Fig. 6).

Fig. 7
Fig. 4
l
Start operation of the air conditioning (Fig. 7).
l
Fold the air intake grid (Fig. 4) back.

Fig. 8
Fig. 5
l Open the air outlet nozzles (Fig. 8).
l Clean the condenser fins on front and back with
compressed air or cold water (Fig. 5). l Check, whether the out flowing air is noticeably
cooler.

!Caution
During cleaning work do not damage the cooling i Note
fins and realign bent fins. The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.

008 911 53 BOMAG 399

9.11 Servicing the air conditioning

Checking the moisture level of the drying

agent

Fig. 9
l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top. Fig. 11
l Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
i Note
The refrigerant level is correct. orange = Drying agent o.k.
colourless= moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.

Caution
!

Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

Fig. 10 !Caution
l
If the white float (Fig. 10) inside the inspection glass According to the regulation for pressure reser-
of the drier/collector unit floats at the bottom, inform voirs all pressure reservoirs must be repeatedly
the service department. inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
i Note
with this inspection the drier/collector unit must
The refrigerant level is not correct.
be visually examined twice every year. During
l Refrigerant must be filled up, if necessary check the these inspections special attention must be paid
air conditioning system for leaks. to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.

! Danger

Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.

400 BOMAG 008 911 53

Check condition and tension of refrigerant compressor V-belt, 9.12
9.12 Check condition and tension
of refrigerant compressor V-
belt, replace the V-belt

Danger
!

Danger of injury!
Work on the V-belt must only be performed with
the engine shut down.

Checking the V-belt

Fig. 12
l Check the drier/collector unit (Fig. 12) for mechani-
cal damage or rust.

Fig. 13
l
Inspect the entire circumference of the V-belt (Fig.
13) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l
Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.

Retightening the V-belt

Fig. 14
l Slacken the bearing screw 2 (Fig. 14) for the com-
pressor bracket.
l Slightly loosen the hexagon screw (1) on the slot for
the compressor bracket.
l Loosen the counter nut (3).

008 911 53 BOMAG 401

9.13 Drying and evacuation

l Turn down tensioning screw (4) in direction of ar- 9.13 Drying and evacuation
row, until the correct V-belt tension is reached.
Evacuation of air conditioning systems using R-type
l Retighten screws and counter nut.
refrigerants not only has the purpose of emptying the
system of all air before filling in refrigerant, but also to
Changing the V-belt verify the leak tightness over a longer lifetime in the
achieved vacuum. However, the most important factor
in this work step is the drying of the system.
Any water residues in the refrigerant circuit will com-
bine with the refrigerant, which will lead to the previ-
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration
system.
The refrigerant compressor is not suitable for the pur-
pose of evacuation, because it is not able to achieve
a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
Fig. 15 tion when running empty during evacuation.
l Remove the V-belt of the fan drive. It is common practice to evacuate the refrigeration
l Slacken the bearing screw 2 (Fig. 15) for the com- system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
pressor bracket. An exact time for evacuation and drying cannot be
l Slightly loosen the hexagon screw (1) on the slot for predicted. It can only be determined by means of a
the compressor bracket. vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
l Loosen the counter nut (3). than 1 hour too less.
l Turn tensioning screw (4) in direction of arrow to the
Function drying:
stop.
Under normal ambient pressure (1.013 mbar) evapo-
l Take the old V-belt off the V-belt pulley.
rates absolute at 100° C. If the pressure is reduced,
l Fit the new V-belt to the V-belt pulleys. water will already evaporate, e.g. under a pressure of
l Tension the V-belt as previously described. 10 mbar, at an ambient temperature of almost 7°C,
but the water will not evaporate all at once. Since it is
l
Reinstall and tension the fan drive V-belt. very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
i Note the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
Retighten new V-belts after a running time of 15 min-
dried nitrogen absorbs the moisture in the refrigerant
utes.
circuit, which can then be easily discharged together
with the nitrogen.

402 BOMAG 008 911 53

Emptying in case of repair 9.14
9.14 Emptying in case of repair 9.15 Leak test
For repair work the air conditioning systems must very
often be emptied of all refrigerant. ! Caution
Especially with expensive refrigerants and larger The use of leak detection colouring matter is not
amounts of oil it may be necessary to keep the refrig- permitted, because its chemical composition is
erant for later use. unknown and its effect on compressor oil and rub-
For later use these refrigerants must be drawn out ber elements is not predictable. The use of leak
with suitable equipment and intermediately stored in detection colouring matter makes any warranty
collecting containers. claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
Environment
er valve (approx. 22 bar). After this all connections in
Contaminated refrigerant must be disposed of en- the air conditioning system are checked with the help
vironmentally of a suitable leak detection spray. A leak is thereby in-
Releasing refrigerant into the atmosphere is pro- dicated by means of foam bubbles.
hibited (see restrictive injunction concerning A leak test is required if a pressure drop is noticed.
CFC, day of enforcement 01. 08. 1991, § 8)
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
! Danger
Leak test with electronic leak tester
For draining refrigeration systems you should not
simply use any delivery containers, but only ap-
propriate pressure bottles, which must be special-
ly marked and should comply with the pressure
gas directive.
When transferring refrigerant you must make sure
Fig. 1 Electronic leak tester
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suf- Small leaks with only very low amounts of refrigerant
ficient gas space for expansion (filling factor: 0,7). escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
In order to reduce the evacuation period in case of than 5 gr. per year.
short repairs, you may fill the refrigerant circuit with
approx. 0.5 bar nitrogen when opening. This ensures The leak tester used must be specially designed for
that nitrogen will flow out of the refrigerant circuit while the refrigerant composition in the air conditioning sys-
it is open and no air or moisture can enter. However, tem. For example, leak detectors for refrigerant R12
the necessity for vacuum generation and a dryer are not suitable for R134a, because the refrigerant
change remains. R134a is free of chlorine atoms, meaning that this leak
detector will not respond.

Leak test with soap bubbles

Fig. 2 Soap bubble test

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.

008 911 53 BOMAG 403

9.16 Filling instructions

Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).

! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.

i Note
White frost on the suction line is no measure for as-
sessing the filling.

404 BOMAG 008 911 53

Filling instructions 9.16

Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge

008 911 53 BOMAG 405

9.16 Filling instructions

19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.

406 BOMAG 008 911 53

Trouble shooting in refrigerant circuit, basic principles 9.17
9.17 Trouble shooting in refriger-
ant circuit, basic principles

Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l technical equipment

Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
l
Service station
Filling the system with refrigerant causes an excess
l
Pressure gauge pressure of Pe = 3 bar.
l
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
l
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
l
Container for old oil
l
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Hoses
l Scales
l Suction station
l Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.

Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.

Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)

008 911 53 BOMAG 407

9.17 Trouble shooting in refrigerant circuit, basic principles

Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.

Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
Δ to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature. Δ to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.

Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause

408 BOMAG 008 911 53

Trouble shooting in refrigerant circuit, basic principles 9.17
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.

Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.

Supercooling is calculated as follows:

Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"

008 911 53 BOMAG 409

9.17 Trouble shooting in refrigerant circuit, basic principles

Fig. 1 Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion

410 BOMAG 008 911 53

Trouble shooting, refrigerant circuit diagram 9.18
9.18 Trouble shooting, refrigerant
circuit diagram

Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air

008 911 53 BOMAG 411

9.19 Trouble shooting procedure

9.19 Trouble shooting procedure l Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
l Ambient temperature above 15 °C.
about the system design, the installed components l The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:

Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.

i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.

Test prerequisites
l Cooler and condenser are clean, clean if neces-
sary.
l The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.

412 BOMAG 008 911 53

Trouble shooting procedure 9.19
Measuring points and measurements

Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
l C, condenser measuring points tainer the inspection glass is most suitable to check
l E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
l O, evaporator measuring points
The hot gas temperature can be used to check wheth-
l V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
l a) Which measuring equipment is required?
can be used to derive the overheating of the evapora- l b) Where to measure with which size?
tor. Overheating is a clear indicator for the evaporator l c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is l
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- l e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „Δto2h“ ?
Pressure and temperature at the condenser outlet can l
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used

008 911 53 BOMAG 413

9.19 Trouble shooting procedure

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

l a) Pressure gauge, thermometer, steam table oil recirculation.
l b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
l c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
l
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
l e) Δto2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required?
l
b) Where to measure with which size?
l
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
l
f) Evaluation of the measured supercooling.

Solution:
l
a) Pressure gauge, thermometer, steam table
l
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
l e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.

Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also

414 BOMAG 008 911 53

Trouble shooting procedure 9.19
Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X

008 911 53 BOMAG 415

9.19 Trouble shooting procedure

Suction pressure too low (1), high pressure too

low to normal (2)

Fig. 3

Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently

416 BOMAG 008 911 53

Trouble shooting procedure 9.19
Suction pressure normal (1), high pressure too
high (2)

Fig. 4

Cause Possible effect Remedy

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power

008 911 53 BOMAG 417

9.19 Trouble shooting procedure

Suction pressure too high (1), high pressure too

low to normal (2)

Fig. 5

Cause Possible effect Remedy

Compressor defective Cooling power too low Replace the compressor

418 BOMAG 008 911 53

Trouble shooting procedure 9.19
Suction pressure too high (1), high pressure too
high (2)

Fig. 6

Cause Possible effect Remedy

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

008 911 53 BOMAG 419

9.19 Trouble shooting procedure

Other faults

Symptom Cause Possible effect Remedy

Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil
high, the hot gas line be- wear
comes so hot that it cannot
be touched long with a
hand
Compressor does not start Pressure switch or any oth- System stopped Check the control units,
er safety feature has trig- check cause for switching
gered, electrical fault, and rectify
cylinder filled with liquid re-
frigerant
Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units,
tinuously small, triggering of a creased wear, too low cool- check cause for switching
switching element (over- ing power and rectify
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating Expansion valve deadjust- low cooling power, hot gas Replace the expansion
ed or screen blocked, lack temperatures too high valve, clean the screen, fill
of refrigerant in refrigerant, leak test
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator sion valve, lack of refriger- into the evaporator valve, check the refrigerant
ant filling
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost flow volume tem check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure
shows condensation filter dryer clogged drop, replace the filter dryer
Exceptionally cold pres- "Wet intake" of the com- low cooling power, exces- Clean the compressor, re-
sure lines pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator the expansion valve if nec-
essary

Noise in system

Faults Possible cause Remedy

V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Refrigerant compressor is loud Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Fan is loud, fan motor excessively Replace the fan motor
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn Replace the bearing, check V-belt
tion, noticeable unevenness when pulley for wear
turning by hand
Rattling noise or vibration of high System overfilled Draw out refrigerant
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, refrigerant level in system too low Perform a leak test, fill up the system
on expansion valve, turbidity in in-
spection glass or ball does not float

420 BOMAG 008 911 53

Trouble shooting procedure 9.19
Inspection glass

Faults Possible cause Remedy

008 911 53 BOMAG 427

10.1 System layout

The sanitary landfill compactors are equipped with an
automatically working central lubrication system.

Fig. 1 Lubrication system RB machine

Fig. 2 Lubrication system RS machine 6 Main distributor in rear frame

1 Ignition switch 7 Piston detector, monitors and ends duty cycle
2 Fuse F16 8 Sub-distributor in front frame
3 Push button with control light
4 Lubrication pump with integrated control
5 Main distributor

428 BOMAG 008 911 53

Technical description 10.2
10.2 Technical description New version

The system is equipped with an electronic control and

a monitoring device for the function of the lubricant
distributor. The electronic control is integrated in the
pump case and controls the lubrication cycle automat-
ically.
When switching the ignition on, the automatic lubrica-
tion system is supplied with voltage via fuse (F16) At
the same time the system performs a function test for
drive motor and control light.
During this function test the motor is activates for 1
seconds (short movement of stirring blade), at the
same time a 2 second voltage pulse is sent to the
monitoring board.

Control lights for central lubrication system

The control light 11 (Fig. 3) or (m) (Fig. 4) informs
about the operating status of the central lubrication
system.
Faults are indicated by flashing frequencies of differ-
ent lengths. Fig. 4 Monitoring module, new design
m yellow = lights during the lubrication process and
Old design
flashes in case of functional disturbanc-
es.

i Note
The control light indicates the same operating states
as the function display (Fig. 5) on the control board.

Fig. 3 Monitoring module, old design

11 yellow= lights during the lubrication process and
flashes in case of functional disturbanc-
es.

Fig. 5 Function display on control board

008 911 53 BOMAG 429

10.2 Technical description

Function control
i Note
The fault can also be acknowledge or reset by trigger-
ing an additional lubrication cycle by pressing push
button 4 (Fig. 8) on the control board.

Fig. 6 Push button

To check the function of the system you can perform
a test run. For this purpose press the push button (Fig.
6) longer than 2 seconds after switching the ignition
on. This triggers a normal lubrication cycle.
Start an additional lu-
brication cycle. = Press the push button longer than
2 seconds (> 2 s). Fig. 8 Control board
Short pressing of button acknowledges the fault sig-
nal, i.e the flashing control lamp changes to a perma-
nent light.
Acknowledging a
fault = Press the push button for short
moment (< 1 s).

i Note
An acknowledged fault also remains stored after
switching off the ignition. When switching on again the
control lamp flashes again, according to the respec-
tive fault.

Fig. 7 Operating states

A = Fault indicator
B = Function display or acknowledged fault
in case of a fault= Switch the pump on again by
pressing the button (> 2 s).

430 BOMAG 008 911 53

Control 10.3
10.3 Control Intermittent flashing signal (Fig. 11)

Control board
The control board is integrated in the pump housing.

Fig. 11 Jumper B/D plugged on

Voltage supply (Fig. 12)

Fig. 9 Control board installed in the housing

Fig. 12 Jumper 15/30 plugged on

With jumper 39/15 plugged on the connections 15 and
30 are bridged within the control board.
Fig. 10 Control board

008 911 53 BOMAG 431

10.3 Control

Function display Pause time P (Fig. 15)

Fig. 15 Sequence of a lubrication cycle

A Monitoring of motor and control light

Fig. 13 Function display on circuit board
B Sequence of time
C Sequence of monitoring time
i Note I Duty cycle
The function display indicates the same operating P Pause
states as the control light in the LCD group display.
The pause time P(Fig. 15)
l The control board (Fig. 13) automatically controls l determines the frequency of lubrication cycles with-
the sequence of pause and work cycles for the cen-
in the time of use
tral lubrication pump, in dependence on the operat-
ing hours of the machine. l is started and stopped with the ignition switch
l can be changed
When switching the ignition off, all pause times that
have expired as well as the present operating states
(faults) are saved and added up. This takes place, un-
til the time set by the blue rotary switch (Fig. 20) has
been reached.
When switching the ignition back on, the control will
start exactly at the same point where it stopped before
the ignition was switched off.

Fig. 14 Time diagram

tB Operating hours
tP individual pause times
T Lubrication cycle
T1 saved pause times
T2 Duty times
l The lubrication cycle consists of a pause and a duty
time. The duty time starts after the pause time has
finished. After the machine has been started, the lu-
brication cycle will continue repeating itself.
l
During the duty time the pump element delivers lu-
bricant through the progressive distributors to the
lubrication points.

432 BOMAG 008 911 53

Control 10.3
Duty cycle I (Fig. 16) Monitoring time C (Fig. 18)

Fig. 16 Sequence of a lubrication cycle Fig. 18 Sequence of a lubrication cycle

A Monitoring of motor and control light A Monitoring of motor and control light
B Sequence of time B Sequence of time
C Sequence of monitoring time C Sequence of monitoring time
I Duty cycle I Duty cycle
P Pause P Pause

The duty cycle A(Fig. 16) is approx. 45 seconds. It de- A fixed monitoring time of max. 5 or 30 minutes (de-
pends on the grease used for lubrication and the op- pending on jumper setting) runs parallel to the duty
erating temperature. It is monitored by a piston time (Fig. 19).
detector mounted to the sub-distributor. The piston
detector (initiator, B52 (Fig. 17)) terminates the duty
time after all pistons in the sub-distributors have eject-
ed their quantity of grease. The duty cycle is indicated
by the control light in the cabin lighting up.

Fig. 19 Jumper for monitoring ranges

1 - Jumper for monitoring time, 5 minutes (5min) or 30
minutes (30min).
Fig. 17 Piston detector, B52 2 - Jumper for 1st lubrication circuit (1 O) or for 2nd lu-
brication circuit (2 O).
If the duty time is interrupted by switching of the igni-
tion switch, it will be eresrated from the beginning
when switched on again. i Note
The monitoring time normally ends with the end of the
duty time.
l If no shut-down signal from the piston detector (ini-
tiator, B52) is received by the control board within 5
or 30 minutes, a fault message will be displayed.

008 911 53 BOMAG 433

10.3 Control

Time setting
i Note
The indicator lamp will flash with the corresponding
frequency and the pump will stop.
l
If the work cycle takes longer than 5 minutes, the
monitoring time must be changed from 5 minutes (5
min) to 30 minutes (30 min) by simply replugging
the jumper,
l
If two monitored lubrication circuits are available,
the jumper must be replugged for two lubrication cir-
cuits (2 O).

Fig. 20 Setting the pause time

l
Open the cover.

i Note
The pause time can be set in 15 stages by the blue ro-
tary switch.

!Caution
Set the pause time to position (1).

i Note
The time ranges (hours or minutes) can be changed
by replugging the jumper on the control board.
Replugging the jumper requires removal of the circuit
board.

!Caution
Plug the jumper for the time range hours (1 - 15h,
right).

Caution
!

After setting the pause time close the cover again.

434 BOMAG 008 911 53

Lubrication process 10.4
10.4 Lubrication process 10.5 Progressive distributor

Main and sub-distributor Components

Lubrication points
The sub-distributor in the rear frame supplies the fol-
lowing points in the rear frame with grease:
l the rocker bearings (4 pieces) on both steering cyl-
inders
l
top and bottom bearings on the articulated joint
The sub-distributor in the front frame supplies the fol-
lowing points in the rear frame with grease:
l the live ring bearing in the oscillating joint
l all bucket bearings
Fig. 21
l the upper rocker bearing on the bucket cylinder
1 Inlet fitting
Main distributor and sub-distributors are connected by 2 Delivery bore from piston
a main grease line. This results in a positive connec-
3 Fitting, assembled
tion between the pump and the downstream progres-
sive system. 4 Plug, piston
If a piston in a distributor does not move or is not able 5 Check valve, complete
to displace any lubricant through its outlet ports, this 6 Clamping ring (brass)
distributor will block itself. 7 Valve body
If one of the sub-distributors is blocked, the positive 8 Cutting ring
connection of the system will also block the main dis- 9 Spigot nut
tributor. The complete progressive system will stop.
10Connecting channel
The fundamental internal structure of the progressive
11Copper seal ring
distributor ensures self-monitoring of the working cy-
cle in the distributor. 12Plug
The cross-linking of this system enables monitoring of Features of a progressive distributor
the complete system.
The expression “Progressive” hints to a speciality that
Due to the use of the piston detector functional faults occurs during the lubricant supply inside the distribu-
are immediately detected and indicated by a flashing tor, such as
sequence of the control light. l
successive movement of the individual pistons in
The complete system can be visually monitored by the the distributor caused by the supplied pressurized
pressure relief valve of the pump. If grease emerges lubricant.
from this pressure relief valve during the pumping
process, there must be a blockage in the system.
l The pistons move in a preset sequence and in con-
stantly repeated cycles.
l
Each piston must have fully completed its move-
ment before the movement of the next piston can
take place, irrespective of whether the supply of lu-
bricant is constant or intermittent.
l The pistons work in dependence on each other.
None of the connected lubrication points will be
missed out.
Progressive distributors of type SSV are piston distrib-
utors.
l They control the distribution of the lubricant (pro-
gressively) to the connected lubrication points.
l
Per outlet and piston stroke a quantity of 0.2 cm3 of
lubricant is supplied.

008 911 53 BOMAG 435

10.5 Progressive distributor

l By closing single outlets it is possible to deliver the Phase 2

double or multiple amounts of lubricant.
l This distributor provides the possibility to connect
several lubrication points to one central lubrication
point.

Description of function
The following five illustrations show how the individual
outlets are supplied with the proper amount of lubri-
cant.

i Note
For simplification we only show the delivery details for
the outlets 2, 7, 5, 3 and 1. All other processes result
from the logic pumping sequence.

Phase 1 Fig. 23 Phase 2

When piston A (Fig. 23) reaches its left hand stop po-
sition it opens the connecting passage at the right
hand end of channel B.
The lubricant flowing in from above (vertical arrow)
likewise moves piston B (horizontal arrow) to the left
and presses the confined lubricant from the left hand
end of piston B to outlet 7.

Phase 3

Fig. 22 Phase 1
The lubricant enters from above (vertical arrow) into
the lubricant distributor and flows to the right end of
piston A (Fig. 22).
The lubricant pressure moves piston A (horizontal ar-
row) to the left and presses the confined lubricant from
the left hand end of piston A to outlet 2.

Fig. 24 Phase 3
When piston B (Fig. 24) reaches its left hand stop po-
sition it opens the connecting passage at the right
hand end of piston C.
The lubricant flowing in from above (vertical arrow)
likewise moves piston C (horizontal arrow) to the left
and presses the confined lubricant from the left hand
end of piston C to outlet 5.

436 BOMAG 008 911 53

Progressive distributor 10.5
Phase 4 When lubricant flows through the distributor again, the
cycle starts exactly at the point where it was interrupt-
ed.

Fig. 25 Phase 4
The connecting passage at the right hand end of pis-
ton D (Fig. 25) is now open (bottom horizontal arrow).
Lubricant flowing in from above (vertical arrow) press-
es piston D to the left hand side, thus the confined lu-
bricant from the left hand end of piston D leaves the
distributor through outlet 3.

Phase 5

Fig. 26 Phase 5
In phase 4 piston D (Fig. 26) opens the connecting
passage to the left end of piston A.
The flowing lubricant (vertical arrow) pushes piston A
to the right (upper horizontal arrow) and conveys the
confined lubricant to outlet 1.
During the continuing delivery sequence the pistons B
- D move from left to right, one after the other.
Thus one complete revolution has come to an end and
a new cycle can start.
If the flow of lubricant is interrupted the piston will stop.
In this case no lubricant is conveyed to the lubrication
points.

008 911 53 BOMAG 437

10.6 Lubrication oil pump

10.6 Lubrication oil pump Hydraulic diagram

During the lubrication cycle the pump delivers lubri-

cant to the connected lubrication points via several
distributors.

i Note
Despite an existing fault monitoring feature the visual
inspections and function checks of the lubrication sys-
tem must be performed at regular intervals.

Components

Fig. 28 Hydraulic diagram of pump

1 Container with agitator wing
2 Pump
3 Check valve, spring loaded
4 Pressure relief valve
R = Return line
P = Pressure line
Fig. 27 Pump components:
(3) (Fig. 28) Check valve
1 Tank
The check valve serves the function of the pump ele-
2 Pump element
ment. It prevents the back flow of lubricant to the
3 Pressure relief valve housing, i.e. to the container.
4 Filling nipple, for emergency lubrication
(4) (Fig. 28) and (Fig. 29) pressure relief valve
5 Connection plug 2A1 (only for industrial applica-
tions), on BOMAG machines with fixed cable The pressure relief valve limits the pressure in the
system to the adjusted value.
6 Filling nipple, pump
7 Control board The valve opens at a pressure of 305 bar.
8 Connection plug 1A1 (only for industrial applica- Lubricant escaping from the pressure relief valve indi-
tions) cates a fault in the system.
9 Return flow connection, not used
The pump is a compact multiple-line pump and con-
sists of:
l
Container with agitator wing
l
housing with built-in motor
l
Control unit
l
Pump element with pressure relief valve
l
Filling facility

438 BOMAG 008 911 53

Lubrication oil pump 10.6
Pump element

Fig. 29 Pressure relief valve

Checking the pressure relief valve Fig. 31 Pump element

1 Piston
2 Resetting spring
3 Check valve
The electric motor drives the eccentric 1 (Fig. 32).
During operation the piston 2 (Fig. 31) draws lubricant
out of the grease container and delivers it via the dis-
tributor to the connected lubrication points in front and
rear frames.

Fig. 30 Checking the pressure relief valve

3 Pressure relief valve Fig. 32 Pump element drawing in grease

A Hose, at least 1 m long
B T-piece 1 Eccentric
C Pressure gauge (0-600 bar / 0-8708 psi) 2 Piston
D Relieve cock 3 Spring
l Connect the pressure gauge C (Fig. 30) to the 4 Check valve
valve.

i Note
Do not connect the pressure gauge (C) directly to the
pump element (3). Use a hose (A) with a length of at
least 1 m. Very high pressure peaks, exceeding the
above measuring range, will occur. In such cases the
pump motor may stop. It can be blocked for up to 30
minutes without any harm.
l Start an additional lubrication cycle. Fig. 33 Pump element pumping
1 Eccentric
2 Piston
3 Spring
4 Check valve

008 911 53 BOMAG 439

10.7 Check the central lubrication system, topping up

10.7 Check the central lubrication

system, topping up

!Caution
When using an external heavy duty lubrication de-
vice lubricate slowly and with interruptions.

The following lubrication points are effectively

and reliably supplied with lubricant by the central
lubrication system.
l 2 x on bearing block at bottom of dozer blade,
l 1 x eye for dozer blade cylinder, Fig. 35
l 4 x steering cylinder eyes, l The agitator in the transparent container 1 (Fig. 35)
l 2 x articulated joint, moves and presses the grease to the lubrication
points.
l 4 x live ring of articulated joint
A differentiation is made between the time cycles for
pause and duty.
i Note
Use the push button only to check the system.
Pause: No lubrication over a period of 60 minutes.
Duty cycle: Factory set. Failure of a lubrication point
(e.g. a clogged lubrication point)
Check
l
Grease emerging from opening 3 (Fig. 35) indicates
that one of the lubrication points is clogged.
l
Identify and rectify the cause.

Filling through the grease nipple

Caution
!

Ensure strict cleanliness, as otherwise the distrib-

utors may seize.
Do not fill the grease container by removing the
cover.
Fill the grease container if it is only 1/4 filled.
Fig. 34 l
Clean the grease nipple.
l Switch on the ignition. l
Fill the grease container through the grease nipple
l
Actuate push button (Fig. 34) for 2 seconds. (2) up to the "Max"-mark.

For quality and quantity of grease refer to the ta-

ble of fuels, lubricants and filling capacities.
l Switch on the ignition, actuate the push button (Fig.
34) for two seconds, the system will start.

Filling with the hand pump

! Caution
Ensure strict cleanliness, as otherwise the distrib-
utors may seize.
For quality and quantity of grease refer to the ta-
ble of fuels, lubricants and filling capacities.

440 BOMAG 008 911 53

Faults and causes 10.8
10.8 Faults and causes

Indication of faults

Fig. 36
l Remove both lids from the cartridge 1 (Fig. 36).
l Unscrew the connecting fitting from the hand pump
(2).
l Pull the actuator rod completely out.
l Slide the cartridge into the hand pump with the tri-
angle mark to the front.
l Check whether the seal ring has been inserted into
the connecting fitting.
l Screw the connecting fitting onto the hand pump.

Fig. 38 Flashing frequencies in case of faults

A = Motor defective

Faults
If the motor does not start when operating the starter
switch or the machine contact, or if the cable of the
motor is defective, the control lamp will flash after 2
seconds as follows:
l
A= 1 second ”ON” - 1 second ”OFF”
Fig. 37
B = Fault in lubrication circuit 1
l
Clean the area around the locking cap on the cen- e.g.:
tral lubrication system.
l
blocked lubrication point(s)
l
Unscrew the locking cap from the central lubrication
system and the locking plug from the hand pump l
blocked distributor
(Fig. 37). l
main hose to distributor with piston detector inter-
l Screw the hand pump onto the socket on the central rupted
lubrication system. l
air in system.
l Push the grease into the transparent container by The above faults mean that the piston in the moni-
operating the actuating rod. tored distributor cannot move any more.
l
Unscrew the hand pump, insert a new cartridge and The control lamp shows the following flashing se-
repeat the pumping procedure until the transparent quence:
container is filled up to the "Max"-mark. l 0.5 seconds ”ON” - 1 second ”OFF”
C = Fault in lubrication circuit 2 (not appli-
Caution
!
cable)
After filling screw locking cap and locking plug
D = Fault in lubrication circuits 1 and 2
back on.
(not applicable)

008 911 53 BOMAG 441

10.8 Faults and causes

E = Empty signal: Container empty

The control lamp shows the following flashing se-
quence:
l 0.5 seconds ”ON” - 0.5 seconds ”OFF”

i Note
After 6 motor revolutions the empty signal will be con-
verted to a flashing signal with the above mentioned
frequency.
In case of a malfunction the piston detector (initiator)
is not able to detect a piston movement and therefore
cannot switch the pump off.
With the help of the parallel running monitoring time
the controls switch the pump off at the end of the mon-
itoring time (5 minutes).
l
This is followed by a fault signal
l The contact lamp flashes
l
The pump does no longer start automatically.
F = Acknowledged fault (permanent light)
Short pressing of button (< 1 second) acknowledges
the fault signal, i.e the flashing of the control lamp
changes to a permanent light.

i Note
An acknowledged fault also remains stored after
switching the drive switch or the machine contact off.
When switching on again the control lamp flashes
again, according to the respective fault.

Rectify the fault and release additional lubrication

l
In the event of a fault check the central lubrication
pump and the connected system for faults.

Rectify the cause of the fault.

l Switch the pump on again by triggering an addition-
al lubrication cycle. Keep the button slightly longer
depressed (> 2 seconds). If the fault is eliminated,
the control lamp will go out at the end of the lubrica-
tion process.

!Caution
In case of a malfunction the pump will not auto-
matically start to run again after rectification of
the fault. The pump must be switched on.

442 BOMAG 008 911 53

Fault - Cause - Remedy 10.9
10.9 Fault - Cause - Remedy

Fault Cause Remedy

Pump does not work Electric line interrupted Replace the electric line
Pump defective Replace the pump
Pump works, but does not deliver Air cushion in pumping piston Vent the pump
Min. filling level fallen short of
Fill up the provision container
Pump element defective Replace the pump element
No grease collar at the lubrication Pump does not work See "Pump does not work"
points Pause time too long or lubrication
Reduce pause time or extend lubri-
period too short cation time
System blocked See "Grease emerging from pres-
sure relief valve"
No grease collars at various lubrica- Supply line to secondary distributor Replace the line
tion points burst or leaking
Screw fittings leaking Retighten or replace screw fitting
No grease collar on one lubrication Corresponding grease line burst or Replace the line
point leaking
Screw fitting leaking Retighten or replace screw fitting
Pump speed too low High system pressure or low ambi- Check system / bearing point
ent temperature No damage (perform 1 or 2 interme-
diate lubrication cycles)
Grease emerging from pressure re- System pressure too high Check system
lief valve Progressive distributor blocked Replace the distributor
System blocked Repair blocked / seized bearing
points

Cause for a blockage in the system

l
A crushed or blocked lubricant line
l
A bearing overfilled with lubricant or blocked
l
An unsuitable lubricant for central lubrication systems
l
A blocked distributor outlet
l
A blocked distributor

Indication of a blockage
l Grease emerging from pressure relief valve

008 911 53 BOMAG 443

10.9 Fault - Cause - Remedy

Identify the location of the blockage

!Caution
All repair work must be carried out with utmost cleanliness.

Fig. 39
l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered
properly.
l
2.) Unscrew the cap screws on the distributor one after the other and operate the pump each time a cap screw
is removed. The line (cap screw) at which the pressure drops, is the blocked line or lubrication point.
l 3.) Follow the same principle when checking the associated secondary distributor all the way to the lubrication
point.

Fig. 40 KIT to check central lubrication systems

444 BOMAG 008 911 53

Failure of central lubrication system (grease emerges from re- 10.10
10.10 Failure of central lubrication system (grease emerges from relief valve)

Central lubrication system not working

(lubricant emerging from the relief valve)

Check the grease pump

no
Pressure
OK?

yes

Check the pressure relief valve

no
valve Replace the pres-
OK? sure relief valve

yes

Replace the lubrica-

tion pump

008 911 53 BOMAG 445

10.10 Failure of central lubrication system (grease emerges from re-

Check the main distributor

none top
Changing/cleaning the main Grease emerging
distributor

bottom

Check the sub-divider in the Check the sub-distribu-

Replace, clean no yes

Repair the respective bearing
the respective Grease emerging
location
sub-distributor

446 BOMAG 008 911 53

11 Engine

008 911 53 BOMAG 447

11.1 Diesel engine

11.1 Diesel engine The engines are characterized by the following posi-
tive features:
Refuse compactors of series BC 772 RB-2 are pow- l compact design
ered by 6-cylinder Deutz diesel engines type TCD
2015 and the BC 972/1172 RB-2 by an 8-cylinder en-
l low noise level
gine type TCD 2015. l almost vibration free operation
These engines are V-type engines with water cooling,
l low fuel consumption
whereby the cylinder banks are arranged to each oth- l low exhaust emission EPA/COM IIl
er under a 90° angle. l high power density
The engines are designed in four-valve technology l excellent access to all service locations.
with turbo charging and intercooler. They are ex- l high reliability
tremely compact and are fitted with a solenoid valve
controlled electronic injection system (MVS).
l low running costs,
l long lifetime
Emission limit values acc. to EPA/ COM/ Tier/ stage lll

Fig. 1 Deutz diesel engine TCD 2015

448 BOMAG 008 911 53

Engine description TCD 2015 V 6 cylinder 11.2
11.2 Engine description TCD 2015
V 6 cylinder

Fig. 1 Deutz diesel engine TCD 2015 V06 right hand side 15 Connection to EMR3 system
16 Connection to MVS system
1 Crankcase ventilation 17 Connection from air filter
2 Connection to coolant heat exchanger 18 Cylinder head cover
3 Pre-heating plug 19 Connection to exhaust silencer
4 Connection from intercooler 20 Exhaust turbo charger
5 Connection to intercooler 21 Charge air suction line
6 Connection from coolant heat exchanger 22 Transport device
7 Lubrication oil filter cartridge
8 Coolant pump
9 Connection from separate lubrication oil tank
10 Connection to separate lubrication oil tank
11 Vibration damper / V-belt pulley
12 Generator
13 Engine type plate (company plate)
14 Exhaust manifold

008 911 53 BOMAG 449

11.2 Engine description TCD 2015 V 6 cylinder

Fig. 2 Deutz diesel engine TCD 2015 V06 left hand side

23. Auxiliary drive

24. Engine suspension
25. Transmission connection (SAE)
26. Flywheel
27. free auxiliary drive
28. Crankcase ventilation line
29. Lubrication oil cooler
30. Injection pump (plug-type pump)
31. Injection line

450 BOMAG 008 911 53

Lubrication oil circuit TCD 2015 11.3
11.3 Lubrication oil circuit TCD
2015

Fig. 1 Lubrication oil schematic 16 Plunger with rocker arm pulse lubrication
17 Push rod, oil supply to rocker arm lubrication
1 Lubrication oil sump 18 Rocker arm
2 Lubrication oil suction pipe 19 Oil return bore in cylinder head leading to crank-
3 Lubrication oil pump case
4 Pressure relief valve 20 Oil pressure sensor / oil pressure switch
5 Lubrication oil cooler 21 Oil line to exhaust turbo charger
6 Lubrication oil filter 22 Exhaust turbo charger
7 Main oil galleries 23 Oil line to crankshaft and camshaft, compressor /
hydraulic pump
8 Crankshaft bearings
24 Compressor (optional)
9 Conrod bearings
25 Hydraulic pump (optional)
10 Camshaft bearings
26 Pressure retaining valve (adjustable)
11 Oil flow to individual injection pumps
27 Return flow from compressor / hydraulic pump to
12 Injection pump with injection valve
crankcase
13 Camshaft lubrication
28 Return flow from exhaust turbo charger
14 Line to spray nozzle
15 Spray nozzle with pressure retaining valve for pis-
ton cooling

008 911 53 BOMAG 451

11.4 Coolant circuit TCD 2015

Fig. 1 Coolant diagram

1 Coolant pump
2 Lubrication oil cooler
3 Coolant channel
4 Cooling of cylinder liner/cylinder head (number-
ing/arrangement of cylinders depending on en-
gine series)
5 Compressor (optional)
6 Transmission oil cooler (optional)
7 Additional cooler (optional)
8 Temperature sensor
9 Thermostat
10 Compensation tank
11 Filler socket
12 Heat exchanger
13 Cabin heater (optional)

452 BOMAG 008 911 53

Fuel circuit TCD 2015 11.5
11.5 Fuel circuit TCD 2015

Fig. 1 Fuel diagram

1 Fuel tank
2 min. distance 500 mm
3 Fuel supply line from tank
4 Manual priming pump for bleeding
5 Fuel pre-filter (example)
6 Fuel priming pump
7 Fuel twin filter
8 Fuel supply line to injection pumps
9 Injection pump
10 Injection line
11 Injection valves
12 Fuel supply line to injection pumps
13 Fuel return line from injection pumps
14 Pressure retaining valve
15 Fuel return line to fuel tank

008 911 53 BOMAG 453

11.5 Fuel circuit TCD 2015

Fuel pre-filter

Fig. 2 Fuel pre-filter

1 Filter bracket
2 Filter cartridge
3 Water collecting bowl
4 Electric connection
5 Drain plug
6 Manual fuel pump
7 Bleeding screw
8 Sealing face
A Electric water level sensor

454 BOMAG 008 911 53

Fuel circuit TCD 2015 11.5
Fuel filter system

2
2

4
4
1 11 3
1
4
2

Fig. 3 Fuel pre-filter

1 Fuel pressure filter min. 3µm
2 Bleeding screws
3 Fuel pre-filter
4 additional hand pump

008 911 53 BOMAG 455

11.6 Injection system (MVS) TCD 2015

11.6 Injection system (MVS) TCD The solenoid valve closes the fuel bypass in the
plunger chamber, thus causing an increase in injec-
2015 tion pressure and finally triggers the injection when
The solenoid valve system (MVS) is a new fully elec- the nozzle opening pressure is reached. If injection is
tronically controlled diesel injection system without to be ended, the valve will open the bypass, the sys-
mechanical link to the operator (no governor rod). In tem pressure drops and the spring force closes the
contrast to conventional injection systems the MVS nozzle needle.
enables an absolutely unrestricted control of delivery The solenoid valves are triggered by the electronic
period (injection quantity) and start of delivery (injec- control unit in dependence on the operatig parame-
tion timing) and thus ensures reliable compliance with ters. The system is capable of providing a wide range
current emission regulations. of limp-home functions, should any of the sensors fail.
The MVS consists of a pump with solenoid valve and This ensures a reliable and safe completion of travel
injection nozzle for each individual cylinder. and work.

Overview of electronic diesel fuel control

Sensors Control unit (EMR3) Actuators

Fig. 1 MVS - Injection system TCD 2015

456 BOMAG 008 911 53

Injection system (MVS) TCD 2015 11.6

Fig. 2 Electrics of TCD 2015 18 Diagnostics push button

19 Fault lamp with flashing code
1 Oil pressure sensor 20 Diagnostics interface/CAN-Bus
2 Fuel temperature sensor
3 Sensor for charge air temperature and charge air
pressure
4 Engine control unit
5 Coolant temperature sensor
6 Oil level sensor
7 Central plug
8 Rotary speed sensor for crankshaft
9 Rotary speed sensor for camshaft
10 Power supply
11 Multi-function display
12 Outputs (configurable)
13 Inputs (configurable) (PWM/Digital/Analog)
14 Travel pedal
15 Manual throttle (optional)
16 Changeover function
17 Key switch Start/Stop

008 911 53 BOMAG 457

11.6 Injection system (MVS) TCD 2015

Injection pump with solenoid valve

Fig. 3 Pump/solenoid valve TCD 2015

Pump

Nozzle

Fig. 4 Injection pump and nozzle

458 BOMAG 008 911 53

Exhaust gas recirculation TCD 2015 11.7
11.7 Exhaust gas recirculation TCD
2015
In order to be able to meet the exhaust gas stand-
ards EC and stage/Tier3, all engines are designed
with exhaust gas recirculation.

On 6 and 8 cylinder engines TCD 2015 the exhaust

gas recirculation has been realized internally
through the exhaust valves. For this purpose the
camshaft has been manufactured with an addi-
tional cam for short-term opening of the exhaust
valve

Exhaust valves

Camshaft

Fig. 1 Exhaust valve control TCD 2015

008 911 53 BOMAG 459

11.8 Wastegate - charge pressure controller on TCD-engines

The Wastegate is a exhaust gas bypass valve and is located on or in the exhaust turbocharger

The Wastegate (exhaust gas bypass valve) is used to control the charge pressure
The charge pressure control takes place by means of a charge pressure triggered pressure valve in connection
with the exhaust gas bypass valve. Depending on this bypass valve hot exhaust gases flow past the exhaust
gas turbine into the exhaust without the available energy being utilized

The bypass valve is normally closed

Control line

Pressure contro

Bypass valve
closed

Fig. 1 Exhaust gas turbocharger with Wastegate

Wastegate active, charge pressure control, i.e. bypass valve open

Bypass valve
open

Fig. 1 Exhaust gas turbocharger with Wastegate

460 BOMAG 008 911 53

Wastegate - charge pressure controller on TCD-engines 11.8
Wastegate on TCD 2013

Fig. 2 Exhaust gas turbocharger with Wastegate

008 911 53 BOMAG 461

11.9 Check, adjust the valve clearance

11.9 Check, adjust the valve clear-

ance

!Caution
We recommend to have this work carried out by
trained personnel or our after sales service.
Before checking the valve clearance let the engine
cool down for at least 30 minutes. The engine oil
temperature must be less than 80 °C.

Fig. 5

Check the valve clearance

l Intake valves 0,25 mm
l Exhaust valves 0,30 mm
l A feeler gauge of appropriate thickness (1) must fit
with little resistance between rocker arm (2) (Fig. 5)
and valve (3).
l If the gap is too narrow or too wide for the feeler
gauge, the valve must be adjusted.
Fig. 3
l
Remove all valve covers (Fig. 3). Adjusting the valve clearance
l Loosen counter nut (4) (Fig. 5) for 2 to 3 turns.
l Adjust the setscrew (5) with a screwdriver, until the
feeler gauge can be inserted and pulled out with lit-
tle resistance after retightening the counter nut.
l Repeat the adjustment procedure on each cylinder.

Fig. 4
Adjustment diagram (Fig. 4)

Valves Cylinder
overlapping A1 B3 A3 B2 A2 B1
adjustment B2 A2 B1 A1 B3 A3 Fig. 6
l Assemble all cylinder nead covers with new gaskets
l Turn the crankshaft until the valves are overlapping. (Fig. 6), tightening torque: 22 Nm.

!Caution Caution
!
This engine is equipped with an internal exhaust After a short test run check the engine for leaks.
recirculation system. During the intake cycle the
exhaust valve opens for a short moment.
This must not be mistaken as overlapping of
valves!

462 BOMAG 008 911 53

Check the engine oil level 11.10
11.10Check the engine oil level 11.11Change the engine oil

i Note i Note
The machine must be in horizontal position. Just be- Drain the engine oil only when the engine is warm.
fore testing run the engine approx. 2 minutes with idle Preferably use oils of ACEA-classification E4-99/E6-
speed. Shut the engine down. 04. This allows the utilisation of the longest oil change
intervals.

Oil change intervals (operating hours) for ACEA

quality:
E4-99/E6-04 = 500 operating hours

Caution
!

With a fuel consumption of >50l/h the oil change

must be performed every 250 operating hours

Danger
!

Danger of scalding!
Fig. 7 Danger of scalding when draining off hot oil!
l
Pull the dipstick (Fig. 7) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms. Environment
l Pull the dipstick back out again. Environmental damage!
l
The oil level must be near the ”Max”-mark. Do not let old oil seep into the ground, but dispose
l
If the oil level is too low top up oil immediately. off environmentally.

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

cants and filling capacities.

Fig. 8
l Remove the rear service door.
l Unscrew the safety cap 2 (Fig. 8) from the oil drain
socket (1).
l Take the oil drain hose (3) out of the right hand stor-
age compartment and screw it on, drain the engine
oil off and collect it.
l Once the old oil has run out remove the drain hose
and screw the safety cap back on.

008 911 53 BOMAG 463

11.12 Changing the engine oil filter

11.12Changing the engine oil filter

! Danger

Danger of scalding!
There is a danger of scalding by hot oil when un-
screwing the engine oil filter.

Environment
Environmental hazard!
Catch running out oil and dispose of environmen-
Fig. 9 tally together with the engine oil filter cartridge.
l Fill in new engine oil (Fig. 9) through the oil filler
neck.

For quality and quantity of oil refer to the table of

fuels, lubricants and filling capacities.
l Screw the cap back on again.

Fig. 11
l
Loosen the engine oil filter (Fig. 11) with a suitable
filter wrench and screw it off.
l
Wipe the sealing face clean.
l
Apply a thin film of clean oil to the rubber seal of the
Fig. 10
new engine oil filter.
l
After a short test run check the oil level on the dip-
l
Screw the new engine oil filter on hand-tight.
stick (Fig. 10), if necessary top up to the top mark l Perform a short test run, inspect the engine for
("Max"). leaks and check the oil level, top up oil if necessary.

464 BOMAG 008 911 53

Replacing the fuel pre-filter cartridge, bleeding the fuel system 11.13
11.13Replacing the fuel pre-filter l (5) Apply a thin coat of oil to the rubber seal of the
water separator.
cartridge, bleeding the fuel l (6) Turn the water separator on by hand, until the
system seal contacts, then tighten hand-tight.
l (7) Apply a thin coat of oil to the rubber seal of the
Danger
! filter element.
Fire hazard! l (8) Turn the filter cartridge on by hand, until the seal
When working on the fuel system do not use open contacts, then tighten hand-tight. Plug the cable of
fire, do not smoke and do not spill any fuel. the water sensor back on.

Bleed the fuel system

Danger
!

Health hazard!
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
Caution
! makes starting impossible.
Ensure strict cleanliness! Thoroughly clean the Therefore bleed the fuel system after changing the
area around the fuel filters. fuel pre-filter or working on the fuel system.
After work on the fuel system bleed the system,
perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is manda-
tory.

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

Change the fuel pre-filter cartridge

Fig. 13
l Slacken the bleeding screw (1) (Fig. 13) on the fuel
pre-filter for 2 to 3 turns.
l
Operate the fuel hand pump (2) manually, until fuel
flows out of the loosened bleeding screw without air
bubbles.
l
Then tighten the bleeding screw while pumping.
l Slacken the bleeding screws on the fuel pre-filters
for 2 to 3 turns.
l
Operate the fuel hand pump (2) manually, until fuel
flows out of the loosened bleeding screws without
Fig. 12 air bubbles.
l (1) Shut down the engine (Fig. 12). l Then tighten the bleeding screws while pumping.
l (2) Pull the cable off the water separator. Loosen l
Start the engine and run it 5 minutes with idle
the bleeding screw and drain off fuel from the bleed- speed.
ing screw.
l (3) Loosen and unscrew the fuel pre-filter cartridge
using an appropriate filter wrench.
l (4) Unscrew the water separator from the filter car-
tridge.

008 911 53 BOMAG 465

11.14 Changing the fuel filter cartridge

11.14Changing the fuel filter car- 11.15Checking condition of radia-

tridge tor, intercooler and hydraulic
oil cooler, clean, cleaning the
Danger
! engine
Fire hazard!
No open fire, do not smoke, do not spill any fuel. i Note
Do not inhale any fuel fumes. Dirty operating conditions, particularly lubrication oil
and fuel deposits on the cooling fins reduce the cool-
ing effect. You should therefore immediately seal any
Environment oil or fuel leaks near cooling fan, cylinder or oil cooler
Catch running out fuel, do not let it seep into the and subsequently clean the cooling fins.
ground.
l Open the left hand engine compartment doors. ! Danger

Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped!

Fig. 14
l
Loosen both fuel filters (Fig. 14) using a suitable fil-
ter wrench and screw it off.
l
Clean the sealing face on the filter carriers from any Fig. 16
dirt. l Remove the service covers on left (Fig. 16) and

Fig. 15
Fig. 17
l Slightly oil the rubber seal on the new filter cartridge
(Fig. 15).
l right hand side (Fig. 17) of the air duct housing.
l Fill the filter cartridge with clean diesel fuel.
Caution
!
l
Turn the new filter cartridge on by hand, until the
seal contacts. During cleaning take care not to damage the fins
on hydraulic oil cooler, intercooler and radiator.
l Then tighten hand-tight. Keep a safe distance with the spray nozzle.
l Check for leaks after a short test run.

466 BOMAG 008 911 53

Checking condition of radiator, intercooler and hydraulic oil 11.15
i Note
Clean the coolers in the correct sequence.
l
Clean hydraulic oil cooler, intercooler and radiator
from the air duct side first.

Fig. 19
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.
l The drain bore (Fig. 19) must be free, remove
Fig. 18 blockage if necessary.
l Remove the service door (Fig. 18).
l
Clean all coolers from the air intake side.
l
Remove dried on dirt with a suitable brush.
l Blow the cooling air channels out with compressed
air.
l
In case of oily contamination spray the parts with
cold cleansing agent and spray it off with a water jet
after s sufficient soaking time.
l
If steam cleaning equipment is available, this
should preferably be used.

Cleaning the engine Fig. 20

l In case of oily contamination spray the engine with
!Caution cold cleansing agent and spray it off with a water jet
After cleaning the coolers it is mandatory to clean after s sufficient soaking time.
the engine. l
Drain bores (Fig. 20) and (Fig. 19) must be free, re-
Cover all parts of the electrical system, do not move blockage if necessary.
subject to the direct water jet. l
After wet cleaning run the engine warm to evapo-
rate all water residues and to avoid corrosion.
l Reinstall the service covers.

008 911 53 BOMAG 467

11.16 Changing the coolant, venting the cooling system

11.16Changing the coolant, venting

the cooling system

Danger
!

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

!Caution
Do not start the engine after draining off the cool-
ant.
When changing the coolant without any signs of Fig. 23
contamination, cleaning of the cooling system is l Connect the drain hose to the drain cock (Fig. 23).
not necessary.
l Guide the drain hose into a vessel of appropriate
size.
Environment l Open the drain cock and let the coolant run out.
Catch coolant and dispose of environmentally.
l Once all coolant has run out close the drain cock,
remove the drain hose and screw the plug back on.

Fig. 21
l Open the safety flap (Fig. 21). Fig. 24
l
Fill coolant in through the opening in the compensa-
tion tank (Fig. 24).

For coolant quantity refer to the table of fuels, lu-

bricants and filling capacities.
l
Close the compensation tank. For bleeding start the
engine and run it warm.
l
Check the coolant level, top up if necessary.

Fig. 22
l Unscrew the cap (Fig. 22).

468 BOMAG 008 911 53

Checking the anti-freeze concentration 11.17
11.17Checking the anti-freeze con- 11.18Checking the thermostat in
centration disassembled state
The thermostat serves the optimal temperature con-
!Caution trol of the coolant, in order to promote efficient com-
In order to avoid damage to the engine e.g. by cor- bustion and to bring the engine quickly to operating
rosion, cavitation and freezing, particular atten- temperature after starting. At temperatures below ap-
tion must be paid to the inspection of the coolant. prox. 83°C the thermostat is closed. Once the coolant
temperature has reached about 83°C, the thermostat
will start to open, at about 95° C it is fully open. In this
Danger
! condition the full coolant flow is guided through the ra-
Danger of scalding! diator.
Check the anti-freeze concentration only when the
engine is cold.
l
Perform the inspection with conventional test equip-
ment.
l The anti-freeze concentration (additive) must be at
least 35 Vol% and maximum 45 Vol%.

! Danger

Health hazard!
The mixing of nitrite based anti-freeze agents with
amine based agents results in the formation of
health affecting nitrosamines. Fig. 1
l Measure and write down the measurement "a" on
Environment the thermostat (Fig. 1).
Catch all anti-freeze agent and dispose of environ-
mentally. !Caution
Take note of different opening temperatures (Fig.
2) (arrows) of the thermostats.

Fig. 2

i Note
"a" = Start of stroke (A-Bank, colour mark black ven-
tilation groove at top) at approx. 79°C
"a" = Start of stroke (B-Bank, ventilation groove at top)
at approx. 87°C

008 911 53 BOMAG 469

11.19 Servicing the fan V-belt

11.19Servicing the fan V-belt

! Danger

Danger of injury!
Work on the fan V-belt must only be performed
with the engine shut down.

Checking the fan V-belt

! Caution
Fig. 3 A belt tension meter is required to check the V-
belt tension.
l
Warm up the thermostat in a water bath (Fig. 3).

i Note
In order to determine the exact start of opening the
temperature should be measured as close to the ther-
mostat as possible, but without touching it.
The water must thereby be stirred continuously, to en-
sure even temperature distribution.
The temperature increase should not exceed 1°C/
min, as otherwise the start of opening will be delayed
accordingly.

Fig. 5
l
Inspect the entire circumference of the V-belt (Fig.
5) visually for damage and cracks.
l
Replace damaged or cracked V-belts.

Fig. 4
l
Measure and write down the measurement "b" on
the thermostat . (Fig. 4).
l Calculate the stroke.

Stroke = b - a
Fig. 6
i Note l Press the indicator arm (a) of the tester (Fig. 6) into
Stroke length min. 8 mm. the gap of the measuring scale.
l Place the meter in the middle between the V-belt
pulleys on the back of the fan V-belt.

470 BOMAG 008 911 53

Servicing the fan V-belt 11.19
With a new V-belt check the tension after approx.
50 operating hours and tighten it to approx. 1400
N.

Fig. 7
l
Actuate the push button (b) (Fig. 7) evenly with a fin-
ger under a right angle to the V-belt, until the pres-
sure spring disengages audibly and noticeably.
Fig. 9
l Slightly loosen screws (1) and (2) (Fig. 9) as well as
i Note nut (3), so that there is still friction between the com-
The indicator arm remains in the measured position. ponents.
l Take the measuring unit carefully off, without mov- l Loosen the nut (4) for a few turns.
ing the indicating arm. l Turn the nut (5) clockwise and tension the V-belt.
l Tighten the screw (2).
l Measure the V-belt tension, tighten if necessary.
l Slightly slacken the nut (5).
l Tighten the nut (3).
l Screw both nuts (4) and (5) to contact, then counter
both nuts against each other.
l Tighten the screw (1).

Change the fan V-belt

Fig. 8
l Read the V-belt tension where the upper edge of
the indicating arm intersects with the measuring
scale (Fig. 8).
First installation = approx. 1900 N
after approx. 30 - 60
minutes running-in
time = approx. 1400 N
Min. 1100 N = tension to approx. 1400 N

Tensioning the fan V-belt

Fig. 10

!Caution
l Slightly loosen screws (1) and (2) (Fig. 9) as well as
nut (3), so that there is still friction between the com-
Do not tighten the V-belt excessively, since this
ponents.
would damage the V-belt which in turn could lead
to damage on V-belt drive and engine. l
Loosen the nut (4) for a few turns.
Never tighten the new V-belt a second time to the l Turn the nut (5) back so that the idler pulley is able
value of 1900 N, even after only a brief engine op- to swing back far enough.
eration! l Take off the old V-belt and install a new one.

008 911 53 BOMAG 471

11.20 Checking the condition and tension of the generator V-belt, re-

l Turn the nut (5) clockwise and tension the V-belt. 11.20Checking the condition and
l Tighten the screw (2). tension of the generator V-
l Start the engine for a moment or crank it once by belt, replacing the V-belt
hand.
l Measure the V-belt tension, tighten if necessary.
Danger
!

Danger of injury!
Work on the generator V-belt must only be per-
formed with the engine shut down.

Checking the V-belt

Fig. 11
l
Inspect the entire circumference of the V-belt (Fig.
11) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l
Check with thumb pressure whether the V-belt can
be depressed more than 5 to 10 mm between the V-
belt pulleys, retighten if necessary.

Retightening the V-belt

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.

472 BOMAG 008 911 53

Check the engine mounts 11.21
Changing the V-belt 11.21Check the engine mounts
l
Remove the V-belt of the fan drive.

Fig. 14
Fig. 13 l Check all fastening screws on the engine mounts
l Slacken the fastening screws 3 and 4 (Fig. 13) for tight fit, tighten if necessary (Fig. 14).
slightly.
l Loosen the counter nut (2).
l Turn tensioning screw (1) in direction of arrow to the
stop.
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 Reinstall and tension the fan drive V-belt.

i Note
Retighten new V-belts after a running time of 15 min-
utes.

008 911 53 BOMAG 473

11.22 Checking the fastening of engine / turbo charger / combustion

11.22Checking the fastening of en-

gine / turbo charger / combus-
tion air hoses

Fig. 17
l Check combustion air tube and connecting sleeves
for tight fit (Fig. 17).

Fig. 15
l Check charge air pipe (Fig. 15) and intercooler for
tight fit and leaks.
l Check the exhaust gas pipe and the lubrication oil
line to and from the exhaust gas turbo charger for
tight fit and leaks.
l Check the connecting sleeves for tight fit.

Fig. 16
l Open the maintenance flap on the ROPS.
l Check the combustion air hose for tight fit and leaks
(Fig. 16).

474 BOMAG 008 911 53

General trouble shooting chart TCD 2015 11.23
11.23General trouble shooting
chart TCD 2015

Faults Causes Action

Temperature below starting limit
Engine oil with wrong SAE viscosity class Change the lubrication oil
Fuel quality not as specified in the operating Change the fuel
Engine does not
instructions
start or starts
Air in the fuel system Bleed the fuel system
poorly
Battery defective or not charged Check the battery
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not engage Check starter
Engine does not Engine electronics prevent starting Check fault by fault code, repair as necessary
start and diag-
nostic lamp flash-
ing
Engine starts, but Fuel quality not as specified in the operating Change the fuel
runs irregularly or instructions
misfires Injection line leaking Check the injection line
Injection valve defective Check the injection valve / replace if neces-
sary
Speed changes Engine electronics detected a system fault Check fault by fault code, repair as necessary
are possible and and activates a substitute speed
diagnostic lamp
lights
Oil level too low Fill up lubrication oil
Engine oil level too high Check oil level, drain off if necessary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
Engine overheat-
fective
ing. Temperature
Air filter service switch / indicator defective Check / replace if necessary
warning system
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
responds
Short circuit of heat in cooling system Check the cooling system
Resistance in cooling system too high / flow Check the cooling system
quantity too low
Engine oil level too high Check the oil level
Fuel quality not as specified in the operating Change the fuel
instructions
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
Insufficient en-
fective
gine power
Air filter service switch / indicator defective Check / replace if necessary
Charge air pipe leaking Check the charge air pipe
Injection line leaking Check the injection line
Injection valve defective Check the injection valve
Insufficient en- Engine electronics reducing the output power Check fault by fault code, repair as necessary
gine power and
diagnostic lamp
lights
Engine does not Injection line leaking Check the injection valve / replace if neces-
work with all cyl- sary
inders Injection valve defective Check the injection valve / replace if neces-
sary

008 911 53 BOMAG 475

11.23 General trouble shooting chart TCD 2015

Faults Causes Action

Oil level too low Fill up lubrication oil
Engine has to low Extremely slanted position of engine Check engine pillow blocks / reduce the en-
or no oil pressure gine inclination
Engine oil of wrong SAE class or quality Change the lubrication oil
Engine has ex- Engine oil level too high Check oil level, drain off if necessary
cessive oil con- Extremely slanted position of engine Check engine pillow blocks / reduce the en-
sumption gine inclination
Blue engine ex- Engine oil level too high Check oil level, drain off if necessary
haust smoke Extremely slanted position of engine Check engine pillow blocks / reduce the en-
gine inclination
Temperature below starting limit
Fuel quality not as specified in the operating Change the fuel
White engine ex-
instructions
haust smoke
Injection valve defective Check the injection valve / replace if neces-
sary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
fective
Black engine ex- Air filter service switch / indicator defective Check / replace if necessary
haust smoke Charge air pipe leaking Check the charge air pipe
Injection valve defective Check the injection valve / replace if neces-
sary

476 BOMAG 008 911 53

Special tools, Deutz engine (TCD 2015) 11.24
11.24Special tools, Deutz engine
(TCD 2015)

TCD 2015 Standard tools

8005
Compression pressure tester 057 250 67
for diesel engines
10 - 40 bar
Checking compression pressure

8008
Nozzle tester
with spray mist collecting vessel
Check injection nozzles

8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe

008 911 53 BOMAG 477

11.24 Special tools, Deutz engine (TCD 2015)

Standard tools TCD 2015

8015
Socket wrench insert
SW 14, reinforced
Unscrew and tighten big end bearing screws.

8016
Socket wrench insert
SW 17, reinforced
Unscrew and tighten flywheel screws.

8018
Claw wrench
SW 17, reinforced
Unscrew and tighten union nuts of the injection pipes.

478 BOMAG 008 911 53

Special tools, Deutz engine (TCD 2015) 11.24

TCD 2015 Standard tools

8024
Assembly pliers 057 250 68
e. g. removing valve stem seals

8115
V-belt tension measuring device
150 to 600 N
079 947 09
Check V-belt tension

8189
Pricker 057 250 76
Removing rotary shaft lip seal

008 911 53 BOMAG 479

11.24 Special tools, Deutz engine (TCD 2015)

Standard tools TCD 2015

8190
Rotation angle disc
with magnet (e. g. setting valve clearance)
057 250 72

7
8191
Socket wrench insert 057 250 74
with slotted screwdriver insert (8x1.6)
(e. g. setting valve clearance)

Special tools, Deutz engine (TCD 2015) 11.24

Special tools TCD 2015

170120
Disassembly and assembly tool
Pressing the ball stud of the rocker arm shaft out and in

170160
Stoppers/caps 079 947 29
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

008 911 53 BOMAG 495

11.24 Special tools, Deutz engine (TCD 2015)

496 BOMAG 008 911 53

12 Working hydraulics

008 911 53 BOMAG 497

12.1 Hydraulic system

Hydraulic system 12.2 Working hydraulics

12.1 Hydraulic system

Travel system as well as steering and dozer blade on

The working hydraulics on the sanitary landfill com-
these machines are hydraulically operated.
pactors BC 672-772 RB/RS (EPA II) cover the hydrau-
This guarantees an almost loss-free transfer of engine lic systems for steering and dozer blade/bucket
output power to compactor wheels, steering cylinders controls.
and dozer blade/bucket control.
The working hydraulics mainly consist of the axial pis-
The pumps for the corresponding circuits are driven ton pump, the control valve block for the function doz-
by the engine via a transfer box and convert the me- er blade/bucket up / down, steering and on RS-
chanical energy provided by the engine into hydraulic machines also tipping of bucket, the 2 steering and
energy. the dozer blade cylinder (RS: additional tipping cylin-
Inside the motors or the cylinders for steering or dozer der) and the electrical parts (control potentiometer for
blade actuation this hydraulic energy is then convert- steering and dozer blade/bucket control and ESX-
ed back to mechanical energy. control).
Since the medium oil is used for this transfer of power, A swash plate type axial piston pump supplies the
any losses in power are only of minor significance. system with pressure oil.
All hydraulic circuits are protected against contamina- The movement of the dozer blade or bucket is control-
tion by charge oil filters and a hydraulic oil return flow led via a joystick next to the driver’s seat. The control
filter. is extremely light moving and sensitive.
Safety elements in pumps and hydraulic control units When shifting the control lever forward and pressing
protect the hydraulic system and the drive engine the top push button at the same time the dozer blade/
against overloads and damage resulting from such bucket can be held in floating position (piston and pis-
excessive loads. ton rod sides of the lift cylinders are open to the tank).
In this operating mode the dozer blade/bucket can be
To ensure quick heating of the hydraulic oil up to op- used to level the landfill site surface while driving in re-
erating temperature the return flow from the hydraulic
verse.
system flows directly back to the hydraulic oil tank, un-
til the operating temperature is reached. When the oil The electro-hydraulic operation of the working hydrau-
temperature comes close to operating temperature a lics is similar to the system used in machines of series
thermostat valve will start to open and guide the oil BC 671/771-RS and identical with the machines of
flow through the hydraulic oil cooler back to the tank. range BC 972. The joystick units are potentiometers,
the signals of which are converted to dedicated cur-
This ensures that the operating temperature is quickly
rent pulses in the ESX-control, to operate the corre-
reached, particularly during the cold season, and that
sponding valves in the valve block.
the hydraulic system can be operated without any
risks.

498 BOMAG 008 911 53

Steering and working pump 12.3
Steering and working pump pumps deliver oil only to one direction, i.e. the swash
12.3 Steering and working pump

plate moves out of neutral position only to one direc-

The tandem pump for the working hydraulics consists
tion. They are therefore particularly suitable for the
of two identical swash-plate operated axial piston
use in open hydraulic circuits.
pumps with variable displacement. However, the

Fig. 18 Hydraulic pump for working hydraulics As long as the steering system or the bucket hydrau-
1 Working pump lics do not require any oil, the pumps will maintain the
2 Flow control valve so-called ”Stand-by pressure” (30 ±1 bar). Due to the
flow control in the working hydraulics the engine has
3 Pressure control valve to supply power only when it is actually needed.
4 Resetting piston
Working principle
5 Control piston
When looking at the working hydraulics, for better un-
(B) to dozer blade control and steering
derstanding one must always consider two different
(L) to hydraulic oil tank operating conditions:
(S) from hydraulic oil tank l
Engine not running
(X) LS, load signal from steering and dozer blade l Engine running
When the engine is not running the swash plate is in
When the engine is not running the swash plate in the
max. displacement position, however, when starting
steering and working pump is at maximum displace-
the engine the swash plate will move immediately
ment position. The spring of the smaller control piston
back towards zero, until the stand-by pressure adjust-
in the pump holds the swash plate in this position.
ed on valve 2 (Fig. 18) is reached.

008 911 53 BOMAG 499

12.3 Steering and working pump

When starting the engine pressure builds up between

the outlet on the steering and working pump and the
inlet ”P” (front pump) and "P2" (rear pump) on the
valve block. These two ports are connected inside the
control block. This pressure increase is possible, be-
cause all three 8/3-way valves in the valve block are
closed in neutral position (all consumers in neutral po-
sition).
The now increasing pressure moves the flow control
valve spools on the pumps and opens a connection
between the pump flow and the bigger control piston
(reversing piston) for the pump swash plate.
Since the effective area of this piston is much bigger
than the area of the counter piston, the increasing
pressure moves the swash plates towards zero (de-
spite the spring force supporting the counter piston).
The setting of the flow control valves ensures a so-
called ”stand-by pressure” in the system.
The pressure control valve on the working pump limits
the high pressure in the working hydraulics to 230 bar.
If the system pressure increases up to the adjusted
value because of steering or dozer blade operation,
this pressure will move the spool inside the pressure
control valve. This guides high pressure on the piston
area of the reversing pistons inside the pumps and the
swash plates are thereby moved towards zero posi-
tion.
If the pressure drops below the adjusted value, the
spring is able to close the pressure control valve and
the pumps return to the previous displacement.

500 BOMAG 008 911 53

Control valve block, steering and dozer blade 12.4
Control valve block
12.4 Control valve block, steering and dozer blade

Fig. 19 Control valve block sections of the control block are perfectly adapted to
(A) LS signal to the working pumps the individual requirements for steering or dozer blade
control by the geometry of their measuring orifices.
(P) from rear working pump
The control valve block is located in the hydraulic con-
(P2) from front working pump
nection from steering and working pump to the con-
Pst1, Pst2) from rear right hand charge pump sumers (steering and dozer blade cylinders). Both
The function of the control valve block is based on the work functions are integrated in the control block
principle of load pressure independent flow distribu- housing.
tion. This concept enables quick and precise working Pump, tank and LS-lines are internally linked and
with overlapping movements of several consumers combined as central connections on the control block.
under different load pressures. In the control block all consumers are arranged in par-
The operator controls the speed for steering and doz- allel mode.
er blade proportional to the deflection of the joystick or The geometry of the fine control grooves in the control
the dozer blade control lever, irrespective of the load pistons is specially adapted to the characteristics of
pressure. The control valve spools in the individual

008 911 53 BOMAG 501

12.4 Control valve block, steering and dozer blade

the corresponding consumer. The control pistons for Load-Sensing

the individual axes can thus be interchanged. The pis- If the working hydraulics (steering and dozer blade
tons must not be turned by 180°. control) does not demand any power, the load signal
Besides the piston axes to control the consumer (load sensing line ”LS”) for all consumers is dumped
movements, the control block also contains compo- into the tank, in this case the load signal is 0 bar.
nents serving necessary system functions: If one of the consumers requires hydraulic oil, the ac-
l Stabilizing the system tuation of the steering or bucket hydraulics will gener-
ate a load signal.
l Securing the primary and secondary pressure
l
Limiting the permissible LS-pressure Example steering
l Avoiding cavitation caused by external loads or de- In neutral position the steering valve is ”closed”, i.e.
celeration there is no connection between the valve inlet ”P” and
one of the outlets ”A2” or ”B2” to the steering cylin-
The optimal adjustment of pump and control block en- ders. The load signal line is directly connected with
sures quick response with high stability. the tank return line.
When operating the steering joystick the valve inlet
port ”P” is connected with one of the outlets ”A2” or
”B2” and with the load sensing line ”LS”.
The pressure, which is now increasing because of the
load resistance, is applied to the back of the flow con-
trol valve on the steering and working pump through
the ”LS”-line. The spool in the flow control valve
moves and interrupts the oil flow to the reversing pis-
ton for the swash plate.
The spring loaded counter piston actuates the swash
plate and the pump delivers oil to the steering system.
When stopping the steering joystick movement after
this steering operation, the 8/3-way valve in the steer-
ing valve block will automatically return to neutral po-
sition. The connection between valve inlet port ”P” and
the valve outlets ”A2” or ”B2” and the load signal line
”LS” is interrupted again. The LS-drain valve in the
valve block connects the load signal line ”LS” with the
return flow to the tank, the pump returns immediately
towards zero and the pressure drops to the stand-by
pressure value.

502 BOMAG 008 911 53

Control valve block, steering and dozer blade 12.4
Steering control Dozer blade control
The steering movements are controlled by means of The dozer blade movements (up, down and float posi-
the "steering joystick" in the left hand arm rest of the tion) are controlled by means of a ”joystick” on the
operator's seat. The steering speed is proportional to right hand side of the driver’s seat.
the displacement of the joystick. With this joystick the ESX-control is electrically pro-
Due to the electronic control via the ESX-control the portionally triggered via a potentiometer.
solenoid valves of the steering valve are triggered in The lowering speed is proportional to the displace-
pulses. With each pulse a minimum oil quantity is ment of the joystick.
guided to the control piston of the steering spool (in-
crease of steering angle) or relieved. This increases When operating the joystick forward and pressing the
the opening cross-sections of the 8/3-way valve in push button at the same time, the 2/2-way valve for
both positions ”left” and ”right” very sensitively propor- float position will switch to ”float position”, i.e. both pis-
tional to the actuation of the steering joystick. This en- ton and piston rod sides of the lifting cylinders are con-
ables very sensitive steering of the machine. nected with the tank. This position is particularly
suitable for levelling the landfill site surface during re-
verse travel.
When the joystick is pulled back, the valve is switched
to position ”up”. Oil flows from the working pump
through the valve block to the piston rod sides of the
lifting cylinders and the dozer blade moves up.
The lifting speed is proportional to the displacement of
the joystick.

008 911 53 BOMAG 503

12.4 Control valve block, steering and dozer blade

Description of individual components LS shuttle valve

The LS signal reported by the pressure balance with
LS drain valve
the highest pressure reaches the pump control
The LS drain valve relieves the LS line to the tank, through orifice 1 (Fig. 21). In neutral position the LS
when all work functions are in neutral position (no pump control is relieved to the tank through orifice (2)
function operated). When operating steering / dozer and the LS drain valve.
blade, the flow control valve will regulate the flow vol-
ume from the LS line to the tank, irrespective of the
load pressure.

Fig. 21 LS shuttle valve

1 Orifice
Fig. 20 LS drain valve 2 Orifice
1 Spring 3 LS signal to pump control
2 Control piston 4 LS signal in control block
3 Control orifice 5 effective to the valve block
The 2-way flow limiting valve in cartridge design con- 6 effective to the pump
sists of housing, control piston with control orifice and The cooperation of various orifices in the LS shuttle
spring. The control piston maintains the pressure drop valve with the capacity of the LS hose between control
across the orifice constant, irrespective of the LS block and pump (defined oil volume / line cross-sec-
pressure and the outflowing LS flow volume. tion) leads to the damping of excessive pressure puls-
es in the system. Short and strong pressure pulses in
the system will thus not cause immediate undesired
reactions of the pump.

504 BOMAG 008 911 53

Control valve block, steering and dozer blade 12.4
LS-pressure limitation Primary pressure relief valve
The LS pressure limitation limits the maximum LS
pressure in the system. Once the LS pressure reach-
es the value set by the spring, the valve seat will open
a connection to the tank and maintain the max. LS
pressure at a constant level.
The cartridge type valve is screwed into the control
block and factory set to a specific value.

Fig. 23 Primary pressure relief valve

1 Consumer port
2 Orifice D1
3 Spring 1
4 Main taper
5 Area A2
6 Orifice D2
Fig. 22 LS-pressure relief valve 7 Counter nut
1 Counter nut 8 Protective cap
2 Basic housing 9 Adjustment spindle
3 Valve seat 10Adjustment spring
4 High pressure setting 11Pilot control taper
5 Spring 12Spring 2
6 Tank 13Tank port
7 LS system pressure 14Area A3
15Volume C
16Area A1
The pilot controlled primary pressure relief valve is
screwed into the side of the control block and, in its
function of a safety valve, it limits the maximum pump
pressure to the adjusted value (approx. 260 bar).
Pressure peaks may be experienced in the pump line,
e.g. if the pump does not regulate the flow volume
down quick enough or a malfunction occurs in the sys-
tem. The supplier of the valve block has set the pres-
sure and sealed the block. Primary pressure relief
valve (pump side) and secondary relief valves (cylin-
der side) are identical in design and function. System
pressure p is applied to chamber C through orifice D1.
As the area A2 is bigger than the area A1, the main ta-
per remains closed. Spring 1 in chamber C ensures a
stable installation position.
As long as the system pressure p is lower than the val-
ue adjusted with the adjustment spindle, the valve will
remain closed. If pressure p exceeds the adjusted val-
ue, the pilot control taper will open and allow oil to flow
from chamber C through orifice D2 into the tank. The
pressure in chamber C collapses, because the flow
through the smaller cross-section of orifice D1 is
smaller than the drain through the opened pilot control
taper. The higher pressure p on the area A1 opens the

008 911 53 BOMAG 505

12.4 Control valve block, steering and dozer blade

main taper against the spring 1 and links the pump line Secondary / consumer valves
with the tank. The feed function is not used on the pri-
mary side. Shock valve
The cartridge type pilot controlled pressure/feed
valves in the individual consumer ports A and B are
screwed into the individual sections, above the control
pistons. The valve protects the consumer circuit
against overloads or damage caused e.g. by external
forces or sudden decelerations (control piston in neu-
tral), by relieving pressure peaks to the tank.
As a safety valve it limits the maximum pressure in the
consumer and in the connecting line to the way valve
to the adjusted value. The pressure has been adjust-
ed and the blocked sealed by the manufacturer before
delivery.

Fig. 24 Shock valve

1 Consumer port
2 Orifice D1
3 Spring
4 Main taper
5 Area A2
6 Orifice D2
7 Counter nut
8 Protective cap
9 Adjustment spindle
10Adjustment spring
11Pilot control taper
12Spring 2
13Tank port
14Area A3
15Volume C
16Area A1

Function
The corresponding load pressure of the consumer
port is applied to chamber C through orifice D1. Spring
1 in chamber C only ensures a stable installation po-
sition. As long as the consumer pressure p is lower
than the value adjusted with the adjustment spindle,
the valve will remain closed. If pressure in the con-
sumer port A or B exceeds the adjusted value, the pi-
lot control taper will open and allow oil to flow from
chamber C through orifice D2 into the tank. The pres-

506 BOMAG 008 911 53

Control valve block, steering and dozer blade 12.4
sure in chamber C collapses, because the flow Pre-tensioning valve
through the smaller cross-section of orifice D1 is The valve block has two internal tank channels. The
smaller than the drain through the opened pilot control first one connects the shock valve for steering to the
taper. The higher pressure p on area A1 opens the right and the outlet of a floating position valve directly
main taper and links the pump line with the tank. with the tank. The second tank line is pre-tensioned by
a 18 bar valve. Here all consumer outlets are closed.
This protects the cylinders against cavitation, which
could be caused e.g. by abrupt lowering of the. Fur-
thermore, the shock valve for steering to the left and
for lifting the dozer blade as well as the other float po-
sition valve, are connected to this pre-tensioned chan-
nel for reasons of design.

008 911 53 BOMAG 507

12.4 Control valve block, steering and dozer blade

Float position valves Function of the control valve block

When switching the solenoids Y102, the float position (General description, the components may vary in de-
valves connect both sides of the hydraulic cylinder tail from the BOMAG version. For better understand-
with the tank return line. ing the pressure balances, in particular, are shown as
3/3-way proportional valves, instead of 2 individual
valves, as shown in the original hydraulic diagram.
However, the function is absolutely identical).

Neutral position

Fig. 25 Neutral position 6 Control piston

1 Lift limitation 7 Infeed measuring orifice p –› A
2 Secondary pressure relief/boost check valve 8 Infeed measuring orifice p –› B
3 Load retaining valve 9 Outlet orifice B –› T
4 LUDV- pressure balance 10Outlet orifice A –› T
5 11Passage p –› A

508 BOMAG 008 911 53

Control valve block, steering and dozer blade 12.4
12Passage p –› B load retaining valves is in this situation relieved to tank
13Control piston pressure through the piston clearance. The consumer
ports are blocked by the overlapping of the control pis-
14Pressure balance
ton in the housing. The consumer is thus locked and
15Pressure spring, pressure balance fixed between two oil columns.
With the control piston in neutral position (no control The pressure balances for the individual functions
current applied to the proportional solenoids connec- (steering / dozer blade) are arranged downstream of
tions a or b) the connection between pump and p’- the control piston measuring orifice. They consists of
channel (after measuring orifice) is blocked by the a control piston (13) and a pressure spring (15), which
spool. Load retaining valves and pressure balance are ensures a stable initial position.
closed. The pressure in the p’- channel and behind the

008 911 53 BOMAG 509

12.4 Control valve block, steering and dozer blade

Individual operation or consumer with highest

load

Fig. 26 movement is initiated. The oil displaced from the con-

The force of the pilot pressure, which is released by sumer flows from B through the outlet orifice (9) back
the control solenoids, shifts the control piston (6) pro- to the tank. The secondary pressure relief valves (2)
portionally against spring pressure. In this illustration remain closed as long as the pressure in the consum-
the solenoid on connection "a" shifts the piston to the er connection is lower than the adjusted pressure. In
right against the spring in the control cover on side B. case of cavitation in the consumer connection the
The inlet orifice (7) of the control piston opens a pas- main taper of the combined pressure relief/boost
sage from pump port P to channel p’. The pressure in check valve in the infeed line (side A) opens, e.g.
this chamber opens the pressure balance (14) and is caused by extern negative forces, and enables the in-
applied up to the load retaining valves (3). feed from the pre-tensioned tank channel into the
block.
The consumer pressure pc in port A keeps the left
hand load retaining valve (3) closed through the pas- In case of individual movements or if the load pres-
sages in control piston (11). As p’ increases higher sure of the consumer pc is the highest in the system,
than pc, the non-return valve will open. The connec- the LS pressure is generated from the p'-channel
tion between pump and consumer is opened and the through the bore in the pressure balance and fed back

510 BOMAG 008 911 53

Control valve block, steering and dozer blade 12.4
to the pump control and to the section pressure bal- Overlapping of movements
ances with lower load pressure.
System saturated
Feeding the LS-signal from the p’-channel, before the
load retaining valves, ensures blocking of the con- In saturated operation of the system the quantity re-
sumer port, until the required working pressure is quested through the measuring orifices is smaller than
reached. This prevents short-term dropping of the or identical with the pump flow.
consumer by removing oil volume from the consumer Σ Q consumer <= maximum Q pump (within the output
lines to feed the LS-system. control)
The pressure balance is completely open and the p’- Δpmeasuring orifice approximately corresponds with the
channel is connected with the consumer port pc with- ΔpLS control adjusted on the pump flow control.
out any pressure drop. The difference between both values results from the
losses in the supply line between pump and measur-
ing orifices.

008 911 53 BOMAG 511

12.4 Control valve block, steering and dozer blade

Overlapping with a consumer with higher load

pressure

Fig. 27 regulating position the control edge of the pressure

A typical example for this is lifting the dozer blade balance generates a pressure drop from channel p’ to
while steering. The higher load pressure in the dozer pc of the consumer port. The Δp across the measuring
blade circuit reduces the cross-section of the orifice in orifice (7) is identical and the consumer speed thus
the pressure balance for the steering section. In this depends on the difference of the load pressures.

512 BOMAG 008 911 53

Control valve block, steering and dozer blade 12.4
Subsaturation / priority function

Fig. 28 Function of pressure balance under different load pressures blade pressure balance is already closed. This gives
(A) Load pressure low the steering function priority.
(B) Load pressure high If the speed of one consumer is reduced during the
overlapping of movements in subsaturation, i.e. the
1 Spring chamber
measuring orifice is closed, the degree of subsatura-
2 Control orifice tion will drop. The Δp measuring orifice of the still actuat-
In case of subsaturation of the system the oil quantity ed section will increase and the speed of the
demanded by the sum of the open measuring orifice corresponding movement will follow proportionally.
cross-sections exceeds the maximum flow rate of the
pump. The flow control valve no longer is able to gen-
erate the required system pressure by operating the
pump to a higher displacement. The pump pressure
drops, because the pump has already reached its
maximum displacement, as specified by the perform-
ance characteristic.
In case of subsaturation the pump flow rate is solely
determined by the power controller.
Σ Q Consumer > Maximum Q Pump
In case of subsaturation of the system the pressure
balances of both consumers are wide open and the
LS pressure corresponds with the pressure p' behind
the measuring orifice. However, the system/pump
pressure drops with every degree of subsaturation
and this applies also for the Δp measuring orifice and the
section quantity.
The pressure springs in the pressure balances for
steering and dozer blade are of different designs
(steering 1-2.5 bar, dozer blade 58 bar). This has the
effect, that the steering pressure balance will stay
open in case of subsaturation, whereas the dozer

008 911 53 BOMAG 513

12.4 Control valve block, steering and dozer blade

514 BOMAG 008 911 53

13 Tests and adjustments in working hydraulics

008 911 53 BOMAG 515

13.1 Measuring and adjustment points on control valve block

Measuring and adjustment points

13.1 Measuring and adjustment points on control valve block

Fig. 29 Control valve block

516 BOMAG 008 911 53

Measuring and adjustment points on control valve block 13.1

Pos. Designation Pos. ii electric wir- Pos. in hydraulic Measuring

008 911 53 BOMAG 517

13.2 Tests and adjustments on the steering/working pump

Measuring and adjustment points

13.2 Tests and adjustments on the steering/working pump

Fig. 30 Tandem working pump with pressure/flow control valve

Pos. Designation Pos. in hydraulic dia- Measuring value

gram
1 Stand-by pressure adjustment screw 30 ± 1 bar at Pos. 3
2 High pressure adjustment screw 230 +10 bar at Pos. 3
3 High pressure test port 0 - 230 +10 bar
4 LS-pressure test port X 0 - 210 +10 bar

518 BOMAG 008 911 53

Tests and adjustments on the steering/working pump 13.2
Tests and adjustments Checking/adjusting high pressure

Checking/adjusting stand-by pressure

Fig. 32
l Connect a 600-bar pressure gauge to high pressure
Fig. 31
test port (Fig. 32).
l
Connect a 60-bar pressure gauge to high pressure
test port (Fig. 31).
l Connect a 600-bar pressure gauge to LS pressure
test port 4 (Fig. 29).
l
Connect a 60-bar pressure gauge to LS pressure
test port 4 (Fig. 29).
Caution
!

Danger of squashing!
! Caution
Do not operate the steering and the dozer blade, Make sure nobody is near the dozer blade.
since this would destroy the pressure gauge. l Start the engine and run it with high idle speed.
l Start the engine and run it at low idle speed. l Raise the dozer blade and hold the control lever
against the end stop.
l Read high and LS pressure values in non-operated
state. Nominal value:
Nominal value: 230 +10 bar on the high pressure test port
30 ± 2 bar high pressure (stand-by pressure) LS-pressure 210 + 10 bar.
approx. 0 bar LS-pressure Adjustment procedure
Adjustment procedure l If necessary correct high pressure on the lower set-
screw 2 (Fig. 29).
l
If necessary correct the standby pressure on the
flow control valve (upper setscrew 1 (Fig. 29)).

008 911 53 BOMAG 519

13.2 Tests and adjustments on the steering/working pump

Checking/adjusting the LS-pressure for the work-

ing pumps

Fig. 33
l Connect a 600-bar pressure gauge to high pressure
test port (Fig. 33).
l Connect a 600-bar pressure gauge to LS pressure
test port (4) (Fig. 29).
l
Operate the steering/dozer blade slowly from neu-
tral to end stop, read both pressure gauges.

Nominal value:
As long as the working cylinders are moving the LS-
value should always be approx. 30 bar lower than the
actual high pressure. When holding the control levers
against the end stop the LS-pressure should increase
to 210 + 10 bar.
l
If there is no or a too low LS-signal, you should first
check the electric triggering of the control valves. If
the electrical system is Ok, you should check the
LS-system (valve block, hoses).
l
If both pressures are too low at the same level, the
fault is caused by the pump. The pump high pres-
sure can be corrected on the lower adjustment
screw. Should this not be possible, either the pres-
sure/flow control valve or the pump itself is defec-
tive.

520 BOMAG 008 911 53

14 Travel hydraulics

008 911 53 BOMAG 521

14.1 Hydraulic system

Hydraulic system
14.1 Hydraulic system

Travel system as well as steering and dozer blade on

these machines are hydraulically operated.
This guarantees an almost loss-free transfer of engine
output power to compactor wheels, steering cylinders
and dozer blade/bucket control.
The pumps for the corresponding circuits are driven
by the engine via a transfer box and convert the me-
chanical energy provided by the engine into hydraulic
energy.
Inside the motors or the cylinders for steering or dozer
blade actuation this hydraulic energy is then convert-
ed back to mechanical energy.
Since the medium oil is used for this transfer of power,
any losses in power are only of minor significance.
All hydraulic circuits are protected against contamina-
tion by charge oil filters and a hydraulic oil return flow
filter.
Safety elements in pumps and hydraulic control units
protect the hydraulic system and the drive engine
against overloads and damage resulting from such
excessive loads.
To ensure quick heating of the hydraulic oil up to op-
erating temperature the return flow from the hydraulic
system flows directly back to the hydraulic oil tank, un-
til the operating temperature is reached. When the oil
temperature comes close to operating temperature a
thermostat valve will start to open and guide the oil
flow through the hydraulic oil cooler back to the tank.
This ensures that the operating temperature is quickly
reached, particularly during the cold season, and that
the hydraulic system can be operated without any
risks.

522 BOMAG 008 911 53

Travel system (general description) 14.2
Travel drive
14.2 Travel system (general description)

Fig. 34 Schematic, front right hand travel circuit All four pumps are simultaneously controlled by pilot
1 Diesel engine pressure. The pilot oil needed to control the travel
2 Transfer box pumps is supplied by four charge pumps. The pump
flow from the charge pumps is also used to feed the
3 3.1 travel pump front right, 3.2 travel pump rear closed travel circuits and to compensate leak oil and
right, 3.3 charge pump left flushing quantities.
4 Control piston
The end of each tandem pump unit carries a charge
5 Travel direction valve pump. The charge pumps are gear pumps which are
6 Travel direction switch driven by through-shafts with the output speed of the
7 DA-control valve transfer box.
8 Speed range selector switch The charge pumps draw the hydraulic oil out of the hy-
draulic oil tank and deliver it through a 12 µ fine filters
9 Solenoid valve for travel speed ranges
to serve the individual functions (control of travel
10Control piston pumps, boost check valves). The charge oil flow from
11Travel motor the rear right charge pump (when looking in travel di-
12Planetary drive rection forward) is additionally used to open the multi-
disc parking brakes in the planetary gears on the com-
13Solenoid valve for brake
pactor wheels. All leak oil and flushing oil quantities
14Brake switch are returned to the hydraulic oil tank through a central
15Emergency stop return flow filter block, a temperature controlled 3/2-
16Throttle pedal way valve and the hydraulic oil cooler.
17ESX control The travel pumps are equipped with all control and
safety elements needed for operation in a closed hy-
The travel system of the sanitary landfill compactor
works with four closed hydraulic circuits. Each of draulic circuit, such as servo control unit, combined
these circuits consists of a travel pump (variable dis- high pressure relief and boost check valves, charge
pressure relief valve and pressure override valve. At
placement pump) and a travel motor (variable dis-
this point it must be mentioned that each of the pumps
placement motor). Always two travel pumps are joined
is fitted with a pressure override valve.
together to a tandem unit.
All travel motors can be operated with two different
Both tandem units are driven by the diesel engine via
displacements and therefore with two different travel
a transfer box. This transfer box is flanged to the fly-
speed ranges. The highest speed range is used as
wheel side of the engine.
transport speed, whereas the slow speed range is

008 911 53 BOMAG 523

14.2 Travel system (general description)

used as working speed. Since the travel motors have

the possibility to adjust themselves towards the slow
travel speed range whenever demanded by the load,
it is possible to operate the machine solely in high
speed range. However, in such a case it must be not-
ed that the motors will immediately change back to the
higher speed range when the load is relieved (when
pushing the refuse over the tipping edge).
All planetary gears are equipped with integrated multi-
disc brakes.
These multi-disc brakes are opened by charge pres-
sure and will close automatically when the charge
pressure supply is interrupted. This can be accom-
plished by shutting the engine down, by a fault in the
hydraulic system (travel system), by the brake switch
or the emergency stop via one of the 4/2-way valves.

524 BOMAG 008 911 53

Travel pump 14.3
Travel pump pump) and one pump of series A4VG 71 DG (dragged
14.3 Travel pump

pump) are connected. The end of each tandem pump

The travel pumps are swash plate controlled HYDRO-
unit carries a charge pump. The charge pump is a
MATIK axial piston pumps with variable displacement.
gear pump with fixed displacement.
Always one pump of series A4VG 71 DA (driven

Fig. 1 Hydraulic diagram of travel pump The pump is equipped with all control and safety ele-
1 Travel pump ments needed for operation in a closed hydraulic cir-
2 4/3-way valve (travel direction) cuit, such as
3 Control piston l High pressure relief valves
4 High pressure relief valves with boost check l
Boost check valves
valves l Charge pressure relief valve
5 Charge pressure relief valve l Pressure override valve and
6 DA-control valve
l
Servo control
7 Pressure override valve
8 Shuttle valve .

(A) to / from travel motor

(B) to / from travel motor
(PS) to PS pump 2
(X1) to X1 on pump 2
(X2) to X2 on pump 2
The flow rate of the travel pump is determined by the
displacement and the actual drive speed of the pump.
It is proportional to drive speed and displacement. The
possibility of the infinite swash plate adjustment ena-
bles an infinite alteration of the pump flow rate and
therefore an infinite adjustment of the travel speed
within the chosen travel speed range.

008 911 53 BOMAG 525

008 911 53 BOMAG 533

14.3 Travel pump

The closed circuit

As soon as the swash plate inside the travel pump is
displaced out of neutral position, the pump will start to
deliver oil to the respective travel motor.
In dependence on the speed of the diesel engine the
swash plate can be infinitely displaced out of neutral
position up to maximum displacement position.
Immediately after the swash plate has been moved
out of neutral the pressure in the hoses from pump to
motor will increase. This pressure is higher than the
pressure in the hose from the motor to the pump. The
pressure in the hose from pump to motor depends on
the actual load condition of the motor. Under normal
conditions this pressure may increase up to the set-
ting of the pressure override (for pressure values refer
to the technical data).
The high pressure relief valves protect the closed hy-
draulic circuit and the combustion engine against
overloads (e.g. short pressure peaks). In such a case
the valve on the high pressure side will open and re-
lieve oil through the boost check valve into the low
pressure side.
Since permanent responding of the high pressure re-
lieve valves would cause extreme overheating of the
hydraulic oil and quickly lead to serious damage, this
system is protected by another kind of primary pres-
sure limitation, the pressure override. Each of the trav-
el pumps is equipped with a pressure override valve.
The high pressure in the system is permanently re-
ported to the pressure override valve via a shuttle
valve between both sides of the closed hydraulic trav-
el circuit. The pressure override valve itself is connect-
ed with the pilot oil flow from the DA-control valve to
the 4/3-way valve for the travel direction.
If the high pressure in the travel system increases up
to the setting of the pressure override, this high pres-
sure will push the valve spool in the pressure override
against the pressure spring. This guides part of the pi-
lot oil flow between DA-control valve and 4/3-way so-
lenoid valve through the now open spool to the valve.
The pressure drop in the pilot oil supply reduces the
force acting on the control piston and the pump
swashes back towards neutral. This reduces the
pump displacement, until the pump pressure is in ac-
cordance with the value adjusted with the pressure
spring.
If the pressure drops below the setting of the pressure
override, the pilot oil flow is opened again and the
pump will return to the previously chosen displace-
ment.
As a measure to avoid any reaction of the high pres-
sure relief valves, the pressure override is adjusted to
a lower value than the high pressure relief valves.

534 BOMAG 008 911 53

Travel pump 14.3
Pressure override valve

Fig. 10 Pressure override valve The minimum difference between high pressure relief
1 Valve piston valve and pressure override is 30 bar.
2 Bore
3 Valve seat
4 Piston
5 Valve bushing
6 Control piston
7 Spring cup
8 Pressure spring
9 Setscrew
10Pilot pressure channel
11Housing channel
12High pressure circuit
13High pressure circuit
14Valve seat
Adjustment values see next page.

008 911 53 BOMAG 535

14.4 Travel motors

Travel motors 2T. These motors are designed with two different dis-
14.4 Travel motors

placements an can therefore be operated in two differ-

Each wheel of the sanitary landfill compactor is driven
ent travel speed ranges, as desired.
by a HYDROMATIK bent axle motor A6VM 160 HA

Fig. 1 Travel motor A6VM 160 HA 2T

1 Control start setscrew
The motors are connected to the associated travel
pumps via the high pressure ports A and B. The high
pressure hydraulic oil flows through the respective
high pressure port to the back of the working pistons.
Since these pistons are arranged under an angle to
the output shaft, the pressurized pistons perform an
axial movement, thereby generating the rotary move-
ment of the connected output shaft.
Once a piston has passed through its dead centre
(max. extension), the piston will change to the low
pressure side. The continuing rotation presses the
piston back into the cylinder. This forces the hydraulic
oil from the cylinder chamber through the low pres-
sure side back into the pump.
Charge pressure can be applied to the control unit on
the travel motor via a solenoid valve. This changes the
angle between piston drum and output shaft.
In this context a large angle means high displace-
ment. In low speed range the motor works with a high
torque. With a small angle these conditions are exact-
ly opposite.
When driving the refuse compactor in high speed
range, he travel motors will automatically start to ad-
just towards high displacement once a certain pres-
sure level is reached. At the same time the torque
increases accordingly.

536 BOMAG 008 911 53

Travel motors 14.4

Fig. 2 Hydraulic diagram travel motor Motor works in speed range 1

(A) Stage 1 If speed range 1 (slow) is selected, charge pressure is
(B) Stage 2 applied to port X. This pressure causes reversing of
the pilot control piston (4) against the spring forces F2
(C) Control range
and F3. The high pressure in A or B is guided through
1 Engine the corresponding non-return valve via the pilot con-
2 Check valve trol piston to the control piston area A2. High pressure
3 Check valve is also applied to control piston area A1. The resulting
force F1 (F1 = (A2-A1) x P) has the effect, that the mo-
4 Pre-control piston
tor changes to high displacement (max. torque and
5 Pressure relief valve slowest speed).
6 Flushing valve
7 Planetary drive
8 Control piston

008 911 53 BOMAG 537

14.4 Travel motors

Motor works in speed range 2 or 3 when the charge pressure drops below the brake re-
leasing pressure (when shutting the engine down,
Pilot pressure below control start when actuating the parking brake etc.).
The high pressure in A or B is guided through the cor-
responding non-return valves to the pilot control pis-
ton. With pressures up to control start of the travel i Note
motors (pressure values see technical data) the ad- The brake is designed and intended as a parking and
justable spring force F3 of the control start spring is emergency brake. Unnecessary use of the emergen-
higher than the force applied by the pressure. The cy stop during travel operation reduces the lifetime of
connection to control piston area A2 is interrupted. the brake discs and should therefore be avoided!
High pressure is only applied to control piston area
A1. In this case the control piston force is F1 = A1 x P
and holds the motor at the small swashing angle (min.
torque and high speed).

Operating pressure within the control range

With the automatic displacement control (high pres-
sure dependent), the adjustment of the displacement
(proportional swashing angle) is accomplished auto-
matically in dependence on the operating pressure.
The control start is pre-set by the adjustment of spring
force F3. Once the operating pressure reaches the
adjusted value, pressure is also applied to control pis-
ton area A2 via the control piston.
The pressure increase spring F2 prevents the pilot
control piston from opening completely. Due to the
”restrictor effect” of the slightly opened control piston,
the pressure applied to A2 is lower than the operating
pressure. Only when the operating pressure reaches
the control end (for value refer to the technical data),
the force of the pressure increase spring is exceeded
and the pilot control piston enables operating pres-
sure to flow to the control piston area A2.
The two motors on one side of the machine are linked
via the ports ”G”. Through these ports the pressure in
the travel circuit with the highest pressure is reported
to the other motor. The motor with the lower pressure
thereby responds exactly in the same way as the mo-
tor with the higher pressure. This installation synchro-
nizes the motor controls of the two motors on one side
of the machine.
This type of control ensures that both motors on one
machine side work with almost the same displace-
ment / speed. This prevents the unloaded motor from
changing to max. speed, if one of the wheels is un-
loaded (e.g. when raising the wheels with the dozer
blade).
Since the output speed of the motors is too high for di-
rect driving of the wheels, the motor output speed is
reduced to final working speed by planetary gears.
Each wheel unit therefore consists of a hydraulic mo-
tor with a planetary gear.
The motors are directly connected to the planetary
gears via splined shafts.
The housings of the planetary gears also contain the
multi-disc brakes. The brakes run in an oil bath and
are therefore almost wear-free. The brakes are re-
leased by charge pressure and close automatically

538 BOMAG 008 911 53

Filtration 14.5
Filtration
14.5 Filtration

Function and lifetime of a hydraulic system depend

decisively on the cleanliness of the power transmis-
sion medium (hydraulic oil).
For this reason it is mandatory to filter the hydraulic oil
permanently while the machine is working. In closed
hydraulic circuits the full flow filtration of the charge
circuit and the return flow from the individual compo-
nents has been found very beneficial.

Charge circuit filtration

Both charge circuits are fitted with one 12 µm fine filter
each. The oil flows through these filters to the individ-
ual consumers and functions.
The filters are fitted with by-pass valves. These open
at a pressure differential (pressure difference between
filter inlet and filter outlet) of 3.5 bar. This pressure dif-
ferential depends on the filter contamination and the
viscosity of the hydraulic oil.
Pressure differential switches on the filters report any
increase of the pressure differential into the cabin.
These switches are designed for a pressure differen-
tial of 2.5 bar. The respective information will therefore
already be available before the by-pass valve opens.

Return flow filter block

As a second measure to keep the oil free of any impu-
rities, all leaks, flushing quantities and return flows are
guided back to the tank through a central return flow
filter block.
The return flow filter block contains two 80 µ filters,
two dirt sensors, one pressure switch and a tempera-
ture controlled 3/2-way valve.
All return flows pass through the primary filter, fol-
lowed by a temperature controlled valve (thermostat).
This valve guides the oil flow directly back to the tank,
until the operating temperature is reached. At an oil
temperature of 55 °C the valve starts to switch over
and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.
If the primary filter is dirty, the oil flow is guided
through the secondary filter. The oil can only pass
through this filter when the static pressure in front of
the primary filter is higher than 2 bar. In this case the
oil is no longer cooled. The pressure switch reports a
too high static pressure in front of the primary filter and
informs the operator via the fault indicator module.
In addition to this the dirt sensor (permanent magnet)
reports any metallic contamination in the oil via a vis-
ual indicator in the cabin.

008 911 53 BOMAG 539

14.6 Transfer box filter unit

Oil circuit A pressure relief valve is installed in front of the filter

14.6 Transfer box filter unit

inlet. It limits the pressure to 12 bar in low and 25 bar

A pump inside the transfer box pumps the oil in the
in high idle speed of the engine, at a gear oil temper-
transfer box through a cooling circuit and finally
ature of min. 40°C.
through a filter.

Fig. 1 4 Pressure relief to gearbox

1 Filter unit 5 filtered oil to transfer box
2 Pressure relief valve 6 from cooling circuit
3 Differential pressure switch 7 Separation PRV-setting

Pos. Designation Measuring value

1 Filter unit
2 Pressure relief valve 25 bar in high idle and min. 40°C oil temperature
3 Differential pressure switch 2.4 bar

540 BOMAG 008 911 53

15 Tests and adjustments in travel hydraulics

008 911 53 BOMAG 541

15.1 Measuring and adjustment points on tandem travel pump unit

Measuring and adjustment points

15.1 Measuring and adjustment points on tandem travel pump unit

Fig. 2

542 BOMAG 008 911 53

Measuring and adjustment points on tandem travel pump unit 15.1

Pos. Designation Pos. in elec- Pos. in hy- Measuring value

), ), ); see adjustment instructions

008 911 53 BOMAG 543

15.2 Pressure tests in the travel circuit

Danger
!

Whenever performing tests make sure you di-

rect visual contact with the driver.
1. Run the machine warm to operating temperature
(approx. 40°C hydraulic oil temperature).
2. Connect the following pressure gauges (Fig. 1):
1 High pressure, travel pump rear left, 600 bar.
2 High pressure, travel pump front left, 600 bar.
3 High pressure, travel pump front right, 600
bar.
4 High pressure, travel pump rear right, 600
bar.
5 Charge pressure, left hand tandem pump 60
bar.
6 Charge pressure, right hand tandem pump 60
bar.
Fig. 1
7 Control chamber pressure, left hand tandem
pump 60 bar.
8 Control chamber pressure, right hand tandem
pump 60 bar.

Danger
!

Make sure there are no persons in front of or

behind the machine.
3. Input module (Fig. 2) enter PIN-CODE.
4. Start the engine, select 2nd speed range and
switch to travel direction reverse.

i Note
Do not actuate the emergency stop.
5. Accelerate the engine slowly up to full speed and
watch the pressure gauges.

Nominal values:
High pressures must increase evenly to 430 +10/
-20 bar. The charge pressures must not drop con-
Fig. 2 siderably (<28 bar). At least 28 bar at idle speed,
increasing to 30 bar.
Control chamber pressures must increase evenly
to approx. 14 bar.

544 BOMAG 008 911 53

Checking high pressure relief valves and pressure override 15.3
15.3 Checking high pressure relief valves
and pressure override
1. Run the machine up to operating temperature
(40°C hydraulic oil temperature).
2. Input module (Fig. 1) enter PIN-CODE.

Fig. 1
3. Connect a 600 bar pressure gauge to both high
pressure ports (Fig. 2) of a tandem pump.

Fig. 2
4. Pull the electric plugs A and B (Fig. 3) off the
magnets on the other pump, since the machine
might drive through the brake.

Fig. 3

008 911 53 BOMAG 545

15.3 Checking high pressure relief valves and pressure override

5. Turn the adjustment screw of the pressure over-

ride (Fig. 4) completely in (block).

! Danger
Make sure there are no persons in front of or
behind the machine.
6. Start the engine, select 2nd speed range and shift
the travel lever to the desired travel direction

i Note
Do not actuate the emergency stop.
Fig. 4
! Caution
Perform the following test for max. 3 seconds,
as otherwise the pump may be destroyed by
overheating!
7. Accelerate for a moment (max. 3 seconds) to full
speed and read the pressure gauges.

Nominal value:
480 -20 bar
8. If necessary adjust the high pressure relief valves
(Fig. 5).
9. Repeat this test to the opposite travel direction.
10. Repeat these tests for the rear pump.

Fig. 5
11. Adjust the pressure override (Fig. 6) on the front
pump to 430 bar (high pressure measurement on
front pump!).
12. Adjust the pressure override on the rear pump to
430 bar (high pressure measurement on rear
pump).

! Caution
If the pressure override is not correctly ad-
justed on one of the pumps (remains blocked)
the high pressure in the respective circuit
may increase up to the setting of the high
Fig. 6 pressure relief valves.
13. Perform the same tests for the second tandem
pump.

546 BOMAG 008 911 53

Charge pump high pressure test 15.4
15.4 Charge pump high pressure test
Special tools:
Gear pump testing device, 600 bar pressure
gauge.
1. Close the pump outlet port with a 200 bar pres-
sure gauge (Fig. 1) fitted with a pressure gauge.
Hold the open end of the hose into a collecting
vessel.
2. Crank the engine with the starter (pull the plug off
the solenoid valve or keep the engine shut-down
depressed).
3. Read the pressure gauge.

Nominal value:
200 bar
4. If the nominal value is not reached, replace the
Fig. 1 charge pump.

008 911 53 BOMAG 547

15.5 Travel pump high pressure test (individual test)

15.5 Travel pump high pressure test (indi-

vidual test)
1. Close the high pressure ports (Fig. 1) on one trav-
el pump with plugs.

Fig. 1
2. Input module (Fig. 2) enter PIN-CODE.

Fig. 2

! Danger
Pull the electric plugs A and B (Fig. 3) off the
magnets on the other pumps, because the
machine might drive through the brake.

Fig. 3

548 BOMAG 008 911 53

Travel pump high pressure test (individual test) 15.5
3. Connect a 600 bar pressure gauge to the high
pressure test port of the pump (Fig. 4).

i Note
Do not actuate the emergency stop.
4. Start the engine, select 2nd speed range and shift
the travel lever to the desired travel direction
5. Raise the engine speed for a moment and read
the pressure gauge.

Nominal value:
410 to 440 bar
Fig. 4
6. If the nominal value is not reached, check pres-
sure override and high pressure relief valves. If
the valves are o.k., replace or repair the travel
pump.

008 911 53 BOMAG 549

15.6 Checking charge pressure

1. Run the machine until operating temperature is
achieved, then shut down the engine.
2. Block the front charge pressure relief valve 1 (Fig.
5) on a tandem pump, turn the setscrew com-
pletely in to do so.
3. Connect a 60 bar pressure gauge to the charge
pressure test port (3).
4. Start the engine and run it with half speed.
5. Set the rear charge pressure relief valve (2) to 30
bar.
6. Run the engine with maximum speed (the charge
pressure increases).
7. Loosen the blocked valve until the charge pres-
Fig. 5
sure of 30 bar is reached again.
8. Check the charge pressure again at idle speed.

Nominal value:
min. 28 +/- 2 bar
9. Should the pressure of 28 bar not be reached, re-
peat the basic adjustment with a pressure higher
than 30 bar, but on both valves identical.
10. Check and adjust the other tandem pump accord-
ingly.

550 BOMAG 008 911 53

Adjusting the DA-control valve 15.7
15.7 Adjusting the DA-control valve
1. Warm the machine up to operating temperature.
2. Input module (Fig. 1) enter PIN-CODE.
3. Select 2nd speed range.

Fig. 1
4. Connect 600 bar pressure gauges to both high
pressure test ports (MA or MB) of both tandem
pumps (1) / (2) and (3) / (4) (Fig. 2).
5. Start the engine and raise the engine speed to
950 ± 50 rpm (1025 ± 50 rpm on BC572RB-2).
6. Select the travel direction in accordance with the
chosen high pressure test port (in this illustration
reverse) and read the pressure gauge.

i Note
Do not operate foot brake and emergency stop.

Fig. 2 Nominal value:

High pressure 50 bar as mean value
7. Raise the engine speed to 1700 rpm.

Nominal value:
High pressure 400 bar
8. If deviations from the nominal value for control
start are found the pressure must be adjusted on
the corresponding DA-control valve (Fig. 3).

i Note
Turn clockwise = control start at higher engine
speed.
Turn anti-clockwise = control start at lower engine
speed.
Both tandem pumps must be equalized, i.e. for a
synchronous operation the adjustment values of
right and left hand pumps should be almost iden-
Fig. 3 tical.

008 911 53 BOMAG 551

15.8 Stellkammerdrück prüfen

1. Maschine betriebwarm fahren.
2. Eingabemodul (Fig. 1) PIN-CODE eingeben.
3. Zweite Fahrstufe einlegen.

Fig. 1
4. Je ein 60 bar Manometer Messanschluss (X1 und
X2) (Fig. 2) Stellkammerdruck anschließen.
5. Dieselmotor starten.

i Note
Fußbremse und Not-Aus-Schalter nicht betäti-
gen.

Sollwert:
Motordrehzahl 950 ± 50 1/min (1025 ± 50 1/min
bei BC572RB-2): ca. 6 bar
Motordrehzahl 1700 ± 50 1/min: ca. 12...14 bar
Fig. 2

i Note
Die Messungen vom Regelbeginn und Rege-
lende sind im Hochdruck aussagekräftiger als
Stellkammerdruck, da hier der effektive, zu den
Rädern geführte Druck gemessen wird.

552 BOMAG 008 911 53

Measuring and adjustment points on travel motors 15.9
15.9 Measuring and adjustment points on travel motors

Fig. 1 Travel motor front right

Pos. Designation Pos. in elec- Pos. in hy- Measuring value

tric wiring di- draulic dia-
agram gram
1 Control pressure test port M23, M24, 0 - 430 bar
M25, M26
2 High pressure test port M27, M28; 0-430 bar (actual
M29, M30, G high pressure)
3 Setscrew for control start
4 Setscrew for Qmax G do not turn!
5 Flushing valve

008 911 53 BOMAG 553

15.9 Measuring and adjustment points on travel motors

Adjusting the control start of the travel motors

● Run the machine up to operating temperature (min. 40°C hydraulic oil temperature).
● Install 600 bar pressure gauges to both test ports on the corresponding travel motor.
● Use input code 500 on the CAN-Bus input module to block the brake.
● Choose 2nd speed range and any travel direction and slowly increase the engine speed while keeping
an eye on the pressure gauges.

Nominal value:
up to 280 bar high pressure can be read on the lower test port (G) actual high pressure, the upper test
port (M1) approx. 0 bar.
from a high pressure of approx. 280 bar the pressure at M1 must increase together with the high pressure,
so that full high pressure is also indicated here when approx. 380 bar is reached.
● If necessary correct the adjustment on the setscrew. Turning in reduces and turning out increases the
control start.

i Note
1 revolution of the control start adjustment screw results in a 100 bar change!

554 BOMAG 008 911 53

Checking the displacement setting of the travel motors 15.10
15.10 Checking the displacement setting of the travel motors

Fig. 1
1 Pilot pressure port (pressure in swashing cylinder) 3 Electric plug, brake solenoid valve
2 High pressure port „G“ 4 Setscrew, displacement adjustment

008 911 53 BOMAG 555

15.10 Checking the displacement setting of the travel motors

Special tools:
2 x 600 bar pressure gauges
2 pressure test hoses

i Note
Always perform this test after replacing one or several motors.
If a new motor was installed, fill, bleed and, if necessary, flush the hydraulic system as described.
1. Run the machine warm in the first speed range, until the hydraulic oil has a reached a temperature of ap-
prox. 50 °C.
2. Connect a high pressure gauge 2 (Fig. 1) to port “G“ on the respective motor.

i Note
This pressure gauge shows the load dependent high pressure in travel operation.
3. Connect a high pressure gauge (1) to the corresponding pilot pressure test port on the motor to be tested.

i Note
This pressure gauge shows the pressure in the swashing cylinder.

! Danger
Input module, enter PIN-CODE.
Secure all wheels with wedges.

i Note
The adjustments can be made in any travel direction.
4. Start the engine and let it run in idle speed, select second speed range and the respective travel direction.

! Caution
Do not actuate the emergency stop switch.
5. Slowly raise the engine speed, read both pressure gauges.

Nominal value:
As the engine speed increases, the pressure on pressure gauge (2) port “G“ will increase.
The pressure on pressure gauge (2) increases from approx. 29 bar to 280 bar, while pressure gauge (1)
does not indicate any pressure.
Once the pressure on pressure gauge (2) exceeds 280 bar, the pressure on pressure gauge (1) also starts
to increase.
When pressure gauge (2) reaches 380 bar, pressure gauge (1) must also reach 380 bar.
At pressure above 380 bar both pressure gauges (2 and 1) must have identical readings.

Evaluation of test:
If the specified values are not reached adjust the pilot pressure on screw (4).

i Note
If pressure gauge (2) shows 380 bar, while pressure gauge (1) shows less than 380 bar, turn the adjust-
ment screw in anti-clockwise direction.
If pressure gauges (2) and (1) show identical pressure values before reaching 380 bar, turn the adjust-
ment screw in clockwise direction.
6. Repeat this test on all other travel motors.

556 BOMAG 008 911 53

Filter unit for transfer box / pressure relief valve 15.11
15.11Filter unit for transfer box / pressure relief valve

Filter unit

Fig. 1

1 Filter unit
2 Pressure relief valve
3 Pressure differential switch
4 Pressure relief to gearbox
5 filtered oil to transfer box
6 from cooling circuit
7 Separation PRV-setting

Pos. Designation Measuring value

1 Filter unit
2 Pressure relief valve 25 bar in high idle and min. 40°C oil temperature
3 Pressure differential switch 2.4 bar

008 911 53 BOMAG 557

15.11 Filter unit for transfer box / pressure relief valve

Adjusting the pressure relief valve

● Run the machine warm (min. 40°C gear oil temperature) and shut the engine down.
● Unscrew the pressure relief valve from the filter inlet port (Fig. 1).
● Close the outlet towards the filter on the disconnected T-fitting with a plug (P/N 055 427 05).
● Close the filter inlet port with plug (P/N 055 427 05) and nut (P/N 055 450 25).
● Start the engine and adjust the pressure relief valve to 25 bar in high idle speed / 12 bar in low idle
speed; then shut the engine down again.
● Reconnect the pressure relief valve to the filter.

558 BOMAG 008 911 53

16 Special tools, tests and adjustments

008 911 53 BOMAG 559

16.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80

Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
BOMAG part-no.: 059 710 02

Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C

BOMAG part-no.: 050 100 75

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

BOMAG part-no.: 079 948 99

Fig. 4

560 BOMAG 008 911 53

Special tools, tests and adjustments 16.1
5. Digital rpm-meter for petrol engines

BOMAG part-no.: 059 711 12

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

BOMAG part-no.: 079 948 98

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

BOMAG part-no.: 057 668 06

Fig. 7
8. Hydraulic test case, large

BOMAG part-no.: 007 610 03

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

Fig. 8

008 911 53 BOMAG 561

16.1 Special tools, tests and adjustments

9. Hydraulic test case, small

BOMAG part-no.: 079 930 01

i Note
2X 60 bar pressure gauge
2X 600 bar pressure gauges
4 pressure test hoses

Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03

Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04

Fig. 11
12. Adapter for pressure test hose

BOMAG part-no.: 055 439 02

Fig. 12

562 BOMAG 008 911 53

Special tools, tests and adjustments 16.1
13. Gear pump testing device

BOMAG part-no.: 007 610 05

Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)

Fig. 14

008 911 53 BOMAG 563

16.1 Special tools, tests and adjustments

564 BOMAG 008 911 53

17 Oscillating articulated joint

008 911 53 BOMAG 565

17.1 Removing and installing live ring, oscillating articulated joint

17.1 Removing and installing live ring, os-

cillating articulated joint
Disassembling the live ring

! Danger
Safely support front and rear frames as well
as oscillating articulated joint.
Danger of squashing!
1. Remove the front cover 1 (Fig. 1), remove the
rear cover

Fig. 1
2. Disassemble the cover 1(Fig. 2) from above the
hoses.

Fig. 2
3. Remove cover 1 (Fig. 3) from the front frame.

Fig. 3

566 BOMAG 008 911 53

Removing and installing live ring, oscillating articulated joint 17.1
4. Raise the dozer blade to end position and tie it to
the front frame in this position (Fig. 4). Support
the raised dozer blade with wooden blocks so
that the front frame can be moved forward.
5. Release the brakes on both front final drives.

! Danger

Before releasing the multi-disc brake secure

the machine against unintended rolling.
6. Remove the brake lines.

Fig. 4
7. Install measuring adapters 1 and 2 (Fig. 5) to the
disconnected brake line and the free port on the
final drive. Connect the installed measuring
adapters with a pressure test hose (3).
8. Start the engine, the multi-disc brake will open
automatically.
9. After releasing the brake shut down the engine.
Disconnect the pressure test hose from the
measuring adapter fitted to the port on the final
drive.

! Danger
Fig. 5 Front drive without brake, secure the front
frame against rolling.
10. Connect the vacuum pump and generate vacuum
in the hydraulic oil tank.
11. Mark all hydraulic lines, hoses and electrical lines
from the front to the rear frame, disconnect them
from the connection points in the front frame, re-
move the hose clamps and lay the hoses down.
Close all connections immediately with plugs.

i Note
Ensure correct routing of hoses and lines in the
roller guide 1 (Fig. 6).
12. Drain or pump the fuel from the fuel tank.

! Caution
Fire hazard! Do not smoke, do not use open
fire!

Fig. 6

008 911 53 BOMAG 567

17.1 Removing and installing live ring, oscillating articulated joint

13. Safely support the rear end of the rear frame on

both sides 1 (Fig. 7).

!Danger
Danger of squashing!

Fig. 7
14. Fasten the lifting tackle to the front frame.
15. Front lifting points 1 (Fig. 8).

Fig. 8
16. Rear lifting points 1 (Fig. 9).

Fig. 9
17. Front frame safely suspended by lifting gear (Fig.
10).

! Danger
Do not stand or step under loads being load-
ed.
Danger of squashing!

Fig. 10

568 BOMAG 008 911 53

Removing and installing live ring, oscillating articulated joint 17.1
18. Place a plastic pad 1 (Fig. 11) under the steering
cylinder rod.
19. Disconnect the lubrication hoses from connec-
tions (2).
20. Remove the bars and knock out the bolts (3).

i Note
Grease the parts.

Fig. 11
21. Unscrew all hexagon screws 1 (Fig. 12) from the
console

i Note
Cover the threads with copper paste OKS 240.
Tightening torque: 463 Nm.
22. Move the front frame carefully forward for approx.
2 m, until the oscillating articulated joint is free.

! Danger
Secure dozer blade or front frame against
Fig. 12 turning over.
Danger of squashing!
Do not step or work under suspended loads.
Danger of squashing!
23. Support front frame and dozer blade in a safe
manner.
24. Disassemble roller guide 1 (Fig. 13) from the tank
25. Attach the lifting tackle to the fuel tank.

Fig. 13

008 911 53 BOMAG 569

17.1 Removing and installing live ring, oscillating articulated joint

26. Unscrew the rear hexagon screws from fuel tank

1 (Fig. 14).

Fig. 14
27. Remove the front bracket (Fig. 15) from the tank
28. Lift the fuel tank out of the front frame.

Fig. 15
29. Disconnect lubrication hoses 1 (Fig. 16) from the
connections on the live ring. Unscrew socket (2).
30. Attach the lifting tackle to the oscillating articulat-
ed joint.

!Danger
Danger of squashing!

Fig. 16
31. Disconnect the top and bottom grease hoses 1
(Fig. 17) from the connections on the bearings
from the inside.

Fig. 17

570 BOMAG 008 911 53

Removing and installing live ring, oscillating articulated joint 17.1
32. Unscrew the socket head cap screws 1 and 2
(Fig. 18) from the live ring.
33. Take the live ring off completely.

Fig. 18

i Note
Tighten the outer socket head cap screws first,
then lubricate the live ring. During the lubrication
process keep turning the live ring and lubricate
until the grease emerges from the sealing lip.
34. Align and fasten the live ring accordingly (Fig.
19).
G = position of lubrication bores
B = position of filler plug

i Note
Fig. 19 Cover the threads with copper paste OKS 240.
Tightening torque: 463 Nm.
35. Extract the oscillating articulated joint completely.
36. Replace screws and sleeves.
37. Use a sleeve for each screw.

008 911 53 BOMAG 571

17.2 Repairing the oscillating articulated joint

Fig. 1

572 BOMAG 008 911 53

Repairing the oscillating articulated joint 17.2
1 Self-aligning bearing 9 Snap ring
2 Central block 10 Seal ring
3 Console 11 Bolt
4 Taper roller bearing 12 Sleeve
5 Dirt scraper 13 Cover
6 Hexagon screw 14 Flanged cover
7 Hexagon screw 15 Washer
8 Roll pin

1. Store the disassembled oscillating articulated

joint safely.

! Danger
Danger of squashing!
2. Unscrew the hexagon screw 6 (Fig. 1).
3. Take off cover (13) and disc (15).

i Note
Insert roll pin (8) into the bore of the disc.
4. Attach the lifting tackle to the console (3).

! Danger
Danger of squashing!
5. Drive bolt (11) with a mandrel.

i Note
Grease the bolt.
6. Knock sleeves (12) out of the console.
7. Unscrew hexagon screws (6) from the flanged
cover (14).
8. Take off the flanged cover (14).
9. Remove the dirt scraper (5).

i Note
Assemble the new dirt scraper with grease.
10. Take out the snap ring (9)..
11. Knock out taper roller bearing (4), take out inner
dirt scrapers (5).

i Note
Assemble the new dirt scraper with grease.
Use new taper roller bearings.
12. Check the pivot bearings (1) for the steering cyl-
inders, if necessary assemble new ones.

008 911 53 BOMAG 573

17.3 Removing and installing the steering cylinders

17.3 Removing and installing the steering

cylinders

Securing the machine

1. Drive the machine on a level base of sufficient
load bearing capacity.
2. Swing the articulation lock 1 (Fig. 1) forward out
of its holding bracket and fasten with bolt (2) to
the eye on the front frame. Secure the bolt with
the cotter pin (3).

Fig. 1
3. Push the lever for dozer blade control (Fig. 2) for-
ward to position "I" and lower the dozer blade
slowly ........

Fig. 2
4. .... and rest it on the ground (Fig. 3).

Fig. 3

574 BOMAG 008 911 53

Removing and installing the steering cylinders 17.3
5. Press button "a" (Fig. 4).
6. Shift the dozer blade control lever to float position
"I".
7. Shut down the engine.

Fig. 4

Removing the steering cylinders

1. Open the rear access door (Fig. 1).

Fig. 1
2. Remove the plates for the electric end position
damping (Fig. 2).

Fig. 2

Environment
Catch running out hydraulic oil and dispose
of environmentally.

! Danger
Before disconnecting any hydraulic connec-
tions you must make sure that the engine has
been shut down and the system pressure has
been relieved.
3. Disconnect the hydraulic hoses (Fig. 3).
4. Close connections and hoses with plugs.
Fig. 3

008 911 53 BOMAG 575

17.3 Removing and installing the steering cylinders

5. Disassemble lubrication grease hose 1 (Fig. 4),

screw (2) and lock washer.
6. Unscrew the screws (3) and remove the flat steel
bar (4).

! Danger

Danger of squashing!
The steering cylinder has a weight of approx.
45 kg.
7. Knock out steering bolts (5).

Fig. 4
Old design lubrication grease hose (Fig. 5)
8. Disassemble lubrication grease hose 1 (Fig. 5),
screw (2) and lock washer.
9. Unscrew the screws (3) and remove the flat steel
bar (4).
10. Knock out steering bolts (5).
11. Lift the steering cylinders out of the machine and
lay them down safely.

Fig. 5
New design lubrication grease hose (Fig. 6)
12. Remove the lubrication grease hose 1 (Fig. 6).
13. Unscrew the screws (3) and remove the flat steel
bar (3).
14. Knock out steering bolts (5).
15. Lift the steering cylinders out of the machine and
lay them down safely.

Fig. 6

Assembling the steering cylinders

1. Reassemble in reverse order.
2. Check the rocker bearing, replace if necessary
(Fig. 1).

i Note
The cylinders may be carefully retracted and ex-
tended with compressed air or by pressing man-
ually.
Assemble the bearing bolt with some grease

Fig. 1

576 BOMAG 008 911 53

Removing and installing the steering cylinders 17.3
Bleeding
1. Check the hydraulic oil level (Fig. 1).

! Danger
Do not step or stand in the articulation area of
the machine when the engine is running.

i Note
Steer the machine several times to right and left
with the engine running at idle speed.
Due to trapped air hydraulic cylinders may initially
perform erratically, but normally vent themselves
after a few stroked
Fig. 1
2. Check hydraulic connections for leaks.
3. Check the hydraulic oil level once again.

Adjust the electric end position damp-

ing
i Note
Steer the machine fully to the left to adjust the
right hand initiator.
Steer the machine fully to the right to adjust the
left hand initiator.
1. Turn the initiators (Fig. 1) completely back.
2. Steer the machine against the end stop.
3. Adjust the space between initiator and contact
face to 5mm.
4. Tighten the counter nut.

Fig. 1

008 911 53 BOMAG 577

17.3 Removing and installing the steering cylinders

578 BOMAG 008 911 53

18 Suppliers documentation

008 911 53 BOMAG 579

580 BOMAG 008 911 53
18.1 Travel pump

008 911 53 BOMAG 581

18.1 Travel pump

582 BOMAG 008 911 53

Travel pump
Electric Drives Linear Motion and
18.1
and Controls Hydraulics Assembly Technologies Pneumatics Service

Verstellpumpe A4VG 71–180 RDE 92 003-21-R/01.06

Variable Pump A4VG 71–180

Baureihe/Series 32 R1
Reparaturanleitung / Repair Manual
Baugruppen / Assembly Groups

008 911 53 BOMAG 583

2/40
18.1
Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

Vermeidung von Gefahren Avoiding Dangers

Für einen sicheren Betrieb und um Schäden bei der Reparatur To ensure safe operations and avoid damages during repairs,
zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig read this complete repair manual carefully and attentively.
und aufmerksam durch!
Für Personen- oder Maschinenschäden, die durch Nichtbe- Bosch Rexroth AG accepts no responsibility for personal
achtung dieser Reparaturanleitung entstehen, verfällt jegliche injuries or damages to the machine that arise from disregarding
Gewährleistung von Bosch Rexroth AG. this repair manual.

1 Zu dieser Anleitung 1 About this Manual

Diese Anleitung unterstützt Sie bei der Reparatur, den Über- This manual supports you in the repair, adjustment and recom-
prüfungen und der Wiederinbetriebnahme von Rexroth A4VG missioning of Rexroth A4VG variable pumps, sizes 71–180.
Verstellpumpen, NG 71–180. Diese Anleitung umfasst die The manual is structured as follows:
folgenden Kapitel:
„Sicherheit“ auf Seite 7 “Safety” on page 7
Hier erhalten Sie grundsätzliche Hinweise zum sicheren This chapter provides you with basic hints and tips regarding
Umgang mit Verstellpumpen und zu deren Betrieb. working with and operating variable pumps.
Lesen Sie dieses Kapitel bevor Sie anfangen zu arbeiten. Read this chapter before you start working.
„Produktbeschreibung“ auf Seite 11 “Product Description” on page 11
Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe This chapter explains how you identify the variable pump.
feststellen. Ferner ﬁnden Sie hier eine Übersicht über die Addtionally, it provides you an overview of the how the vari-
Funktionsweise und Informationen zur bestimmungsgemäßen able pump and information regarding the correct usage.
Verwendung der Verstellpumpe. Read this chapter to refresh your knowledge of the variable
Lesen Sie dieses Kapitel, um Ihr Grundwissen über die pumps.
Verstellpumpe aufzufrischen.
„Austausch externer Baugruppen“ auf Seite 15 “Exchanging Extermnal Assembly Groups” on page 15
Dieses Kapitel erklärt Ihnen, wie Sie Baugruppen einer Ver- Rexroth provides various replacement parts for repairs. This
stellpumpe austauschen. section provides you an overview of the available spare parts
subassemblies.
„Überprüfungen“ auf Seite 33 “Checking” on page 33
Dieses Kapitel erklärt Ihnen, wie Sie die Einstellarbeiten an Read this chapter to be able to restore the settings on an
einer Verstellpumpe vornehmen. variable pump after a repair.

584 BOMAG 008 911 53

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
18.13/40
Bosch Rexroth AG

1.1 Inhaltsverzeichnis 1.1 Contents

1. Zu dieser Anleitung 2 1. About this Manual 2

1.1 Inhaltsverzeichnis 3 1.1 Contents 3
1.2 Gültigkeitsbereich dieser Anleitung 4 1.2 Validity of this Manual 4
1.3 Wichtige Unterlagen 5 1.3 Important Documents 5
1.4 Gefahrenkennzeichnungen und Pictogramme 6 1.4 Danger Labels and Pictograms 6
2. Sicherheit 7 2. Safety 7
2.1 Grundlegende Sicherheitshinweise 7 2.1 Basic Safety Information 7
2.2 Anforderungen an das Personal 10 2.2 Requirements on the Personnel 10
3. Produktbeschreibung 11 3. Product Description 11
3.1 Typschild 11 3.1 Name Plate 11
3.2 Funktionsbeschreibung 11 3.2 Functional Description 11
3.3 Technische Daten 14 3.3 Technical Data 14
4. Austausch externer Baugruppen 15 4. Exchanging External Assembly Groups 15
4.1 Wellendichtring austauschen 16 4.1 Exchanging the Shaft Seal 16
4.2 Dichtungen austauschen 18 4.2 Exchanging Seals 18
4.3 Hilfspumpe austauschen 24 4.3 Exchanging the Backing Pump 24
4.4 Steuergerät austauschen 26 4.4 Exchanging the Control Unit 26
5. Überprüfungen 33 5. Checking 33
5.1 Niederdruck (Speisedruck) überprüfen 34 5.1 Checking Low Pressure (Charge Pressure) 34
5.2 Hochdruck überprüfen 34 5.2 Checking High Pressure 34
5.3 Mechanische Nulllage überprüfen 35 5.3 Checking the Mechanical Zero Stroke 35
5.4 Hydraulische Nulllage überprüfen 36 5.4 Checking the Hydraulic Zero Stroke 36

008 911 53 BOMAG 585

4/40
18.1
Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

1.2 Gültigkeitsbereich dieser 1.2 Validity of this Manual

Anleitung
Diese Reparaturanleitung gilt für die Axialkolben-Verstellpumpe This manual is valid for the Bosch Rexroth axial piston variable
A4VG NG 71–180 der Bosch Rexroth AG. Informationen zu pump A4VG NG 71–180. Refer to the system manufacturer for
zugelassenen Druckflüssigkeiten entnehmen Sie den Angaben information about the allowed hydraulic fluids.
des Anlagenherstellers.
Diese Reparaturanleitung richtet sich an: This repair manual is directed at:
Anlagenbetreiber, the system operator
den autorisierten Fachbetrieb bzw. Händler, authorized dealers
den Anlagenhersteller. the system manufacturer
Für den Anlagenhersteller sind zusätzlich auch die jeweilige For the system manufacturer, the installation drawing, the
Einbauzeichnung, das technische Datenblatt, die Betriebsan- catalog sheet, the manual, and the confirmation of order from
leitung und die Auftragsbestätigung der Bosch Rexroth AG the Bosch Rexroth AG are also obligatory.
verbindlich.

586 BOMAG 008 911 53

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
18.15/40

1.3 Wichtige Unterlagen 1.3 Important Documents

Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten Before you start any of the procedures described in this manu-
anfangen, stellen Sie sicher, dass Sie folgende Unterlagen al, make sure you have the following documents:
griffbereit haben:
Auftragsbestätigung Confirmation of order
Die Auftragsbestätigung enthält die voreingestellten techni- The confirmation of order contains the values set during the
schen Daten. Die Axialkolbenmaschine darf nur unter den in commissioning by Rexroth. Before you can recommission the
der Auftragsbestätigung angegebenen Werten und Bedin- axial piston unit after a repair, you have to restore the values
gungen betrieben werden. originally set by Rexroth.
Einbauzeichnung Installation drawing
Die Einbauzeichnung der Axialkolbenmaschine enthält die The installation drawing of the axial piston unit contains the
Außenabmessungen, sämtliche Anschlüsse und den Schalt- sizes of all connections.
plan.
Technisches Datenblatt Technical data sheet
Das technische Datenblatt RD 92 003 enthält u.a. die zuläs- The technical data sheet RE 92 003 contains the maximum
sigen technischen Daten für die Axialkolbenmaschine. allowed performance data.
Gesamtschaltplan der Maschine bzw. Anlage Hydraulic diagramWiring diagram
Der Hydraulikschaltplan und der elektrische Schaltplan der The hydraulic diagram and the wiring diagram of the unit
Maschine bzw. Anlage enthalten die Informationen zu den or system contain the information related to the respective
hydraulischen bzw. elektrischen Anschlüssen. Diese Daten machine.You need this data to work with the axial piston as
brauchen Sie, um mit der Axialkolbenmaschine als Teil der part of the machine or system. You can get this information
Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten from the unit or system manufacturer.
Sie vom Maschinen- bzw. Anlagenhersteller.
RD 90 300-B: Allgemeine Betriebsanleitung für Axialkol- RE 90 300-B: General Manual for Axial Piston Units
benmaschinen The general manual supports you during the installation,
Die allgemeine Betriebsanleitung unterstützt Sie bei Installa- initiation, and operation of Rexroth axial piston units.
tion, Inbetriebnahme und Betrieb von Rexroth-Axialkolbenma-
schinen.
Produktspezifische Betriebsanleitung Product Specific Manual
Die produktspezifische Betriebsanleitung enthält spezielle, The product-specific manual contains information specially
für die Axialkolbenmaschine gültige Informationen. Informie- designed for the axial piston unit. Get in touch with Rexroth
ren Sie sich bei Rexroth, ob es zu Ihrer Axialkolbenmaschine to find out if there is any product-specific information on your
eine produktspezifische Betriebsanleitung gibt. specific axial piston unit.
Folgende Rexroth-Druckschriften geben Ihnen weitere Informa- The following Rexroth publications provide additional informati-
tionen zu Installation und Betrieb der Axialkolbenmaschine: on to the installation and operation of axial piston units:
RD 90 220: Druckflüssigkeiten auf Mineralölbasis RE 90 220: Mineral-oil Based Pressure Fluids
Beschreibt die Anforderungen an eine Druckflüssigkeit auf This publication describes the requirements on a hydraulic
Mineralölbasis für den Betrieb mit Rexroth-Axialkolbenma- fluid for operation in an axial piston unit and supports you in
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- the selection of a hydraulic fluid for your installation.
keit für Ihre Anlage.
RD 90 221: Umweltfreundliche Druckflüssigkeiten HEES, RE 90 221: Environmentally Acceptable Hydraulic Fluids
HEPG, HETG für Axialkolbenmaschinen HEES, HEPG, HETG for Axial Piston Units
Beschreibt die Anforderungen an eine umweltfreundliche Describes the demands on environmentally compatible, rea-
Druckflüssigkeit für den Betrieb mit Rexroth-Axialkolbenma- dily biodegradeable hydraulic fluids HEPG, HEES that can
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- be used in Rexroth axial piston units and supports you by the
keit für Ihre Anlage. choice of a hydraulic fluid for your system.
RD 90 223: Axialkolbenmaschinen für den Betrieb mit RE 90 223: Axial Piston Units for Use with HF Fluids
HF-Druckflüssigkeiten Provides additional information for the use of Rexroth axial
Enthält zusätzliche Informationen zum Einsatz von Rexroth- piston units with HF hydraulic fluids.
Axialkolbenmaschinen mit HF-Druckflüssigkeiten.
RD 90 300-03-B: Hinweise zum Einsatz von hydrauli- RE 90 300-03-B: Instructions on the Use of Hydrostatic
schen Antrieben bei tiefen Temperaturen Drives at Low Temperatures
Enthält zusätzliche Informationen zum Einsatz von Rexroth- Provides additional information for the use of Rexroth axial
Axialkolbenmaschinen bei tiefen Temperaturen. piston units for low temperatures.

008 911 53 BOMAG 587

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18.1
Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

1.4 Gefahrenkennzeichnungen 1.4 Danger Labels and Pictograms

und Piktogramme
Diese Anleitung unterscheidet zwischen Kategorien von Gefah- This manual differentiates between the following categories of
ren gemäß ISO Guide 37: danger according to ISO Guide 37:
! GEFAHR ! DANGER

Weist auf hohes Risiko und die Gefahr von Tod oder schwe- Indicates high risk, mortal danger and serious injuries.
ren Verletzungen hin.

! WARNUNG ! WARNING

Weist auf mittleres Risiko und die Gefahr von Verletzungen Indicates middle risk, injuries or serious material damage.
und schweren Sachschäden hin.

! VORSICHT ! CAUTION

Weist auf geringes Risiko und Sachschäden hin. Indicates low risk or material damage.

Hinweis Note

Kennzeichnet Informationen, die zum besseren Verständnis Indicates information that contributes to a better understan-
der Maschinenabläufe beitragen oder weist auf einen beson- ding of the machine processes or indicates important informa-
deren bzw. wichtigen Sachverhalt hin. tion.

Tipp Tip

Kennzeichnet Informationen, die zum efﬁzienteren Arbeiten Indicates information that contributes to more efﬁcient work.
beitragen.

588 BOMAG 008 911 53

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
18.17/40

2 Sicherheit 2 Safety
Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei- Read through this chapter carefully before you start any work
ten an der Verstellpumpe beginnen. on the variable pump.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht- The Rexroth variable pump are in the sense of the machine gui-
linie 98/37/EG Komponenten, die zum Einbau in eine Anlage deline 98/37/EG components of a larger machine or system.
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung be- The safety guidelines in this manual only cover the variable
ziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich pump. You must additionally follow the system manufacturer’s
die Sicherheitsrichtlinien des Anlagenherstellers. safety guidelines.
Informieren Sie sich an Hand der allgemeinen Betriebsanlei- Read the general manual for axial piston units to get more infor-
tung für Axialkolbenmaschinen über die bestimmungsgemäße mation on the designated use and the operator‘s obligation to
Verwendung und die Sorgfaltspﬂicht des Betreibers und exercise dilligence.
Bedieners.

2.1 Grundlegende 2.1 Basic Safety Information

Sicherheitshinweise
Befolgen Sie die folgenden Sicherheitshinweise und die des Pay exact attention to the following safety information and that
Anlagenherstellers genau, um Verletzungen und Gesundheits- of the system manufacturer to eliminate injuries and health
schäden sowie Sach- und Umweltschäden auszuschließen. damages as well as damages to material or the environment.

! GEFAHR ! DANGER

Lebensgefahr Danger to Life

Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen Working on systems that have not been shut down is life-thre-
stellt eine Gefahr für Leib und Leben dar. atening.
Die in diesem Dokument beschriebenen Arbeiten dürfen nur The work described in this document can only be carried out
an stillgelegten Maschinen bzw. Anlagen vorgenommen on a shut down system. Before you start any of the tasks:
werden. Bevor Sie mit den Arbeiten beginnen:
Stellen Sie sicher, dass der Antriebsmotor nicht eingeschal- Make sure that the engine / motor cannot be switched on.
tet werden kann.
Stellen Sie sicher, dass sämtliche kraftübertragenden Kom- Make sure that all components and connections that carry
ponenten und Anschlüsse (elektrisch, pneumatisch, hydrau- energy (electrical, pneumatic, hydraulic) have been shut
lisch) gemäß den Herstellerangaben ausgeschaltet sind und down according to the manufacturer’s instructions and
nicht eingeschaltet werden können. Falls möglich, entfernen cannot be switched on. If possible, disable the main fuse.
Sie die Hauptsicherung der Maschine bzw. Anlage.
Stellen Sie sicher, dass die Maschine bzw. Anlage komplett Make sure that the system is completely unloaded. Follow
hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den the instructions of the the system manufacturer.
Angaben des Maschinen- bzw. Anlagenherstellers.

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Um Verletzungen zu vermeiden, beachten Sie bitte folgende To avoid injuries, pay attention to the following regarding
Empfehlungen betreffend Sicherheitskleidung: safety clothing.
Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicher- When working on the system, wear steel-toed safety shoes.
heitsschuhe mit Stahlkappen.
Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispiels- When working with dangerous substances (for example,
weise Druckﬂüssigkeiten) Schutzhandschuhe und Schutz- certain hydraulic ﬂuids), wear protective gloves and protec-
brille. tive glasses.

008 911 53 BOMAG 589

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8/40 Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
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! GEFAHR ! DANGER

Vergiftungs- und Verletzungsgefahr Danger of poisoing or injuries

Der Kontakt mit Drückflüssigkeiten ruft Gesundheitsschäden Contact with hydraulic fluids can cause health damage (eye
hervor (z.B. Augenverletzungen, Haut- und Gewebeschädi- injuries, skin damage, poisoning due to inhalation).
gungen, Vergiftungen beim Einatmen).
Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf Always check the hydraulic lines for wear and damage prior
Verschleiß bzw. Beschädigungen. to putting the unit into operation.
Tragen Sie dabei Schutzhandschuhe und Schutzbrille. Always wear protective gloves and safety glasses.
Wenn dennoch Druckflüssigkeit in die Augen gelangt oder Should pressure fluid come into contact with your eyes or
in die Haut eindringt, konsultieren Sie unmittelbar einen skin: Get medical help immediately!
Arzt.
Beachten Sie beim Umgang mit Druckflüssigkeiten unbe- When handling hydraulic fluids, pay exact attention to the
dingt die Sicherheitsangaben des Druckflüssigkeitsherstel- manaufacturer’s safety instructions.
lers.

! WARNUNG ! WARNING

Verbrennungsgefahr Danger of burns

Die Axialkolbenmaschine erwärmt sich während des Betriebs. The variable pump heats up during operation. The unit’s sole-
Auch die Magnete an der Axialkolbenmaschine werden im noids get hot during operation. Touching the variable pump or
laufenden Betrieb heiß. Bei Berührung der Axialkolbenma- solenoids can lead to severe injuries.
schine oder der Magnete können schwere Brandverletzungen
entstehen.
Lassen Sie die Axialkolbenmaschine vor jedem Kontakt Let the variable pump cool down prior to any contact.
abkühlen.
Schützen Sie sich mit hitzebeständigen Handschuhen und Protect yourself from burns by wearing safety gloves and
Schutzkleidung. protective clothing.

! GEFAHR ! DANGER

Vergiftungs- und Verletzungsgefahr Danger of poisoning

Beim Suchen nach Leckstellen kann entweichende Druckﬂüs- When looking for leaks, escaping hydraulic ﬂuid can break
sigkeit in die Haut eindringen und schwerste Vergiftungen und into the skin and cause serious poisoning.
Verletzungen hervorrufen.
Suchen Sie nur bei abgestellter und druckloser Maschine Always use a piece of cardboard or paper to look for leaks.
nach Leckstellen.

! WARNUNG ! WARNING

Verletzungs- und Beschädigungsgefahr Danger of injuries or damage

Durch falsch angeschlossene Komponenten können erhebli- Incorrectly connected components can considerably impair
che Fehlfunktionen entstehen. the functionality of a hydraulic system.
Achten Sie auf korrekte Verrohrung gemäß Schaltplan. Make sure that the hydraulic lines are connected properly.
Führen Sie komponentenorientierte Funktionstests durch. Check the correct functioning of all components.

590 BOMAG 008 911 53

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
18.19/40

! GEFAHR ! DANGER

Feuergefahr Danger of ﬁre

Hydraulische Druckflüssigkeit ist brennbar. Hydraulic fluid is inflammable.
Halten Sie offenes Feuer von der Verstellpumpe fern. Keep open fires away from the variable pump.

! WARNUNG ! WARNING

Gehörschäden Danger of hearing loss

Die Geräuschemission von Axialkolbenmaschinen ist u.a. von The noise emission produced by axial piston units depends
Drehzahl, Betriebsdruck und Einbauverhältnissen abhängig. on speed, operating pressure, and installation. During normal
Es ist damit zu rechnen, dass der Schalldruckpegel bei nor- application conditions, over 70 dBA can be anticipated. This
malen Einsatzbedingungen über 70 dBA steigt. Dies kann zu can lead to hearing damage.
Gehörschäden führen.
Schützen Sie sich stets mit Gehörschutz bei Arbeiten in Always wear hearing protection when working in the vicinity
der Nähe der Axialkolbenmaschine während des laufenden of the variable pump during operation.
Betriebs.

! WARNUNG ! WARNING

Umweltschäden Risk of damage to the environment

Druckflüssigkeiten sind wassergefährdende Flüssigkeiten. Hydraulic fluid leakage leads to contamination of the ground
Das Austreten von Druckflüssigkeiten kann zu Grundwasser- and ground water.
vergiftung und Bodenverseuchung führen.
Bringen Sie unter der Axialkolbenmaschine eine Auffang- A basin for catching any hydraulic fluid must be placed
wanne an. under the variable pump.
Beseitigen Sie Leckstellen unverzüglich. Leaks must be cleaned up immediately.
Es sind stets die nationalen Gesetze und Vorschriften zu In Europe, hydraulic systems are considered “Systems
beachten. In Deutschland sind hydraulische Maschinen bzw. using water-threatening substances” in the sense of the
Anlagen „Anlagen zum Umgang mit wassergefährdenden Water Management Law (WHG).Therefore, pay special
Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“. attention to §1 and §19 WHG( §19g, 19i, 19l). Additionally
Beachten Sie in diesem Zusammenhang besonders §1 und pay attention to any national regulations and norms.
§19 WHG (§19g, 19i, 19l).
Weitere Informationen zum richtigen Umgang mit Rexroth- For further information regarding the correct use of Bosch
Hydraulikprodukten finden Sie in unseren Druckschriften Rexroth hydraulic products, see the publications RE 90 220
„Allgemeine Produktinformationen für Hydraulikprodukte“, “Mineral-oil Based Pressure Fluids” and RE 90 221 “En-
RD 90 220 und „Umweltschonende, biologisch schnell vironmentally Acceptable Hydraulic Fluids HEES, HEPG,
abbaubare Druckflüssigkeiten HEPG, HEES für Axialkol- HETG for Axial Piston Units“, RD 90 221.
benmaschinen“, RD 90 221.

008 911 53 BOMAG 591

18.1
10/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

2.2 Anforderungen an das Personal 2.2 Requirements on the Personnel

Diese Reparaturanleitung richtet sich an Fachkräfte mit This repair manual is directed at qualified personnel with
Hydraulik-Fachwissen, die an einer Service-Schulung bei specialized hydraulics know-how who have taken part at a
Rexroth teilgenommen haben. service training at Rexroth.
Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung Qualified personnel is defined as persons who have sufficient
und Erfahrung ausreichende Kenntnisse hat, sowie mit den knowledge on the basis of specialized training and experience,
einschlägigen Bestimmungen so weit vertraut ist, dass er and are familiar with the relevant regulations, so that they are
able to
die ihm übertragenene Arbeiten beurteilen kann, judge the delegated tasks,
mögliche Gefahren erkennen kann, recognize possible dangers,
die notwendigen Maßnahmen zur Beseitigung von Gefahren take the necessary measures for the elimination of dangers,
ergreifen kann,
Kenntnisse über die möglichen Gesundheitsgefahren von judge the possible health risks from hydraulic fluids,
Druckflüssigkeiten hat
und die erforderlichen Reparatur- und Montagekenntnisse and have the required repair and installation know-how.
hat.
Hydraulik-Fachwissen bedeutet, das Personal muss, Specialized hydraulics know-how means that these persons
must:
in der Lage sein, die Hydraulikpläne zu lesen und vollständig be able to read and completely understand hydraulic plans,
zu verstehen,
insbesondere die Zusammenhänge bezüglich der eingebau- especially understand the connections regarding the in-
ten Sicherheitseinrichtungen vollständig verstehen stalled safety equipment,
und Kenntnisse über Funktion und Aufbau von hydraulischen and are familiar with the function and structure of hydraulic
Bauteilen haben. components.

592 BOMAG 008 911 53

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
18.111/40
Bosch Rexroth AG

3 Produktbeschreibung 3 Product Description

Dieses Kapitel gibt Ihnen einen allgemeinen Überblick über die This chapter provides a general overview of the functionality of
Funktionalität der Rexroth A4VG Verstellpumpe. the A4VG variable pump.
Machen Sie sich mit den Inhalten dieses Kapitels vertraut, You should be familiar with the contents of this chapter before
bevor Sie mit Arbeiten an einer Verstellpumpe beginnen. starting any work on the variable pump.

3.1 Typschild 3.1 Name Plate

Die Verstellpumpe ist am Typschild zu identiﬁzieren: The variable pump can be identiﬁed on its name plate:

1 3FYSPUI
D-89275 Elchingen

2 TYP: A4VG90DA2D2/32R-NZF02F001SP 7
3 MNR: R90XXXXXXX
7202 8
4 SN: 12345678
5 FD: 05W28 Rotation:
-1 9
6 n = XXXX min P = XXX kW

Made in Germany 10

Folgende Informationen ﬁnden Sie auf dem Typschild: The following information can be found on the name plate:
1 Hersteller 1 Manufacturer
2 Typschlüssel 2 Ordering code
3 Materialnummer der Axialkolbenmaschine 3 Material number of the axial piston unit
4 Seriennummer 4 Serial number
5 Fertigungsdatum 5 Date of manufacturing
6 Drehzahl 6 Speed
7 interne Werksbezeichnung 7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: rechts) 8 Direction of rotation (when facing the shaft; here: clockwi-
se)
9 vorgesehener Platz für Prüfstempel 9 Designated space for certiﬁcation stamp
10 Leistung 10 Power
Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren- Ensure that the variable pump to be repaired is of the type and
den Verstellpumpe mit dieser Anleitung übereinstimmen. size covered by this manual.

3.2 Funktionsbeschreibung 3.2 Functional Description

Damit Sie in der Lage sind, Probleme an der Verstellpumpe To make sure that you are able to identify problems with a vari-
zu identifizieren und gezielt Reparaturen durchzuführen, sind able pump and to carry out specific repairs, familiarity with how
Kenntnisse der Funktionsweise und des Aufbaus erforderlich. the unit functions and its assembly are required. This section
Dieser Abschnitt gibt Ihnen eine grobe Übersicht. provides you with a rough overview.
Die A4VG Verstellpumpe ist eine Axialkolben-Verstellpum- The variable displacement axial piston pump type A4VG in
pe in Schrägscheibenbauart für hydrostatische Antriebe im swashplate design is designed for closed circuit hydrostatic
geschlossenen Kreislauf. Der Volumenstrom ist proportional zu drives. The flow is proportional to the input drive speed and
der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch displacement. By adjusting the swashplate, it is possible to
die Verstellung der Schrägscheibe ist eine stufenlose Volumen- infinitely vary the flow.
stromänderung möglich.

008 911 53 BOMAG 593

18.1
12/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

3.2.1 Schnittzeichnung 3.2.1 Sectional Drawing

Die folgenden Schnittzeichnungen zeigen das Zusammenspiel The following drawings show the interrelation of the compon-
der Komponenten der A4VG Verstellpumpe. ents of the A4VG variable pump.

Seitenansicht / Side View Steuergerät (siehe unten) /

Control unit (see below)

Schwenkwiege /
Cradle

Antriebswelle /
Drive Shaft
Anschlussplatte
mit Hilfspumpe /
Port Plate with
Auxiliary Pump
Wellendichtring /
Shaft Seal Ring

Triebwerk /
Rotary Group
Draufsicht Verstellungen/
Top View with Controllers
Steuergerät
HWD Control unit DAD

Antriebswelle
Antriebswelle Drive Shaft
Drive Shaft

Verstellkolben
Control Piston

EPD HDD

Antriebswelle
Drive Shaft
Antriebswelle
Drive Shaft

Steuergerät
Control unit

594 BOMAG 008 911 53

RDE 92 003-21-R/01.06
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Bosch Rexroth AG

Ansicht Anschlussplatte /
View Port Plate

HWD / EPD / HDD

DAD

008 911 53 BOMAG 595

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14/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

3.3 Technische Daten 3.3 Technical Data

Die technischen Daten der Verstellpumpe finden Sie in der Auf- You can find the technical data for the variable pump in the
tragbestätigung. Ergänzend dazu ist das jeweilige technische Confirmation of Order. This is supplemented by the unit‘s data
Datenblatt. Für die A4VG Verstellpumpe gilt das technische sheet. For the A4VG variable pump, the valid data sheet is
Datenblatt RD 92 003. RE 92 003.

596 BOMAG 008 911 53

RDE 92 003-21-R/01.06
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18.115/40
4 Austausch externer 4 Exchanging External
Baugruppen Assembly Groups
Dieses Kapitel beschreibt den Austausch von extern zugängli- This chapter describes the replacement of the externally acces-
chen Baugruppen der Verstellpumpe A4VG. sible assembly groups of the variable pump A4VG.
Der Austausch folgender Baugruppen wird beschrieben: The exchange of the following assembly groups is described:
Wellendichtring Shaft seal
Dichtungen Seals
Hilfspumpe Auxiliary pump
Steuergerät Control unit

Hinweis Note

Alle in nachfolgenden Zeichnungen dargestellten Steuergerä- All the following illustrations are only examples and do not
te sind nur stellvertretend und müssen nicht der Konﬁguration have to completely correspond with the conﬁgrations of your
Ihrer Axialkolbenmaschine entsprechen. axial piston unit.

! WARNUNG ! WARNING

Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept. Dirt in the hydraulic fluid can
Verschmutzung der Druckflüssigkeit führt zu Verschleiß und lead to malfunctions. Especially hard foreign matter in the
Funktionsstörungen. Insbesondere harte Fremdkörper in den hydraulic conduits, for example, welding beads and cuttings,
Hydraulikleitungen, wie z.B. Schweißperlen und Metallspäne, can damage the axial piston unit.
können die Axialkolbenmaschine beschädigen.
Beachten Sie daher unbedingt folgende Hinweise: Therefore you should observe the following instructions:
Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschi- Make sure everything is kept extremely clean. The axial pis-
ne muss schmutzfrei eingebaut werden. Verunreinigungen ton unit must be installed in a dirt-free environment. Conta-
in der Druckflüssigkeit können die Funktion und Lebensdau- mination of the hydraulic fluid can lead to considerable wear
er der Axialkolbenmaschine erheblich beeinträchtigen. and malfunctions of the axial piston unit.
Achten Sie besonders bei der Installation darauf, dass Espacially during the istallation, you should make sure that
Anschlüsse, Hydraulikleitungen und Anbauteile (z.B. Mess- ports, hydraulic conduits, and mounting components (for
geräte) sauber sind. Reinigen Sie diese gründlich, bevor example, gauges) are clean. Clean these thoroughly before
Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim you open connections. After that, when sealing the ports,
nachfolgenden Verschließen der Anschlüsse keine Verunrei- make sure that contaminating elements cannot enter the
nigungen eindringen. system.
Verwenden Sie für die Beseitigung von Schmiermitteln und When removing grease and other dirt you should use ap-
anderen starken Verschmutzungen geeignete flüssige Reini- propriate liquid cleaning agents. Cleaning agents must not
gungsmittel. Es darf kein Reinigungsmittel in das Hydraulik- enter the hydraulic system.
system eindringen.
Verwenden Sie zur Reinigung keine Putzwolle oder fasern- Do not use cotton waste or rags which lose threads.
de Putzlappen.
Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder Never use hemp or putty as a sealant.
Kitt.

008 911 53 BOMAG 597

18.1
16/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

4.1 Wellendichtring austauschen 4.1 Exchanging the Shaft Seal

Dieser Abschnitt erklärt, wie Sie den Wellendichtring austau- This section explains how you can replace the shaft seal.
schen.
Benötigtes Sonderwerkzeug: Required Special Tools:
Montagehülse Mounting sleeve
Die Materialnummern sind je nach Pumpenmodell verschie- The material number depends on the pump model.
den:
– A4VG71: Mat.-nr. R909877509 – A4VG71: Mat. no. R909877509
– A4VG90: Mat.-nr. R909877510 – A4VG90: Mat. no. R909877510
– A4VG125: Mat.-nr. R909877511 – A4VG125: Mat. no. R909877511
– A4VG180: Mat.-nr. R909877512 – A4VG180: Mat. no. R909877512
NG 71, 90, 125

NG 180

b
a
a: Sicherungsring Circlip
b: Wellendichtring Shaft Seal
c: Triebwelle Drive Shaft

Um den Wellendichtring auszutauschen: To exchange the shaft seal:

1 Kleben Sie die Triebwelle (c) ab, um Beschädigungen am 1 Mask the drive shaft (c) for protection against damage of the
Wellendichtring (b) zu vermeiden. shaft seal (b).
2 Entfernen Sie den Sicherungsring (a). 2 Remove the safety ring (a).

598 BOMAG 008 911 53

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3 Drehen Sie Blechschrauben in die mit Gummi gefüllten 3 Screw the tapping screw into the rubber lined holes of the
Löcher des Wellendichtrings (b) und ziehen Sie den Wellen- shaft seal (b), and use pliers to pull the shaft seal out.
dichtring mit einer Zange heraus.

4 Fetten Sie den Wellendichtring zwischen Dicht- und Staub- 4 Grease the shaft seal between the seal and dust lip to avoid
lippe leicht ein, um Trockenlauf zu vermeiden. a dry run.
5 Pressen Sie den Wellendichtring mit Hilfe der Montagehülse 5 Using the mounting sleeve (special tool), press the shaft seal
(Sonderwerkzeug) auf Anschlag ein. until it is in stop position.

6 Führen Sie den Sicherungsring so ein, dass er in die dafür 6 Place the safety ring so that it locks into place in the respec-
vorgesehene Nut einrastet. tive slot.
7 Entfernen Sie die Abklebung an der Triebwelle. 7 Remove the mask on the drive shaft.

008 911 53 BOMAG 599

18.1
18/40 Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

4.2 Dichtungen austauschen 4.2 Exchanging Seals

Die Baugruppe „Dichtungssatz komplett“ enthält Dichtungen The assembly group "complete seal set" contains seals for the
für folgende Komponenten: following components:
Stellkolbendeckel Positioning piston covers
Ventile Valves
Druckabschneidung Pressure cut-off
Hilfspumpe (siehe „Hilfspumpe austauschen“) Auxiliary pump (refer to "Exchanging the Auxiliary Pump")
Steuerung (siehe „Steuergerät austauschen“) Control unit (refer to "Exchanging the Control Unit")

Benötigtes Sonderwerkzeug: Keines Required Special Tools: none

Dichtung an den Stellkolbendeckeln austauschen Exchanging the valve positioning piston covers
Die beiden Seiten des Stellkolbens sind mit zwei unterschiedli- Both sides of the positioning piston have their own different
chen Deckeln abgedeckt. Die nötigen Schritte zum Austausch covers. The required steps to exchange the covers are threre-
der Deckeldichtungen unterscheiden sich daher. fore different.
a

c
d

c c
b

e
f
a: Linker Deckel Left cover
b: Rechter Deckel Right cover
c: O-Ring O-ring
d: Stellschraube Adjustment screw
e: Kontermutter Counter nut
f: Befestigungsschrauben Fastening screw

Um die Dichtung an den Stellkolbendeckeln auszutauschen: To exchange the valves of the positioning pistons:
1 Kennzeichnen Sie die Lage des linken Deckels (a) und ent- 1 Mark the position of the left cover (a) and remove the faste-
fernen Sie die Befestigungsschrauben (f). ning screws (f).
2 Verdrehen Sie den Deckel (a) und lösen Sie ihn vorsichtig 2 Twist the cover (a) and carefully loosen it by tapping it with a
mit leichten Hammerschlägen (Gummihammer). (rubber) hammer.

600 BOMAG 008 911 53

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3 Entfernen Sie den alten O-Ring (c). Kontrollieren Sie die 3 Remove the old o-ring (c). Check the slot (h) and the
Nut (h) und das Gehäuse (g) auf Verschleiß und Verunreini- housing (g) for wear and dirt.
gungen.
c

h g

4 Setzen Sie einen neuen O-Ring ein und schrauben Sie den 4 Install a new o-ring and screw the cover shut.
linken Deckel fest.
5 Markieren Sie die Lage des rechten Deckels (b), damit Sie 5 Mark the position of the right cover (b) so that you can set it
ihn nach dem Abdichten wieder lagerichtig aufsetzen kön- back to its original position after sealing.
nen.
Messen und notieren Sie das Maß X der Kontermutter (e) für Measure and write down the dimension X of the counter
die spätere Montage. nut (e). You need this for the subsequent assembly.
Entfernen Sie die Kontermutter (e). Halten Sie dazu die Remove the counter nut (e). To do so, grip the positioning
Stellschraube (d) fest. screw (d).
b

e
X
d
X

6 Schrauben Sie den Deckel von der Stellschraube durch 6 Unscrew the cover from the positioning screw.
Drehen ab.

7 Entfernen Sie die beiden O-Ringe (c). Kontrollieren Sie die 7 Remove the two o-rings (c). Check the slots (h) and housing
Nuten (h) und das Gehäuse (g) auf Verschleiß und Verunrei- (g) for wear and dirt.
nigungen.
c

g h
h

008 911 53 BOMAG 601

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20/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
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8 Kleben Sie das Gewinde ab, um Beschädigungen des O- 8 Mask the screw thread to avoid damaging the o-ring, and
Rings zu vermeiden, und schieben Sie den kleinen O-Ring push the smaller o-ring up to the designated slot.
bis zur vorgesehenen Nut auf.

9 Setzen Sie den großen O-Ring ein, entfernen Sie die Abkle- 9 Insert the larger o-ring, remove the masking and screw the
bung und schrauben Sie den Deckel fest. cover back on.
10 Schrauben Sie die Kontermutter (e) per Hand ein. Blockie- 10 Screw in the counter nut (e) manually. Block the adjusting
ren Sie die Stellschraube (d) während Sie die Kontermutter- screw (d) while you tighten the counter nut.
festziehen.
Kontrollieren Sie das Maß X nach der Montage. Check the dimension X after assembly.
b

e
X
d
X

Hinweis Note

Nach dem Einbau im Gerät bzw. Prüfstand muss die korrekte After the installation of the unit or the test rig, the correct
mechanische Nulllagen-Einstellung erfolgen, siehe „Überprü- mechnical zero stroke must be adjusted, refer to "Checking",
fungen“ auf Seite 29. page 29.

602 BOMAG 008 911 53

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Ventildichtungen austauschen Exchanging the valve seals

Hinweis Note

Möglicherweise sind nicht alle in den Zeichnungen gezeigten It is possible that the valves displayed in these illustrations are
Ventile an Ihrer Einheit vorhanden. not all present in your unit.

Hochdruckventil /
High-pressure valve

Niederdruckventil
Low-pressure valve

Um die Ventildichtungen auszutauschen: To exchange the valve seals:

1 Schrauben Sie das Niederdruckventil heraus. 1 Unscrew the low pressure valve.
2 Kleben Sie die Gewinde der Niederdruckventile ab, um 2 Mask the screw thread to avoid damage to the o-rings.
Beschädigungen der O-Ringe zu vermeiden.

3 Setzen Sie die neuen O-Ringe ein, entfernen Sie die Abkle- 3 Insert the new o-rings, remove the masking from the screw
bungen an den Gewinden und schrauben Sie das Nieder- thread, and screw the low pressure valve back in.
druckventil wieder ein.
Ziehen Sie es mit einem Drehmoment von 70 Nm fest. Tighten it with a torque of 70 Nm.
4 Schrauben Sie die Hochdruckventile heraus. 4 Unscrew the high-pressure valves.
Beachten Sie: Bei NG 71–90 gibt es zwei O-Ringe und Note: NG 71–90 have two o-rings and one There are two
einen Stützring, bei NG 125 und 180 nur einen O-Ring. types of this valve: with or without bypass function.
Sicherungskappe / Tamper prof cap

O-Ring
O-Ring

Stützring /
Support ring

O-Ring

NG 71–90 NG 125, 180

008 911 53 BOMAG 603

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22/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
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5 Entfernen Sie die O-Ringe und den Stützring (NG 71–90) 5 Remove the o-rings and the supprot ring (NG 71–90) and
und kontrollieren Sie das Gehäuse auf Verschleiß und Verun- check the housing for wear and dirt.
reinigungen.
6 Bauen Sie das Hochdruck-Ventil ein und ziehen Sie es mit 6 Install the high-pressure valve and tighten it with a torque of
einem Drehmoment von 150 Nm (NG 71–90) bzw. 200 Nm 150 Nm (NG 71–90) or 200 Nm (NG 125, 180).
(NG 125, 180) fest.

Hinweis Hinweis

Nach dem Einbau muss eine Überprüfung des Hochdrucks Nach dem Einbau muss eine Überprüfung des Hochdrucks
erfolgen, siehe „Überprüfungen“ auf Seite 29. erfolgen, siehe „Überprüfungen“ auf Seite 29.

Dichtung der Druckabschneidung austauschen Exchanging the seals of the pressure cut-off
Um die Dichtung der Druckabschneidung auszutauschen: To exchange the seal of the pressure cut-off:
1 Notieren Sie das Einstellmaß X der Dichtmutter für die späte- 1 Write down the sealing nut's setting dimension X for the
re Montage. subsequent assembly.
2 Bauen Sie die Dichtmutter (a) und die Verschlussschraube 2 Extract the sealing nut (a) and the locking screw (b).
(b) aus.
Entfernen Sie den O-Ring (c). Remove the o-ring (c).
a

b X

3 Setzen Sie einen neuen O-RIng (c) ein. 3 Install a new o-ring (c).
4 Setzen Sie die Verschlussschraube (b) ein und ziehen Sie 4 Install the locking screw (b) and tighten it with a torque of 35
sie mit einem Drehmoment von 35 Nm fest. Nm.
5 Bauen Sie eine neue Dichtmutter (a) ein und stellen Sie das 5 Install the new sealing nut (a) and adjust to the setting
notierte Einstellmaß X ein. measure X that you wrote down previously.
Ziehen Sie die Dichtmutter mit 25 Nm fest. Tighten it with a torque of 25 Nm.

604 BOMAG 008 911 53

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Bosch Rexroth AG

Dichtung des Regelventils austauschen Exchanging the control valve

b
a

a: Regelventil Control valve

b: O-Ring O-ring

Um die Dichtung am Regelventil auszutauschen: To exchange the control valve:

1 Schrauben Sie das Regelventil (a) aus. 1 Unscrew the control valve (a).
2 Kleben Sie das Gewinde zur Vermeidung von Beschädigun- 2 Mask the screw thread to avoid damaging the o-ring.
gen des O-Rings ab.

3 Schieben Sie den neuen O-Ring auf. 3 Slide the new o-ring on.
4 Entfernen Sie die Abklebung und schrauben Sie das Regel- 4 Remove the masking and screw the control valve back on.
ventil ein.
Ziehen Sie sie mit einem Drehmoment von 50 Nm fest. Tighten them with a torque of 50 Nm.

008 911 53 BOMAG 605

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24/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
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4.3 Hilfspumpe austauschen 4.3 Exchanging the Auxiliary Pump

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of an auxiliary pump
einer Hilfspumpe als auch für den Austausch eines O-Rings. as well as to the exchange of an o-ring.
Benötigtes Sonderwerkzeug: Keines Required Special Tools: none
Um die Hilfspumpe auszutauschen: To exchange the auxiliary pump:
1 Markieren Sie die Lage des Deckels (a), damit Sie ihn nach 1 Mark the position of the cover (a), so that you can replace it
dem Abdichten wieder lagerichtig aufsetzen können. in its original position after the sealing.

2 Entfernen Sie die vier Befestigungsschrauben (b). 2 Remove the four fastening screws (b).
3 Drücken Sie den Deckel wie gezeigt ab. 3 Press the cover off as illustrated.

4 Entfernen Sie die Hilfspumpe und untersuchen Sie die Teile 4 Remove the auxiliary punp and check the part for wear and
der Hilfspumpe auf Verschleiß und Verunreinigungen. dirt.
Markieren Sie vorher die Lage der Hilfspumpe, damit Sie sie Mark the position of the auxiliary pump beforehand, so that
später wieder lagerichtig einbauen können (sofern Sie die you can return it to its original position afterwards (if you
alte Hilfspumpe weiter verwenden). keep the old auxiliary pump in use).

Hinweis Note

Die Hilfspumpe kann nur komplett ausgetauscht werden. The auxiliary pump can only be exchanged as a whole.

5 Setzen Sie zwei neue O-Ringe (c) ein. 5 Install two new o-rings (c).

606 BOMAG 008 911 53

RDE 92 003-21-R/01.06
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18.125/40
Bosch Rexroth AG

6 Setzen Sie die (neue) Hilfspumpe ein. 6 Install the (new) auxiliary pump.
Achten Sie darauf, dass die angefaste „Seite“ (d) zum De- Pay attention that the chamfered "side" (d) is assembled
ckel (a) montiert wird. facing the cover (a).

d a
d

Hinweis Note

Die Hilfspumpe wird mit Haltestopfen (e) geliefert. Diese wer- The auxiliary pump is delivered with ﬁxing plugs (e). These are
den bei der Montage auf die Anschlussplatte in die entspre- pressed into the bore of the port plate during assembly.
chenden Bohrungen eingepresst.

7 Schrauben Sie den Deckel (a) fest. Beachten Sie dabei die 7 Screw the cover (a) back on. Pay attention to the marking
vorher angebrachte Markierung. made previously.

008 911 53 BOMAG 607

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26/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
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4.4 Steuergerät austauschen 4.4 Exchanging the Control Unit

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of the whole control
des ganzen Steuergeräts als auch für den Austausch eines O- unit as well as to the exchange of an o-ring.
Rings am Steuergerät.
Benötigtes Sonderwerkzeug: Required Special Tools:
NG 71: Keines NG 71: none
NG 90–180: 2 Hilfsschrauben (Mat.-nr. R02774871) NG 90–180: 2 auxiliary screws (Mat. no. R02774871)
Hinweis Note

Es gibt eine Vielzahl von Steuergeräten (siehe Abbildung). There exists a multitude of control units (as illustrated).
Bitte beachten Sie, dass hier exemplarisch nur der Austausch Please pay attention to the fact that only the example of an
eines HW Steuergeräts gezeigt wird. HW controller is described here.

alt / old

neu / new alt / old

neu / new
EP
HW alt / old

neu / new

Polrohr
Anziehmoment 19 Nm /
Pole tube
Tightening torque 19 Nm

Anziehmoment 5+1 Nm
Steckschlüssel SW 26 /
Tightening torque 5+1 Nm
26 A/F socket spanner

608 BOMAG 008 911 53

RDE 92 003-21-R/01.06
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Austausch des Steuergeräts bei NG 71 Exchanging the Control Unit with NG 71
Um das Steuergerät bei NG 71 auszutauschen: To exchange the control unit:
1 Entfernen Sie die fünf Befestigungsschrauben (a). 1 Remove all ﬁve fastening screws (a).

2 Drücken Sie das Steuergerät (b) wie gezeigt ab. 2 Press the control unit (b) off as illustrated.

3 Entfernen Sie den O-Ring (c) und die Flachdichtung (e). 3 Remove the o-ring (c) and the gasket (e). Check the sealing
Kontrollieren Sie die Dichtﬂächen (d) auf Beschädigungen surfaces (d) for wear and dirt.
und Verunreinigungen.
Tauschen Sie das Steuergerät bei Bedarf aus. Exchange the control unit if required.

Hinweis Note

Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.

d
e
e
d

4 Setzen Sie einen neuen O-Ring (c) und eine neue Flachdich- 4 Insert the new o-ring (c) and the new gasket (e).
tung (e) ein.

008 911 53 BOMAG 609

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28/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
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5 Setzen Sie das (neue) Steuergerät ein. 5 Insert the new control unit.
6 Zentrieren Sie die Dichtung (e) mit zwei Befestigungsschrau- 6 Center the seal (e) with two fastening screws (a) and install
ben (a) und bauen Sie das Steuergerät ein. the control unit.
Ziehen Sie alle vier Befestigungsschrauben mit halbem Screw all four fastening screws tight with half the torque.
Drehmoment an.
a

a: Befestigungsschraube Fixing screw

b: Steuergerät Control unit
e: Dichtung Seal

7 Setzen Sie die fünfte Schraube (f) ein und ziehen Sie sie mit 7 Insert the ﬁfth screw (f) and tighten it with a torque of
einem Drehmoment von 10,4 Nm fest. 10.4 Nm.
Ziehen Sie die anderen vier Schrauben (a) nach Drehmo- Tighten the other four screws (a) crosswise and according
ment über Kreuz fest. to torque.

Hinweis Note

Nach der Montage des Steuergeräts muss die hydraulische After installing the control unit, the hydraulic zero stroke must
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), be re-established. This does not apply to DA-control. Please
siehe „Überprüfungen“ auf Seite 33. refer to "Checking", page 33.

610 BOMAG 008 911 53

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Austausch des Steuergeräts bei NG 90–180 Exchanging the Control Unit with NG 90–180
Hinweis Note

Die folgende Handlungsanweisung behandelt exemplarisch The following instructions show how to exchange an HD
den Austausch eines HD-Steuergeräts. control unit, exemplarily.

Um das HD-Steuergerät bei NG 90–180 auszutauschen: To exchange the HD control unit with NG 90–180:
1 Entfernen Sie die vier Befestigungsschrauben (a). 1 Remove all four fastening screws (a).
Entfernen Sie den Deckel (g) und die Flachdichtung (d). Remove the cover (g) and the gasket (d).

g
d
a

2 Entfernen Sie die zwei Zylinderschrauben (f). 2 Remove the two assembly screws (f).
f

3 Drücken Sie das Steuergerät (b) wie gezeigt ab. 3 Press the control unit (b) off as illustrated.

008 911 53 BOMAG 611

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4 Entfernen Sie die O-Ringe (c). Kontrollieren Sie die Dichtﬂä- 4 Remove the o-rings (c). Check the sealing surfaces for wear
chen auf Beschädigungen und Verunreinigungen. and dirt.
Tauschen Sie Steuergerät bei Bedarf aus. Exchange the control unit if required.
Hinweis Note

Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.

c
d

5 Setzen Sie neue O-Ringe (c) und eine neue Flachdichtung 5 Insert the new o-rings (c) and the new gasket (d).
(d) ein.
6 Setzen Sie das (neue) Steuergerät (b) ohne Deckel auf. 6 Insert the (new) control unit (b) without cover.
Schrauben Sie das Steuergerät diagonal mit zwei Hilfs- Tighten the control unit with two auxiliary screws (e) (special
schrauben (e) (Sonderwerkzeug) an (mit 7 Nm). tools) diagonally (with a torque of 7 Nm).
Schrauben Sie es mit zwei Zylinderschrauben (f) an (mit Fix it with two assembly screws (f) (with a torque of
10,4 Nm). 10,4 Nm).
f e

7 Entfernen Sie die Hilfsschrauben (e) wieder. 7 Remove the auxiliary screws (e).
8 Kontrollieren Sie, ob die Zugfedern richtig in den Kerben des 8 Make sure that both spring catches are hooked to the pair of
Hebelpaares eingehängt sind. leavers.

612 BOMAG 008 911 53

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9 Setzen Sie den Deckel (g) mit der Dichtung (d) auf und 9 Put on the cover (g) with the gasket (d) and ﬁx it with the
schrauben Sie ihn mit den vier Befestigungsschrauben fest. four fastening screws.
Ziehen Sie die schrauben mit 10,4 Nm fest. Tighten the screws with a torque of 10,4 Nm.
a

g
d

Hinweis Note

008 911 53 BOMAG 613

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614 BOMAG 008 911 53

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5 Überprüfungen 5 Checking
Bei der ersten Inbetriebnahme nach einer Reparatur müssen When starting up for the ﬁrst time after a repair, you must
Sie die ursprünglichen Einstellungen der Verstellpumpe kontrol- check the original settings of the variable pump. This chapter
lieren. Dieses Kapitel erklärt folgende Überprüfungen: describes the following checkings:
• Niederdruck • Low pressure
• Hochdruck • High pressure
• Mechanische Nulllage • Mechanical zero stroke
• Hydraulische Nulllage • Hydraulic zero stroke
Hinweis Note

Führen Sie alle Überprüfungen bei Betriebstemperatur durch. Carry out checkings at operating temperature.

Hinweis Note

Wenn die überprüften Werte von den ursprünglichen Einstel- If the checked values differ from the original settings, please
lungen abweichen, setzen Sie sich bezüglich der Einstellung contact Rexroth in terms of adjusting the settings.
bitte mit dem Rexroth-Service in Verbindung.

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Arbeiten an der Verstellpumpe bei Betriebstemperatur sind Working on the variable pump at operating temperature is
gefährlich. dangerous.
Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ Pay exact attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).

! WARNUNG ! WARNING

Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckﬂüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept.
Achten Sie bei Überprüfungen darauf, dass Messanschlüs- When checking settings, you should make sure that gauge
se, Schläuche und Messgeräte sauber sind. Reinigen Sie ports, hydraulic conduits, and und gauges are clean. Clean
diese gründlich bevor Sie die Messpunkte öffnen und mit these thoroughly before you open gauge ports and begin
den Einstellarbeiten beginnen. adjusting settings.
Stellen Sie sicher, dass auch beim nachfolgenden Verschlie- After that, when sealing the ports, make sure that contami-
ßen der Messpunkte keine Verunreinigungen eindringen. nating elements cannot enter the system.

008 911 53 BOMAG 615

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5.1 Niederdruck (Speisedruck) überprüfen 5.1 Checking Low Pressure (Charge Pressure)
Dieser Abschnitt erklärt, wie Sie ND-Ventile überprüfen. This section describes how to check the low pressure valves.
Um den Niederdruck zu überprüfen: To check the low pressure:
1 Schließen Sie wie gezeigt ein Manometer an Anschluss G 1 Connect a manometer to connection G as displayed.
an.

bei DA-
Ausführung /
with DA
version

2 Überprüfen Sie den Niederdruck (G). 2 Check the low pressure (G):

Hinweis Note

Die genauen Einstelldaten entnehmen Sie dem Technischen Refer to the catalog sheet RE 92 003 and your speciﬁcation
Datenblatt RD 92 003 und Ihrer Speziﬁkation. for the detailed setting data.

5.2 Hochdruck überprüfen 5.2 Checking the High Pressure

Die Begrenzung des Hochdrucks erfolgt über die Druckab- The limitation of the operating pressure is performed by a high
schneidung. Zusätzlich ist ein Hochdruckbegrenzungsventil pressure relief valve. Additionally, a high pressure relief valve
(Sicherheitsventil) überlagert. Der Druckwert der Druckab- (safety valve) is in superposition. The pressure value of the
schneidung liegt ca. 10 % unter dem Wert des Hochdruckbe- pressure cut-off is 10 % below that of the high pressure relief
grenzungsventils. valve.
Es kann also nur der Druckwert der Druckabschneidung über- Therefore, only the pressure value of the pressure cut-off can
prüft werden. be measured.
Hinweis Note

Die genauen Einstelldaten entnehmen Sie Ihrer Speziﬁkation. Refer to your speciﬁcation for the detailed setting data.

616 BOMAG 008 911 53

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
18.135/40
Bosch Rexroth AG

5.3 Mechanische Nulllage überprüfen 5.3 Checking the Mechanical Zero Stroke
Dieser Abschnitt erklärt, wie Sie die mechanische Nulllage bei This section describes how to check the mechanical zero stro-
HW-, HD-, EP- und DA-Steuergeräten überprüfen. ke for HW, HD, EP, and DA controllers.

HW HD EP DA

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Die im Folgenden beschriebenen Arbeiten an der Verstellpum- The following procedures carried out on the variable pump are
pe sind gefährlich. dangerous.
Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ Please pay attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).
Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage Block the machinery or unit before you carry out the installa-
bevor Sie die Einstellarbeiten durchführen. tion.

mind. / at least
Nennweite 6 / Nominal Width 6

Messbereich/
Metering range
0 ... 600 bar

Um die mechanische Nulllage zu überprüfen: To check the mechanical zero stroke:

1 Verbinden Sie beide Stellkammern über einen Schlauch mit 1 Connect the two position chambers with a hose (with at
mindestens Nennweite NW6. least nominal width NW6).
Dadurch stellen Sie sicher, dass ein Restsignal aus dem Thus, you ensure that a residual signal from the controller
Steuergerät keine Auswirkung auf die Einstellung der me- has no inﬂuence on the setting of the hydraulic zero stroke.
chanischen Nullage hat.
2 Schließen Sie an die Messanschlüsse MA und M B Manome- 2 Connect manometers to the measuring ports MA and M B.
ter an.
3 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 3 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked.

008 911 53 BOMAG 617

18.1
36/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

5.4 Hydraulische Nulllage überprüfen 5.4 Checking the Hydraulic Zero Stroke
Dieser Abschnitt erklärt, wie Sie die hydraulische Nulllage bei This section describes how to check the hydraulic zero stroke
HW-, HD- und EP-Steuergeräten überprüfen. for HW, HD, and EP controllers.

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Die folgenden Arbeiten an der Verstellpumpe sind gefährlich. The following procedures carried out on the variable pump are
dangerous.
Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“
auf Seite 7). Pay attention to the safety advice (refer to "Safety",
page 7).
Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage Block the machinery or unload the unit before you procede
bevor Sie die Einstellarbeiten durchführen. with the installation.

HW HD EP

Messbereich/
Metering range
0 ... 60 bar

Um die hydraulische Nulllage zu überprüfen: To check the hydraulic zero stroke:

1 Schließen Sie an die Anschlüsse X1 und X2 Manometer an. 1 Connect manometers to the ports X1 und X2.
2 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 2 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked

Hinweis Note

Verdrehen Sie die Exzenterjustierung (a) am Steuergerät nicht Never turn the eccentric calibration (a) of the controller over
über ±90°. ±90 degrees.

618 BOMAG 008 911 53

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
18.137/40
Bosch Rexroth AG

008 911 53 BOMAG 619

18.1
38/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

620 BOMAG 008 911 53

RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
18.139/40
Bosch Rexroth AG

008 911 53 BOMAG 621

18.1 Travel pump

Bosch Rexroth AG
Hydraulics
Produktsegment
Axialkolbenmaschinen
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

© This document, as well as the data, © Alle Rechte bei Bosch Rexroth AG,
specifications and other information auch für den Fall von Schutzrechtsan-
set forth in it, are the exclusive proper- meldungen. Jede Verfügungsbefugnis,
ty of Bosch Rexroth AG. It may not be wie Kopier- und Weitergaberecht,
reproduced or given to third parties bei uns.
without its consent.
Die angegebenen Daten dienen
The data specified above only serve to allein der Produktbeschreibung.
describe the product. No statements Eine 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
information given does not release werden. Die Angaben entbinden
the user from the obligation of own den Verwender nicht von eigenen
judgment and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are
zu beachten, dass unsere Produkte
subject to a natural process of wear
einem natürlichen Verschleiß- und
and aging.
Alterungsprozess unterliegen.
Subject to change. Änderungen vorbehalten.

Printed in Germany
RDE 92 003-21-R/01.06

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008 911 53 BOMAG 643

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644 BOMAG 008 911 53

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Rexroth 3
D-89275 Elchingen

13 TYP: A4VG125EP4D1/32R-NSF02F001SP
4
MNR: R90XXXXXXX SC: X
12
7202
11 SN: 12345678
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10 FD: 08W12 Rotation:
n = XXXX min-1 P = XXX kW m: XXX kg 6

Made in Germany

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008 911 53 BOMAG 645

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008 911 53 BOMAG 671

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008 911 53 BOMAG 675

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008 911 53 BOMAG 681

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18.2 Steering/working pump

008 911 53 BOMAG 683

18.2 Steering/working pump

684 BOMAG 008 911 53

Steering/working pump 18.2

Brueninghaus Hydromatik

R
Reparaturanleitung
Repair Instructions

A10VSO*
Baureihe 31 / Series 31
Nenngrößen 18...140
Sizes 18...140

* auch für
A10 VO ( s. S.2 )/
if its A10 VO see
page 2

RDE 92 711-02-R 01.95

008 911 53 BOMAG 685

RDE 92 711-02-R 01.95
18.2
Inhaltsverzeichnis
Steering/working pump
Reparaturanleitung A10 VSO/31
Contens Repair Instruction A10 VSO/31

HINWEIS NOTE

Teilgeprüfte und vormontierte Original Pretested and preassembled Original

Brueninghaus Hydromatik, Werk Horb-Bau- Brueninghaus Hydromatik, plant Horb -
gruppen ermöglichen bei kürzestem Zeitauf- subassemblies make quick and successful
wand erfolgreiche Reparaturen. repairs possible

Besonders rasch erhalten Sie die richtigen Delivery of the correct spare parts will be
Ersatzteile, wenn Sie uns bei der Bestellung especially quick if you state the type and the
Typ- und Fabriknummer mit angeben. ( Für serial number when orderring. ( We created a
den A 10-Ersatzteilservice wurde ein Schnell- A 10-spare part - quick shipping - service,
versand eingeführt, bitte ggf RD 90124 anfor- order RE 90 124 if necessary.)
dern.)

Die Reparaturarbeiten sind einfach, trotzdem Although repairs are simple, you are
sollten Sie unser Angebot zur Schulung nut- encouraged to enroll in the repair training
zen und sich bei uns das notwendige Spezial- classes offered by Brueninghaus Hydromatik,
wissen aneignen. plant Horb. This will give you the proper
experience and specialized knowledge to make
your own repairs.

Die vorliegende Rep.Anleitung kann auch als This repairing manual also can be used to
Grundlage für die A10VO (Mobilan- repair the mobile A 10 VO. Adjustments of the
wendungen) verwendet werden. Sie unter- mobile pump are the same like the adjustments
scheidet sich nicht in den Einstellwerten von of the stationary units A 10 VSO.
der im Stationärsektor verwendeten A10VSO.

INHALT Seite CONTENTS

Page

Inhaltsverzeichnis 2 Contents

Schnittbild / Hinweise 3 Cross Sectional Diagram / Notes

Ersatzteil kits 4 - 5 spare parts kits

Abtriebswelle abdichten 6 - 7 Sealing the drive shaft

Demontage und Montage der 8 - 14 Disassembly and re-assembly

kompletten Einheit of the complete unit

Hinweise zum Steuerventil 15 - 17 control valve instructions

Zerlegen und Reinigen des 18 - 21 Disassembling and cleaning the control

Steuerventils valve

Montage-Abstimmung 22 Specification tolerance lists

Einstellhinweise und Prüfung 23 set up and testing instruction

Werkzeuge und Anziehdrehmomente 24 Tools and tightening torques

2 Brueninghaus Hydromatik
686 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Schnittbild
18.2
Reparaturanleitung A10 VSO/31
Section Repair Instruction A10 VSO/31

X
NG 100 und 140 mit mechan.
einstellbarem Q min - Anschlag

Size 100 and 140 with stopper

min flow adjustable mechanically

Brueninghaus Hydromatik 3
008 911 53 BOMAG 687
RDE 92 711-02-R 01.95
18.2
Ersatzteil - Kits
Steering/working pump
Reparaturanleitung A10 VSO/31
Spare part kits Repair Instruction A10 VSO/31

K1
Kompletter Dichtsatz ( Dichtsätze sind typenbezogen
festgelegt, Foto z. B. A 10 VSO 28 DFR, ohne
Steuerventildichtelemente), Werkstoff der Dicht-
elemente: Wellendichtring in FPM übrige in NBR

Sealing set complelely( sealing sets are based on

the type of the pump, picture shows for example A
10 VSO DFR, without pilot valve seals). Sealing
material: drive shaft sealing ring FPM, others NBR.

Wie K 1, s. o., jedoch Werkstoff aller Dichtelemente

in FKM.

Same like K 1, see picture on top. Only difference: all

material FKM

K3
Antriebswelle: im Ersatzteilverkauf werden folgende
Ausführungen angeboten:
ISO - Paßfeder, SAE - Paßfeder, SAE - Zahnwelle

Drive shaft: our spare part supply offers you the

following drive shaft types:
ISO - key design, SAE - key design, SAE - splined
design

K4 Die Gruppe "Lagersatz Kleinteile" beinhaltet: 2

Kegelrollenlager, 2 Gleitlagerschalen, Abstimm-
scheibe, Distanzscheibe, Befestigungsschrauben,
diverse Stopfen und Zy-linderstift für Fixierung der
Verteilerplatte.

Contents of kit "bearing set / miscellaneous parts":

2 tapered roller bearings, 2 bearing shells,
adjustment shim, spacer shim, plugs, cylindric pin to
fix the valve plate.

Die komplette Rotationsgruppe mit montierten

Hakenstiften im Zylinder wird für Drehrichtung rechts
oder links angeboten.

We offer the rotary group completely with its cylinder

with mounted pressure - pins for cw or ccw rotating
units ( pls order your direction of rotation ).

4 Brueninghaus Hydromatik
688 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Dichtelemente / Ersatzteil-Kits
18.2
Reparaturanleitung A10 VSO/31
sealing kits / spare parts kits Repair Instruction A10 VSO/31

K6 Schwenkwiegen in Standard - Ausführung stehen für

rechte oder linke Antriebsdrehrichtung zur Verfü-
gung. Ebenso wird zusätzlich für leistungsgeregelte
Pumpen die rechte und linke Schwenkwiege angebo-
ten.

We offer swash plates for cw or ccw rotating units

in the serial design or for horse power controlled
pumps by our spare part service.(Order your
direction of rotation)

K7
Die Abb. li zeigt die Verstellteile ohne Anschläge.
Ggf können auch Verstellteile mit Anschlägen bezo-
gen werden ( s. dazu auch RD 90 124)

Picture leftt shows the control device parts without

the stopper parts. Order with stopper parts if
necessary ( see RE 90 124 ).

K8 Als geprüftes und voreingestelltes Ventil kann das Steuer-

ventil für p- und Q-Regelung bezogen werden. Wenige Hand-
griffe ermöglichen ggf. Modifikationen in der Steuerventilaus-
führung. (Abb. li zeigt Steuerventil für A10 NG 18 bis100;
NG 140 mit Ventil-NG 6 - s. Titelbild bzw. Abb 10* S. 5)

Order a checked and preadjusted pilot valve to control the

pump for pressure compensator and flow control. Easy
handling is possible to convert the design of the pilot valve.
(Picture left shows valve of pump size 18 ..100; size 140 must
have valve size 6 - see cover picture or 10*this page)

9*
Steuerventilausführung für NG 18 bis 100:
X-Adapter am DFR-Steuerventil für metrische
Verrohrung des Steueranschlußes X (ohne Blende).

Pilot valve design 18 to 100:

Adapter without orifice of the DFR - pilot valve, if you
use a metric pilot pipe connection X.

10* Die Abb. zeigt den zerlegten Druckregler als

Zwischenplat-tenventil (NG 140). Als zweite Ventil-
achse wird der Förder-stromregler außen am Druck-
regler angeflanscht.

Picture left shows the pressure compensator

disassembled as a sandwich valve
(of pump size 140). Mount on top of the pressure
compensator housing the valve housing for the flow
control.

Brueninghaus Hydromatik 5
008 911 53 BOMAG 689
RDE 92 711-02-R 01.95
18.2
Antriebswelle abdichten
Steering/working pump
Reparaturanleitung A10 VSO/31
Sealing the drive shaft Repair Instruction A10 VSO/31

1 Die hier beschriebene Möglichkeit zum Wechsel der

Antriebswellen - Abdichtung stellt nicht die serien-
mäßige Montage dar. Für sicheres Dichtungs-
verhalten ist eine Montage des Dichtringes gemein-
sam mit dem Kegelrollenlager von innen her durch
Hinweis ! das Pumpengehäuse durchzuführen. Soll aus Grün-
den der Vereinfachung im Reparaturfall die folgend
beschriebene Vorgehensweise durchgeführt wer-
Note ! den, so ist beim Ausbau der Dichtung besonders
darauf zu achten, daß die Antriebswelle nicht beschä-
digt wird.

2
This discription showes how to change the drive shaft
sealing ring but it isn`t the way of serial assembly.
The sealing ring is assembled together with the taper
roller bearing from inside the pump housing normally
to get a secure sealing condition. If you decide to
repair the pump in the shown way be very careful
while handling so that the drive shaft wouldn`t be
damaged during disassembly of the shaft sealing
ring.

Entfernen der Paßfeder.

Disassemble of the key.

4
Sicherungsring ausbauen.

Remove the retaining ring.

5
Ausbau des WDR mit spitz angeschliffenem Schrau-
bendreher. Achtung: Beschädigung der Welle führt
o. Abb. zur Undichtheit.

Grind screwdriver to disassemble the shaft sealing

no picture
ring carefully. Pay attention: Damages of the drive
shaft indicate leakage.

6 Brueninghaus Hydromatik
690 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Antriebswelle abdichten
18.2
Reparaturanleitung A10 VSO/31
Sealing the drive shaft Repair Instruction A10 VSO/31

Bevor der neue eingefettete WDR montiert wird ist

eine Kontrolle der Lauffläche, Welle und Gehäuse
vorzunehmen.

Change the shaft seal and check the contact surfaces

( drive shaft and housing ), grease sealing ring
before mounting.

7 Einführhülse für die Montage des WDR aufsetzen:

Hülse 74.0.0655 ( NG 18 )
Angaben für
Hülse 74.0.0656 ( NG 28 )
ISO - Wellen /
Hülse 74.0.0657 ( NG 45 )
List shows ISO-
Hülse 74.0.0658 ( NG 71 )
drive shaft standard
Hülse 74.0.0659 ( NG 100 )
only
Hülse 74.0.0660 ( NG 140 )

Use installation tool for the sealing ring ( see tool list
on top ).

8 Mit geeignetem Rohr oder größerem Verstellkolben

wird über die Einführhülse der WDR nur so tief mon-
tiert, daß der Sicherungsring montierbar ist ( zu tiefes
Montieren führt zum Ausfall: Berührung mit dem
Wellenlager ! )
Use a suitable pipe or use the control piston of a
bigger pump size to mount the shaft seal ring via the
installation tool, but don't push it too deap. If the shaft
seal ring touches the bearing ring you will damage
the seal ring.

Sicherungsring einsetzen.

Assemble the retaining ring.

10
Sicherungsring ganz einrasten. Anschließend Montie-
render Paßfeder mit Hilfe eines Kunststoffhammers.
(o. Abb.)

Assemble the retaining ring. Assemble the key next

by using a plastic hammer. This handling isn't shown
in pictures.

Brueninghaus Hydromatik 7
008 911 53 BOMAG 691
RDE 92 711-02-R 01.95
18.2
Demontage und Montage der kompl. Einheit
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

11
Die folgenden Arbeiten sind beispielhaft an einer NG
45 durchgeführt. Abweichungen für andere NG sind
im Bedarfsfall extra angeführt.
Abbau des Steuerventils.

This manual shows the handling of size 45. If

necessary changes to the other pump sizes are
shown separately.
Disassemble the pilot valve.

Markieren der Anschlußplatte zum Pumpengehäuse

und Lösen der Befestigungsschrauben.

Mark position of the port plate to pump housing and

remove socket screws of the port plate.

Abheben der Anschlußplatte und Verteilerplatte mit

Verstellteilen ( Herunterfallen der Verteilerplatte
durch Festhalten vermeiden).

Remove the port plate together with the valve plate

and control device parts (hold the valve plate so
that the plate can´t fall down ) .

Abheben des Kegelrollenlagers und Abstimmscheibe.

Disassemble taper roller bearing and adjustment

shim.

Triebwerk herausziehen.

Disassemble the rotary group.

8 Brueninghaus Hydromatik
692 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Demontage und Montage der kompl. Einheit
18.2
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

O - Ring entfernen.

Remove the O - ring.

Lagerschalen herausheben.

Disassemble beaaring shells.

Kugellager Ab- und Auszieher ( handelsüblich ) für

Kegelrollenlager - Außenring ( antriebswellenseitig ).

Use bearing puller to remove outer bearing race of

front bearing.

Steuerplatte abheben.

Remove the control plate.

Kugellager Ab- und Auszieher ( handelsüblich ) des

Kegelrollenlager - Außenringes (anschlußplattenseitig )

Use bearing puller to remove outer bearing race of rear

bearing.

Brueninghaus Hydromatik 9
008 911 53 BOMAG 693
RDE 92 711-02-R 01.95
18.2
Demontage und Montage der kompl. Einheit
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

O - Ringe entfernen.

Remove the O - rings

Demontage der Hutmutter für Gewindestift.

Disassemble the head nut of threaded pin.

Demontage der Fixiermutter und des Gewindestiftes.

Disassemble the hexagon fixing nut and the

threaded pin.

Kolbenführung des Verstellkolbens (Einbau

"ventilseitig") ausbauen.

Disassemble the guide of control piston (Mounting

position: pilot valve side).

Kolbenführung des Gegenkolbens ausbauen.

Disassembly the guide of opposite piston.

1 0 Brueninghaus Hydromatik
694 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Demontage und Montage der kompl. Einheit
18.2
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

Antriebswelle aus der Rotationsgruppe herausziehen.

Pull out the drive shaft.

Kolben und Rückzugplatte entfernen.

Remove the pistons and the retaining plate.

Rückzugkugel entfernen.

Remove the retaining ball.

Vorspannung der Feder für Ausbau des Sicherungs-

rings erhöhen (mit Hilfsschraube und Scheiben).

Compress the center spring in order to disassemble

the retaining ring (easy handling by a helping bolt
and shims).

Sicherungsring ausbauen.

Disassemble the retaining ring.

Brueninghaus Hydromatik 11
008 911 53 BOMAG 695
RDE 92 711-02-R 01.95
18.2 Steering/working pump
Reparaturanleitung A10 VSO/31
Demontage und Montage der kompl. Einheit
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

Restliche Einzelteile des Zylinders:Zylinderstifte,

Zylinder, Scheibe, Feder und Sicherungsring.

Remaining parts of the cylinder: pins, cylinder, shim,

spring and retaining ring.

Beim Zusammenbau der Pumpe in umgekehrter

Hinweis ! Reihenfolge ist auf die folgeden Punkte zu achten
( 33 - 42 ).

Note ! Assemble the pump in reverse order and note the

following ( 33 - 42 ).

33
Im Graugußgehäuse werden die Kegelrollenlager
mit einer Vorspannung von 0.....0,05 abgestimmt
s.a. S 22.

Taper roller bearing in the cast iron pump housing

must have a initial tension with 0.....0,05 mm ( see
page 22 ).

34
Drehrichtung: rechts
Vorbereiten der Anschlußplatte : Führung für Verstell-
und Gegenkolben mit Loctite einkleben.

- Lagerichtiges Verdrillen der Verteilerplatte in Dreh-

richtung 4 ° .(Verteilerplatte bei BR 31 nur noch in
Originallage montierbar)
- Befetten der O - Ringe.

35
Port plate ( direction of rotation clockwise ) : Both
piston guides are glued with Loctite.

See picture 34 - Correct position of the valve plate ( clockwise 4 ° ):

In case of series 31 the valve plate only can be
installed into the correct position.
- Grease O - rings prior assembly.

1 2 Brueninghaus Hydromatik
696 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Demontage und Montage der kompl. Einheit
18.2
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

36
Drehrichtung: links
Vorbereiten der Anschlußplatte: Führung für Verstell-
und Gegenkolben mit Loctite einkleben.

- Lagerichtiges Verdrillen der Verteilerplatte in Dreh-

richtung 4°. (Verteilerplatte bei BR 31 nur noch in
Originallage montierbar)
- Befetten der O - Ringe

37
Port plate ( direction of rotation anti-clockwise ): Both
piston guides are glued with Loctite.

- Correct position of the valve plate ( anti-clockwise

See picture 36
4 ° ): In case of series 31 the valve plate only can be
installed into the correct position.
- Grease O - rings prior assembly

38
Lagerichtiger Einbau der Schwenkwiege mit großer
Schmiertasche auf der Hochdruckseite, Schwenk-
wiege für Drehrichtung rechts oder Schwenkwiege für
Drehrichtung links verwenden.

Correct position of cradle ( lubrication bore relief on

the high pressure side ), use cradle for clockwise
rotation, if counter clockwise use cradle for counter
clockwise rotation ( two different sub - assemblies ).

39 U. U. Nacharbeit der Schwenkwiege im Laufbereich

durch Läppen möglich( Läppdorn zentriert ), jedoch
Auspressen der Anschläge ( Kugelzapfen mit
Gleitschuh ) nicht zulässig ( Riefenbildung beim
Wiedereinbau ).
If it is possible to lap the cradle (sliding area of the
piston shoes ) it can be possible to use the cradle
again. Notice: It isn't allowed to press out the piston
connection parts out of the cradle ( scorings while
fitting ! ).

40 Falls Zylinder u. Verteilerplatte wiederverwendet

werden ggf. Kontaktstelle Verteilerplatte / Zylinder
nachläppen mit anschließendem Abziehen auf
ebener Unterlage mit 1000er Läpp-Papier.

Connection surfaces between valve plate and

cylinder: if lapping is possible use parts again, but
after lapping procedure use a lapping paper No.1000
to plan the cylinder and valve plate ( plain
underground totally is a must ).

Brueninghaus Hydromatik 13
008 911 53 BOMAG 697
RDE 92 711-02-R 01.95
18.2
Demontage und Montage der kompl. Einheit
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

Überprüfung der Laufeigenschaft des Verstellkolbens.

Check running conditions of the control piston.

Überprüfung der Laufeigenschaft des Gegenkolbens.

Check running conditions of the opposite piston.

1 4 Brueninghaus Hydromatik
698 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Ersatzteil kit: A 10 Steuerventil DFR
18.2
Reparaturanleitung A10 VSO/31
Spare parts kit: A 10 control valve DFR Repair Instruction A10 VSO/31

Vorderseite des Beipackzettels aus dem Cover page of the pamphlet out of the
Ersatzteilpäckchen Steuerventil: spare part kit control valve:
( für NG 18... 100 ) ( pump size 18 to 100 )

1. Allgemeine Hinweise 1. General directions

Zur wesentlichen Erleichterung der Ersatzteilbeschaffung hat Brueninghaus modernized the spare parts service of A10
Brueninghaus den Ersatzteildienst für A10-Produkte moder- products so that you will get spare parts much more easyly .
nisiert . Hinweise dazu finden Sie in der Druckschrift RD The advertizing folder RD 90124 " A10-spare part-service "
90124 " A10-Ersatzteilversorgung " . Der vorliegende gives you more information . This pamflet out of the spare
Beipackzettel aus dem Ersatzteil-Päckchen des DFR Steuer- part kit " control valve : pressure compensator and flow
ventils zeigt auf seiner Rückseite wie die ausgelieferte control DFR " show on its backside: how to change the design
Ausführung einfach umgebaut werden kann, in andere , to the most commen typs of the control valve in an easy way .
gängige Ausführungen . Please note :The valve must be marked with the original
Bitte beachten : bei Änderung der Ausführung muß das number after its change .
Ventil umgestempelt werden . This valve will be delivered only in the Viton-execution (
Die gelieferte Ausführung mit der Teile Nr.942 581 wird nur spare part No.942 581 ) .
in Viton-Ausführung verschickt .

Abb. zeigt Zwischenplattenventil (Option) Teile-Nr.

DR Shown as sandwich valve (option) NBR 920 180
FPM 924 992

Brueninghaus Hydromatik 17
008 911 53 BOMAG 701
RDE 92 711-02-R 01.95
18.2
Zerlegen und Reinigen des Steuerventils
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembling and cleaning the control valve Repair Instruction A10 VSO/31

Lösen der Befestigungsschrauben ( siehe S. 15 ).

Loosen socket screws ( see page 15 ).

Entfernen der O - Ringe.

Remove the O - rings.

48 Am komplett montierten Ventil wird mit Hilfe der

Druckluft die Puls.-Blende herausgeblasen: Druckluft
über Bohrung A, T verschlossen. Zur Vermeidung
von Hautkontakt Bewegungsrichtung der Blende
vorher beachten!
Blow out the pulsations orifice by air pressure out of
the complete valve: pressure at drilling A, close
drilling T. Note that there is no skin connection
during blowing,look how the orifice comes out before
blowing!

Entfernen der Hutmuttern. Die folgenden Arbeiten

werden erst beim Druckregler, dann beim Förderst-
romregler durchgeführt.

Remove the hexagon nuts. First disassemble

pressure control, afterwards flow control.

Kontermutter lösen und Gewindestift herausdrehen.

Loosen the lock nut and unscrew threaded pin.

1 8 Brueninghaus Hydromatik
702 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Zerlegen und Reinigen des Steuerventils
18.2
Reparaturanleitung A10 VSO/31
Disassembling and cleaning the control valve Repair Instruction A10 VSO/31

Verschlußschraube demontieren.

Disassemble the plug.

Herausnehmen des Federtellers.

Remove the spring collar.

Herausnehmen der Federn.

Remove the springs.

Herausnehmen des Federtellers.

Remove the spring cup.

Verschlußschraube entfernen.

Disassemble the plug.

Brueninghaus Hydromatik 19
008 911 53 BOMAG 703
RDE 92 711-02-R 01.95
18.2
Zerlegen und Reinigen des Steuerventils
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembling and cleaning the control valve Repair Instruction A10 VSO/31

Sorgfältiger Ausbau des Kolbens.

Be careful while disassembling the piston.

Demontage des Stopfens bzw. der Entlastungsdüse

(im Förderstromregler - Federraum ).

Disassemble the plug or orifice ( spring area of flow

control ).

Auswaschen des Steuerventilgehäuses und Einzel-

teile mit gründlichem Beseitigen des Waschmittels
durch Ausblasen.

Clean housing and parts with clean fluid and dry

with air carefully.

Zusammenbau des Steuerventils in umgekehrter

Reihenfolge. Dabei ist auf folgende Punkte zu ach-
Hinweis ! ten ( 60 bis 63 ).

Assemble pilot valve in reverse order and note the

Note ! following ( 60 to 63 ).

Kontrolle der Düsendurchlässigkeit.

Check the opening of the orifice.

2 0 Brueninghaus Hydromatik
704 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Zerlegen und Reinigen des Steuerventils
18.2
Reparaturanleitung A10 VSO/31
Disassembling and cleaning the control valve Repair Instruction A10 VSO/31

Einkleben der Düse ( auf verstopfte Düse ist beim

Klebevorgang zu achten ).

Be careful when loctiting the orifice.

Laufeigenschaft der Reglerkolben prüfen, keine

Beschädigungen der Kolben und der Bohrungen.

Check the movement of the pilot valve spools, and

drillings should not be damaged.

63
Einstellungen der Bypaßblende (s. auch S. 16):
1) Schlitz in Längsrichtung ( entspr. der Abb. ):
Blende geöffnet.
2) Schlitz quergestellt: Blende geschlossen

Adjustments of the bypass orifice (see page 16, too ):

1) open position of the orifice: like shown on the
picture
2) turn the orifice 90 ° to close it.

Einstellen des Steuerventils siehe Einstellhinweise

( s. S. 23 ).

For adjustment of the pilot valve see set up

instructions ( page 23 ).

Für die Steuerventilausführung der Pumpen NG 140

sind keine weiteren Angaben gemacht. Sinngemäß
Siehe S. 17.
sind die o. a. Hinweise zu beachten.

see page 17. Pilot valve of pump size 140 doesn't have own
instructions. However see the given hints on top.

Brueninghaus Hydromatik 21
008 911 53 BOMAG 705
RDE 92 711-02-R 01.95
18.2
Tabelle / Montage - Abstimmung
Steering/working pump
Reparaturanleitung A10 VSO/31
List / Adjustment of taper roller bearing set Repair Instruction A10 VSO/31

T a b e l l e " mechanische Förderstrombegrenzung" (gültig für Anschlag Q min und Q max )

L i s t mechanical flow limiter (both stopper max. and min. flow)

NG / Size 18 28 45 71 100* 140*

1,09 1,58 3,23 4,69 6,16 7,06

Volumenänderung ( in cm3 ) pro Gewindestiftumdrehung / Differential volume ( cm3 ) if

you are rotating the threaded pin - each rotation.
* mit vorhandenem einstellbaren Anschlag Q min /
mech. stopper min. flow adjustable

Montage - Abstimmung ( Kegelrollenlager ) / taper roller bearing initial tension

A10VSO Baureihe 31
A10VSO series 31 Hinweis zu den NG 18 und 28/
Note for size 18 and 28:
Die Ausmessung muß mit einer
Nullscheibe -Pos. 12- (1,5 ±
0,01 breit) erfolgen, s. u. Ein-
zelheit X. Diese Scheibe wird
nach der Messung entnommen.
Meßwert, Scheibenstärke der
Nullscheibe und erforderliche
Vorspannung ergibt die Stärke
der Abstimmscheibe (Pos. 12).
The smal pump sizes have to
be measured by using a spezial
shim -Pos. 12- with its
tolerance of 1,5 ± 0,01, see
detail X. This shim will be
disassembled after the
measurement. Measurement,
thickness of the spezial shim
and necessary pretention all
together makes the thickness of
the adjustment shim (Pos. 12).

Nullscheibe /

spezial shim

Einzelheit X/ detail X
Abstimmung der Triebwerkslagerung
Die Vorspannung der Triebwerkslagerung muß im Gußgehäuse von 0 bis 0,05 mm durch Abschlei-
fen der Abstimmscheibe Pos. 12 hergestellt werden.
Cast iron housing must have initial tension of the bearings : 0........0,05 mm , grind Pos. 12 if
necessary.

2 2 Brueninghaus Hydromatik
706 BOMAG 008 911 53
RDE 92 711-02-R 01.95
Steering/working pump
Einstellhinweise
18.2
Reparaturanleitung A10 VSO/31
Testing and set up instuctions Repair Instruction A10 VSO/31

DR: bei geschlossener Verbraucherleitung wird der

Regler auf Sollwert eingestellt ( bei DFR einstellbare
Drossel offen, FR-Feder vorgespannt )

DR: When pressure line is closed adjust the

pressure of the controller ( if it's DFR design then
open the adjustable orifice and increase force of the
FR - spring).

FR: Differenzdruck 14 bar wird eingestellt bei halbem

Schwenkwinkel der Pumpe ( einstellbare Drossel in
der Systemdruckleitung teilweise geschlossen ).

FR: If swivel angle is in the mid position adjust diffe-

rential pressure 14 bar ( adjustable orifice in the
system pressure line is partly closed).

Mechanische Förderstrombegrenzung: Durch

Drehen am Gewindestift kann der Förderstrom der
Pumpe abhängig von der NG um min. 35% von V gmax
reduziert werden. (Soll jedoch eine größere Re-
duzierung des Förderstromes erforderlich werden,
kann auf den Einbau der Kontermutter verzichtet
werden. Bemerkung: Einstellung der Gewinde-
spindel ohne Kontermutter erfolgt unter Betriebs-
druck) Einstellwerte siehe Tabelle Seite 22.

Mechanical flow limiter: While screwing in the

threaded pin you will be able to reduce the flow from
Vg max to 35% reduction of V gmax dependent on the
size of the pump (If you need more reducton of the
flow, don´t mount the fixing hexagon nut. Note: to
adjust the threaded pin without the fixing hexagon
nut do it by the existence of the working pressure.)
Adjustment list see page 22.

Brueninghaus Hydromatik 23
008 911 53 BOMAG 707
RDE 92 711-02-R 01.95
18.2
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Steering/working pump
Reparaturanleitung A10 VSO/31
Tools / auxiliary tools / tightening torques Repair Instruction A10 VSO/31

Verwendete Loctite-Sorten/ Loctite used :

alle Abreißstopfen/ for break-off plugs Nr. 601

sonst / normaly Nr. 242

Anziehdrehmomente / Tightening torques

Festigkeitsklassen / bolt hardness grade : 8,8; 10,9; 12,9

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. Anziehdrehmoments (geölte Schrauben μ = 0,125)

Ma (Nm) = max. tightening torques (screws lubricated μ = 0,125)

Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb 1, Telefon (0 74 51) 9 20, Telefax (0 74 51) 82 21

2 4 Brueninghaus Hydromatik
708 BOMAG 008 911 53
18.3 Travel motor

008 911 53 BOMAG 709

18.3 Travel motor

This repair manual describes the fixed displacement motor A6VM, which is identical with the travel motor A6VE,
which differs only by a different housing design.

710 BOMAG 008 911 53

Travel motor 18.3
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

008 911 53 BOMAG 711

18.3 Bosch Rexroth AG | Mobile Hydraulics
2 A6VM | RDE 91 604-01-R/03.03
Travel motor

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

712 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.33
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

008 911 53 BOMAG 713

18.3 Travel motor

714 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.35
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.

008 911 53 BOMAG 715

18.3 Bosch Rexroth AG | Mobile Hydraulics
6 A6VM | RDE 91 604-01-R/03.03
Travel motor

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)

716 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.37
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

T(T1) M1

008 911 53 BOMAG 717

18.3 Bosch Rexroth AG | Mobile Hydraulics
8 A6VM | RDE 91 604-01-R/03.03
Travel motor

Schnittbild
Sectional drawing

A6VM ... DA1

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.

720 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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

008 911 53 BOMAG 721

18.3 Bosch Rexroth AG | Mobile Hydraulics
12 A6VM | RDE 91 604-01-R/03.03
Travel motor

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".

722 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
13

Baugruppen / Steuerteile
Component groups / Control components

z. B. HA EP

HA2
Auftrags-
bezogen *
"as to order
DA
requirement".

008 911 53 BOMAG 723

18.3 Bosch Rexroth AG | Mobile Hydraulics
14 A6VM | RDE 91 604-01-R/03.03
Travel motor

Baugruppen / Steuerteile
Component groups / Control components

z. B. HZ3 / EZ3

HA3 / HA3U

724 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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.

008 911 53 BOMAG 725

18.3 Bosch Rexroth AG | Mobile Hydraulics
16 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

726 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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.

008 911 53 BOMAG 727

18.3 Bosch Rexroth AG | Mobile Hydraulics
18 A6VM | RDE 91 604-01-R/03.03
Travel motor

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

728 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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

008 911 53 BOMAG 729

18.3 Bosch Rexroth AG | Mobile Hydraulics
20 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

730 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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

008 911 53 BOMAG 731

18.3 Bosch Rexroth AG | Mobile Hydraulics
22 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

732 BOMAG 008 911 53

Travel motor 18.3

008 911 53 BOMAG 733

18.3 Travel motor

734 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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.

008 911 53 BOMAG 735

18.3 Bosch Rexroth AG | Mobile Hydraulics
26 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk ausbauen
Remove rotary group

Oder mit Abziehvorrichtung ausdrücken.

Or press-out with extraction device.

736 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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.

008 911 53 BOMAG 737

18.3 Bosch Rexroth AG | Mobile Hydraulics
28 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

738 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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.

008 911 53 BOMAG 739

18.3 Bosch Rexroth AG | Mobile Hydraulics
30 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

740 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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.

008 911 53 BOMAG 741

18.3 Bosch Rexroth AG | Mobile Hydraulics
32 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

742 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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)

008 911 53 BOMAG 743

18.3 Bosch Rexroth AG | Mobile Hydraulics
34 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

744 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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.

008 911 53 BOMAG 745

18.3 Bosch Rexroth AG | Mobile Hydraulics
36 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

746 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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.

008 911 53 BOMAG 747

18.3 Bosch Rexroth AG | Mobile Hydraulics
38 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

748 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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

008 911 53 BOMAG 749

18.3 Bosch Rexroth AG | Mobile Hydraulics
40 A6VM | RDE 91 604-01-R/03.03
Travel motor

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

750 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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

008 911 53 BOMAG 751

18.3 Bosch Rexroth AG | Mobile Hydraulics
42 A6VM | RDE 91 604-01-R/03.03
Travel motor

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

752 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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

008 911 53 BOMAG 753

18.3 Bosch Rexroth AG | Mobile Hydraulics
44 A6VM | RDE 91 604-01-R/03.03
Travel motor

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.

754 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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!

008 911 53 BOMAG 755

18.3 Bosch Rexroth AG | Mobile Hydraulics
46 A6VM | RDE 91 604-01-R/03.03
Travel motor

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

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

756 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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

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

008 911 53 BOMAG 757

18.3 Bosch Rexroth AG | Mobile Hydraulics
48 A6VM | RDE 91 604-01-R/03.03
Travel motor

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

758 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
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

008 911 53 BOMAG 759

18.3 Bosch Rexroth AG | Mobile Hydraulics
50 A6VM | RDE 91 604-01-R/03.03
Travel motor

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

760 BOMAG 008 911 53

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 18.3
51

008 911 53 BOMAG 761

18.3 Travel motor

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

762 BOMAG 008 911 53

18.4 Wheel drive

008 911 53 BOMAG 763

18.4 Wheel drive

764 BOMAG 008 911 53

Wheel drive
Electric Drives Linear Motion and
18.4
and Controls Hydraulics Assembly Technologies Pneumatics Service

Demontage- Montageanleitung
Disassembly- Assembly Instructions RDE 77977-01-R/01.08
05.02.2008
Planetengetriebe / Planetary Gearbox
HYDROTRAC

GFT 110 R3 9279

008 911 53 BOMAG 765

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 2/39

Inhaltsverzeichnis • Table of Contents

1. Einleitung 1. Preliminary Notes

1.1 Allgemeines 1.1 Generally
1.2 Anziehdrehmomente 1.2 Tightening Torques
1.3 Schmieröl; Gewicht 1.3 Lube Oil; Weight

2. Zeichnungen 2. Drawings
Einbauzeichnung Getriebe Installation Drawing
Ersatzteilzeichnung Getriebe Spare Parts Drawing

3. Teilelisten 3. Parts Lists

Teileliste Getriebe Parts List Gearbox

4. Demontage 4. Disassembly
4.1 Demontage Allgemein 4.1 Disassembly General
4.2 Demontage Bremse 4.2 Disassembly Brake
4.3 Demontage Abtrieb 4.3 Disassembly Output
4.3.1 Demontage Planetenstufen/ Planetenstege 4.3,1 Disassembly Planet Stage/ Planet Carrier
4.3.2 Demontage Wellenmutter 4.3,2 Disassembly Shaft Nut
4.3.3 Demontage Abtriebslagerung 4.3,3 Disassembly Output Bearings

5. Montage 5. Assembly
5.1 Montage Allgemein 5.1 Assembly General
5.2 Montage Abtrieb 5.2 Assembly Output
5.2.1 Montage Abtriebslagerung 5.2.1 Assembly Output Bearings
5.2.2 Montage Wellenmutter 5.2.2 Assembly Shaft Nut
5.2.3 Montage Planetenräder / Planetenstege 5.2.3 Assembly Planet Carrier / Planet Wheels
5.2.4 Montage Deckel 5.2.4 Assembly Cover
5.3 Montage Bremse 5.3 Assembly Brake

6. Probelauf 6. Test Run

6.1 Prüfstandsaufbau 6.1 Test set-up
6.2 Ölversorgung 6.2 Lubrication
6.3 Drehzahl, Laufzeit und Prüflast 6.3 Speed, Running Time, Test Load
6.4 Thermische Werte 6.4 Thermal Parameters
6.5 Laufgeräusch 6.5 Running Noise
6.6 Dichtigkeitsprüfung 6.6 Leakage Testing
6.7 Funktionsprüfung der Bremsen 6.7 Functional Test of Hydraulic Brakes
6.8 Fremdkörper 6.8 Oil Contamination Test

Verkauf Ersatzteile / Sales Spare Parts Kundendienst / Service

Bosch Rexroth AG Bosch Rexroth AG

PO Box 18 60 PO Box 18 60
D - 58408 Witten D - 58408 Witten
Tel. (02302) 877-170 Tel. (02302) 877-183
Telefax (02302) 887-300 Telefax (02302) 877-409
Hotline +49 173-2569948

766 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.43/39
1. Einleitung • 1. Preliminary Notes

1.1 Einführung 1.1 Introduction

Mit diesem Symbol sind Gefahren für das This symbol signifies danger to the prod-
Produkt und die Gesamtanlage gekenn- uct and the overall plant.
zeichnet.

Dieses Symbol kennzeichnet Hinweise. This symbol calls attention to notes.

Zur Demontage; Montage des Getriebes For disassembly, assembly procedure of

werden die Ersatzteilzeichnung und die the gearbox, spare parts drawing and
Teileliste der entsprechenden Getriebe- parts list of the respective gearbox-type is
ausführung benötigt. required.

Beachten Sie unbedingt die Sicherheitsbestimmungen The safety instructions and the appropriate accident pre-
und die einschlägigen Unfallverhütungsvorschriften! vention instructions have absolutely to be observed!

Bauen Sie nur Originalersatzteile ein. Exclusively install original spares.

Lassen Sie das Öl ab. Drain the oil from the gearbox.
Verwenden Sie dabei geeignete Auffanggefäße. For this purpose use suitable containers.

Achten Sie darauf, dass kein Schmutz oder Fremdkörper Make sure that no dirt or foreign bodies are allowed to
in das Getriebe gelangt. enter the gearbox.

Beschädigte Teile, sowie Dichtringe, durch neue Bosch Replace damaged parts and all seals by new Bosch
Rexroth Teile ersetzen. Rexroth parts.

Vor dem Einbau sind alle beweglichen Teile sowie Dicht- Oil all moving parts and seals prior to assembly.
ringe einzuölen.

Unter Umständen ist der Farbanstrich des Getriebes In the event the paint coat of the gear-box has been
durch das Zerlegen und Zusammenbauen beschädigt. damaged as a result of disassembly / assembly work
Erneuern Sie deshalb den Farbanstrich, um das Getrie- touch up or renew the paint coat as necessary to protect
be gegen Korrosion zu schützen. the gear against corrosion.

Führen Sie einen Probelauf des Getriebes durch. Carry out a test run of the gearbox.

Alle Rechte bei Bosch Rexroth AG, auch für den Fall von This document, as well as the data, specifications and
Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie other information set forth in it, is the exclusive property
Kopier- und Weitergaberecht, bei uns. of Bosch Rexroth AG. It may not be reproduced or given
to third parties without its consent.
Die angegebenen Daten dienen allein der Produktbe- The data specified above only serve to describe the
schreibung. Eine Aussage über eine bestimmte Beschaf- product. No statements concerning a certain condition or
fenheit oder eine Eignung für einen bestimmten Einsatz- suitability for a certain application can be derived from
zweck kann aus unseren Angaben nicht abgeleitet werden. our information. The information given does not release
Die Angaben entbinden den Verwender nicht von eigenen the user from the obligation of own judgment and verifi-
Beurteilungen und Prüfungen. Es ist zu beachten, dass cation. It must be remembered that our products are
unsere Produkte einem natürlichen Verschleiß- und Alte- subject to a natural process of wear and aging.
rungsprozess unterliegen.

Hinweis! Note!

Die verwendeten Bilder müssen nicht der beschriebenen The photos may show other drive types than the de-
Getriebetype entsprechen. scribed one.

008 911 53 BOMAG 767

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 4/39

1. Einleitung • 1. Preliminary Notes

1.2 Anziehdrehmomente 1.2 Tightening Torques

Standard-Anziehdrehmomente MA in Nm für ungeschmierte Schaftschrauben (m = 0,13 bis 0,17) mit Regelgewin-

de ohne zusätzliche Einzelangaben (s. LSN 945 0201)
Standard-tightening torque MA in Nm for unlubricated shoulder stud (m = 0,13 - 0,17) with standard thread without addi-
tional details (LSN 945 0201)
Schraube M6 M8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30 M 33 M 36 M 39 M 42
screw
8.8 Dr. 8,5 21,1 42,2 73,6 114,8 176,6 358 618 903 1216 1687 2129 2757 3394

10.9 Dr. 12,4 30,4 60,8 104,0 166,8 255,1 510 873 1285 1736 2364 3021 3924 4836

Dr. = Drehmomentschlüssel (torque wrench)

1.3 Schmieröl; Gewicht 1.3 Lube Oil; Weight

Gewicht ca. 460 kg Weight approx. 460 kg

Getriebeölmenge ca. 6,5 Liter Gear lube oil volume approx. 6,5 litres

Schmieröl CLP 220 oder Lube oil CLP 220 or

SAE 85 W-90 API GL-4 SAE 85 W-90 API GL-4

768 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.45/39
2. Zeichnungen • 2. Drawings

Zeichnungen Drawings
Einbauzeichnung Installation Drawing
1/6158/5279/1 1/6158/5279/1
Ersatzteilzeichnung Spare Parts Drawing
0/6158/1279/3 0/6158/1279/3

008 911 53 BOMAG 769

18.4 Wheel drive

770 BOMAG 008 911 53

Wheel drive 18.4

008 911 53 BOMAG 771

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 6/39

3. Teileliste • 3. Parts List

Teileliste Partslist
Teileliste Parts List
16218391 16218391

772 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 18.47/39
Bosch Rexroth AG

3. Teileliste • 3. Parts List

01.02.2008 Teileliste / Parts List

Matnr./Material No : 16218391
Auftrag/Order :
Produkt/Product : GFT 110 R3 9279 i=83,0 KDN-K
Zeichnungs-Nr./Drawing No : 0 6158/1279 3

Menge Pos. Benennung

Quantity Item Designation

1,000 001 Tragachse GFT 110 R3 9279

Spindle

1,000 002 Stuetzring GFT 110 R3 9279

Supporting ring

1,000 003 Mitnehmer GFT 110

Coupler

1,000 004 Planetensteg 1wg GFT 110

Planet carrier

1,000 005 Lagerring * GFT 80/110

Bearing ring

3,000 006 Sicherungsring 135x4

Snap ring
DIN 472

1,000 007 Verschlussstopfen KAS00119 (D=180)

Cap plug

1,000 008 Sprengring SP 150

Snap ring
DIN 5417

1,000 010 Zwischenring GFT 102 R2**

Spacer ring

5,000 011 Planetenrad GFT 110

Planet gear

10,000 012 Zylinderrollenlager RSL 183013

Cylindrical roller bearing
DIN 5412

10,000 013 Anlaufscheibe F 91809

Locating ring

5,000 014 Sicherungsring 95x3

Snap ring
DIN 472

1,000 015 Gleitringdichtung 265x293x38 A

Face seal
76.97H-26NB60

008 911 53 BOMAG 773

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 8/39

3. Teileliste • 3. Parts List

01.02.2008 Teileliste / Parts List

Matnr./Material No : 16218391
Auftrag/Order :
Produkt/Product : GFT 110 R3 9279 i=83,0 KDN-K
Zeichnungs-Nr./Drawing No : 0 6158/1279 3

Menge Pos. Benennung

Quantity Item Designation

5,000 016 Sicherungsring 65x2,5

Snap ring
DIN 471

1,000 017 Sonnenrad GFT 110

Sun gear

1,000 018 Sicherungsring 120x4

Snap ring
DIN 471

1,000 019 Wellenmutter M 200 x 2,5

Shaft nut

2,000 020 Kegelrollenlager 32940 J

Tapered roller bearing
DIN 720

24,000 024 Zylinderschraube M 24x2x80

Socket head cap screw
DIN 912

1,000 025 Kolben GFT 60 / 80

Piston

1,000 026 Scheibe * GFT60 / 80

Disk

1,000 028 Sicherungsring 170x4

Snap ring
DIN 472

10,000 029 Aussenlamelle 3070-636-33-001

Outer disk

9,000 030 Innenlamelle 3002-740-32-001

Inner disk

18,000 031 Druckfeder 2,5x11,5x37

Pressure spring
DIN 2098

18,000 032 Druckfeder 1,6x6,5x37

Pressure spring
DIN 2098

2,000 035 Stuetzring 136x145,4x1,4 P

Supporting ring

774 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 18.49/39
Bosch Rexroth AG

3. Teileliste • 3. Parts List

01.02.2008 Teileliste / Parts List

Matnr./Material No : 16218391
Auftrag/Order :
Produkt/Product : GFT 110 R3 9279 i=83,0 KDN-K
Zeichnungs-Nr./Drawing No : 0 6158/1279 3

Menge Pos. Benennung

Quantity Item Designation

1,000 036 Quadring 4356 446 A

Piston seal

1,000 037 Quadring 4362 446 A

Piston seal

2,000 038 Stuetzring 159x168,4x1,4 P

Supporting ring

1,000 040 Rillenkugellager 6012 J

Ball bearing
DIN 625

1,000 041 Gehaeusescheibe GS 81112

Housing washer

1,000 042 Scheibe GFT 110 R3 9279

Disk

1,000 043 O-Ring 367x3,5

O-ring
DIN 3771

2,000 044 Zylinderstift 8 m6x18 B

Cylindrical dowel pin
ISO 8734

1,000 049 Hohlrad GFT 110

Ring gear

1,000 051 Hohlraddeckel GFT 110 R3 9279

Ring gear cover

1,000 053 Planetensteg 1wgGFT110W6x

Planet carrier

3,000 054 Planetenrad GFT 110 W 6xx

Planet gear

3,000 055 Zylinderrollenlager F-212543

Cylindrical roller bearing
DIN 5412

3,000 058 Sicherungsring 50x2

Snap ring
DIN 471

008 911 53 BOMAG 775

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 10/39

3. Teileliste • 3. Parts List

01.02.2008 Teileliste / Parts List

Matnr./Material No : 16218391
Auftrag/Order :
Produkt/Product : GFT 110 R3 9279 i=83,0 KDN-K
Zeichnungs-Nr./Drawing No : 0 6158/1279 3

Menge Pos. Benennung

Quantity Item Designation

1,000 059 Sicherungsring 75x2,5

Snap ring
DIN 471

1,000 061 Gehaeusescheibe GFT 36/50

Housing washer

1,000 066 O-Ring 395x4

O-ring
DIN 3771

12,000 067 6kt-Schraube M 12x40

Hex head bolt
DIN 933

2,000 069 Verschlussschraube M 18x1,5 m. Mag.

Screw plug

2,000 070 Dichtring A 18x22x1,5

Seal ring
DIN 7603

1,000 087 Sonnenradwelle GFT 110 R3 9279

Sun gear shaft

1,000 088 Sonnenradwelle GFT 110

Sun gear shaft

1,000 089 Planetensteg GFB 17 T2

Planet carrier

4,000 090 Planetenrad GFT 13 T2 z=27 m=3

Planet gear

4,000 091 Zylinderrollenlager F-208099

Cylindrical roller bearing
DIN 5412

4,000 092 Sicherungsring 40x1,75

Snap ring
DIN 471

1,000 120 Stopfen GPN 700 B M22-1,5

Plug

2,000 121 6kt-Schraube M 12x20

Hex head bolt
DIN 933

776 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 18.411/39
Bosch Rexroth AG

3. Teileliste • 3. Parts List

01.02.2008 Teileliste / Parts List

Matnr./Material No : 16218391
Auftrag/Order :
Produkt/Product : GFT 110 R3 9279 i=83,0 KDN-K
Zeichnungs-Nr./Drawing No : 0 6158/1279 3

Menge Pos. Benennung

Quantity Item Designation

1,000 122 Scheibe GFT 110 R3

Disk

1,000 123 6kt-Schraube M 10x40

Hex head bolt
DIN 931

1,000 022 O-Ring 180x3

O-ring
DIN 3771

008 911 53 BOMAG 777

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 12/39

4. Demontage • 4. Disassembly

4.1 Demontage Allgemein 4.1 Disassembly General

Getriebe nur im ausgebauten Zustand de- Make sure to remove the gearbox from the
montieren. machine frame before disassembling it.

Für die Demontage des Getriebes sind folgende Vorar- Prior to disassembly prepare the drive as follows:
beiten erforderlich:

Beachten Sie hierzu auch Kapitel 8 der Also observe chapter 8 „Operating Instruc-
entsprechenden Betriebsanleitung für die tions" in according of the gearbox type.
Getriebetype.

· Getriebeöl ablassen. Lösen Sie dafür Ver- · Remove screw plugs (items 69) and drain
schlussschrauben (Pos. 69). Verwenden oil. Use suitable oil drain pan.
Sie dabei geeignete Auffanggefäße.
Ölinhalt: Gear lube oil volume:
ca. 6,5 Liter Approx. 6,5 liters

Achten Sie beim Transport auf eine aus- When handling the equipment make sure
reichende Tragkraft des Kranes. the carrying capacity of the crane is ade-
quate.
Getriebegewicht: ca. 460 kg. Gearbox Weight approx 460 kg.

· Stellen Sie sicher, dass das abgesetzte · Make sure the set down gearbox rests im-
Getriebe seine Lage nicht ändern kann. movably.

4.2 Demontage Bremse 4.2 Disassembly Brake

Lassen Sie das Öl ab. Entfernen Sie die Ölablass-

schraube Pos. 69, 70.
Fangen Sie Altöl in geeigneten Behältern auf und ent-
sorgen Sie es unter Beachtung der entsprechenden Vor-
schriften.

Remove screw plugs item69, 70 and drain oil.

Collect spent oil in suitable containers and dispose of the
oil line with the respective regulations.

Bild / fig. 1

Demontieren Sie die Schraube Pos. 123 aus dem Mit-

nehmer Pos. 3.

Disassemble the screws item 123.

Bild / fig. 2

778 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 18.413/39
Bosch Rexroth AG

4. Demontage • 4. Disassembly

Demontieren Sie die Scheibe Pos. 122 aus dem Mit-

nehmer Pos. 3.

Disassemble the disk item122.

Bild / fig. 3

Bild /fig. 4
Pressen Sie mit geeigneter Vorrichtung die Bremse gegen die Federn Pos. 31, 32 und entfernen Sie den Sicherungsring
Pos. 28.

Press gearbox with suitable fixture against springs item 31, 32 and remove snap ring item 28.

Entfernen Sie die Scheibe Pos. 26.

Remove pressure springs item 26.

Bild / fig. 5

Entfernen Sie die Federn Pos. 31, 32.

Remove pressure springs item 31, 32.

Bild / fig. 6

008 911 53 BOMAG 779

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 14/39

4. Demontage • 4. Disassembly

Entfernen Sie den Kolben Pos. 25 mit Quad- und Stütz-

ringen.
Entfernen Sie die Quad- und Stützringe Pos. 25 aus
Tragachse Pos. 1.

Remove piston item 25 with piston seals and supporting

rings.
Remove piston seals as well as supporting rings out off
spindle item 1.

Bild / fig. 7

Entfernen Sie die Lamellen Pos. 29, 30.

Remove brake disks item 29, 30.

Bild / fig. 8

Entfernen Sie den Mitnehmer Pos. 3.

Remove coupler item 3.

Bild / fig. 9

4.3 Demontage Abtrieb 4.3 Disassembly Output

4.3.1 Demontage 4.3.1 Disassembly

Planetenstufen/ Planetenstege Planet Stage/ Planet Carrier

Bild /fig. 10
Lösen Sie die Schrauben Pos. 67 und entfernen Sie den Deckel Pos. 51 mit O-Ring Pos. 66.

Remove bolts item 67 and remove cover item 51 with o-ring item 66.

780 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.415/39
4. Demontage • 4. Disassembly

Bild /fig. 11
Entfernen Sie die Sicherungsringe Pos. 92 von den Planetenrädern Pos. 90. Entfernen Sie die Planetenräder Pos. 90 mit
Hilfe einer Vorrichtung.

Remove snap rings item 92.Pull planet wheels item 90. Use fixture

Entfernen Sie den Sonnenradwelle Pos. 87.

Remove sun gear shaft item 87.

Bild / fig. 12

Heben Sie den Planetensteg Pos. 89 mit Sonnenrad

Pos. 88 aus dem Getriebe.

Remove planet carrier item 89 with sun gear shaft item

88.

Bild / fig. 13

Heben Sie die komplette Planetenstufe (Pos. 54, 53, 55,

17) aus dem Getriebe.

Remove complete planet stage (item 54, 53, 55, 17).

Bild / fig. 14

008 911 53 BOMAG 781

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 16/39

4. Demontage • 4. Disassembly

Drücken Sie den Sprengring Pos.8 aus der Nut des Pla-
netenstegs Pos. 4 und entfernen ihn. (Siehe Bild 15.)
Lösen Sie den Sprengring Pos. 8.

Press snap ring item 8 from the nut of planet stage and
loose the ring. (see fig. 15)

Bild / fig. 15

Heben Sie den kompletten Planetensteg (Pos. 4, 11, 12)

aus dem Getriebe.

Remove complete planet stage (item 4, 11, 12).

Bild / fig. 16

4.3.2 Demontage Wellenmutter 4.3.2 Disassembly Shaft Nut

Entfernen Sie den Sicherungsring Pos. 6 und entfernen

Sie den Lagerring Pos. 5.

Remove snap ring item 6 and disassemble bearing ring

item 5.

Bild / fig. 17

Entfernen Sie den Sicherungsring Pos. 6.

Remove snap ring item 6.

Bild / fig. 18

782 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.417/39
4. Demontage • 4. Disassembly

Entfernen Sie den Sicherungsring Pos. 6 und die Schei-

be Pos. 42.

Remove snap ring item 6 and disk item 42.

Bild / fig. 19

Entfernen Sie die Wellenmutter Pos. 19.

Hierzu sind folgende Arbeitsschritte erforderlich:
ACHTUNG!
Schutzbrille tragen.

Remove shaft nut item 19. To accomplish this you

would do the following:
ATTENTION!
Wear suitable protective goggles.

Bild / fig. 20

Decken Sie den Bauraum zum Kegelrollenlager Pos.

20 hin ab. Entfernen Sie während des Bohrvorganges
die Metallspäne um sicherzustellen, dass keine Me-
tallreste im Getriebe verbleiben.

Cover the area towards to the tapered roller bearing

item 20. Clean away metal scrap from drilling as you
drill to ensure no material gets lost within drive.

Bild / fig.. 21

1.)
Bohren Sie im Bereich der Zylinderstifte Pos. 44 ent-
19 sprechend der beiliegenden Skizze Bild 22 ein Loch in
die Wellenmutter Pos. 19.
ACHTUNG!
Nicht den Innenring des Kegelrollenlagers Pos. 22
beschädigen! Späne entfernen!

Start drilling one side of the shaft nut item 19 close to

one of the dowel pins item 44 according to the at-
tached sketch fig.. 19.
ATTENTION!
Do not damage the bearing inner ring of tapered
23 roller bearing item 20, carefully remove metal
Bild / fig.. 22 scraps!

008 911 53 BOMAG 783

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 18/39

4. Demontage • 4. Disassembly

2.)
Setzen Sie neben diese Bohrung eine weitere und wie-
derholen Sie den Vorgang zum Außen Ø der Wellen-
mutter Pos. 19 hin, bis diese Seite ausgebohrt ist.

Drill another hole next to the one you just completed

and keep working your way towards the shaft nut item
19 outside diameter until that side is drilled out.

Bild / fig.. 23

Wiederholen Sie die Arbeitsschritte 1.) und 2.) um

180° versetzt an der Wellenmutter.

Go 180° degrees around the shaft nut and start the

process over again.

Bild / fig.. 24

Wellenmutter Pos. 19 mit Hilfe eines Meißels im Be-

reich der beiden Bohrungen sprengen und von der
Tragachse Pos. 1 entfernen.
ACHTUNG!
Nicht den Lagerkäfig. des Lagers Pos. 20 beschä-
digen!
ACHTUNG!
Die Wellenmutter darf sich hierbei nicht drehen!

Use a chisel to open up the shaft nut item 19 where

you completed your drilling and remove it from the
spindle item 1.
ATTENTION!
Bild / fig.. 25 Do not damage the bearing cage of bearing item
20!
ATTENTION!
Do not turn the shaft nut – possibility of spindle
thread damage!

4.3.3 Demontage Abtriebslagerung 4.3.3 Disassembly Output Bearings

Heben Sie das Hohlrad Pos. 49, 2 ab.

Remove ring gear item 49, 2.

Bild / fig.. 26

784 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.419/39
4. Demontage • 4. Disassembly

Entfernen Sie das Rollenlager Pos.20 aus Getriebe.

Remove bearing cage of upper tapered roller bearing

item 20.

Bild / fig. 27
Abb. ähnlich/ similar in design

Lösen Sie die Schrauben Pos. 24 und demontieren Sie

den Stützring Pos. 2 vom Hohlrad Pos. 49.

Loose the screws item 24 and disassemble the support-

ing ring item 2.

Bild / fig. 28

Demontieren Sie die Lageraußenringe Pos. 20.

Remove rings of tapered roller bearing item 20.

Bild / fig. 29

Demontieren Sie den Zwischenring Pos. 10 von der

Tragachse Pos. 1.

Disassemble spacer ring item 10 from spindle item 1.

Bild / fig. 30

008 911 53 BOMAG 785

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 20/39

4. Demontage • 4. Disassembly

Entfernen Sie das Rollenlager Pos. 20 von der Tragach-

se Pos. 1.

Remove roller bearing item 20 from spindle item 1.

Bild / fig. 31
Demontieren Sie die Gleitringdichtungen Pos. 51 von der
Tragachse Pos. 1.
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Remove the axial face seal half item 51 out of the spin-
dle item 1.
Attention!
Do not use a tool with a sharp edge!

Bild / fig. 32

Deformiertes Gewinde der Tragachse Pos. 50 im Be-

reich der Zylinderstifte mit Hilfe einer Gewindefeile -
Steigung 3mm nacharbeiten.

Repair deformed threads on the spindle item 50 in the

area of cylindrical dowel pins with a thread file of 3mm
pitch.

Bild / fig. 33

786 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 18.421/39
Bosch Rexroth AG

5. Montage • 5. Assembly

5.1 Montage Allgemein 5.1 Assembly General

Vor der Montage sind folgende Ver- Prior to assembly the following inspec-
schleißprüfungen erforderlich: tions of wear and tear are required:

· Prüfen Sie auf Verschleiß: · Check for wear:

- axiale Anlaufflächen - axial contact faces
- Passsitze - machined seats
- Gewindebohrungen - threaded holes

· Prüfen Sie alle Dichtflächen auf: · Check all sealing faces for:
- Beschädigung - damage

· Prüfen Sie die Lager auf: · Check the bearings for:

- Verwendbarkeit (Spiel übermäßig) - usability (excessive clearance)
- visuelle Prüfung - visual appearance

· Prüfen Sie die Verzahnung auf: · Check the gear teeth for:
- Zahnausbrüche - tooth breakage
- Pittings - pitting
- Rissbildung - cracks
- Gratbildung - burrs
- Verschleiß - wear

MET-L-CHEK / Rissprüfung: MET-L-CHEK /

check for cracks
1. Entfetten und reinigen der Prüfteile 1. Degrease and clean the parts to be
(z.B. Spezialreiniger NPU). checked (e.g. special cleaner NPU).

2. Aufbringen des Eindringmittel 2. Apply penetrant fluid (e.g. DYE VP 30).

(z.B. DYE VP 30). Reaction time approx. 5-30 minutes de-
Einwirkzeit ca. 5-30 Min. je nach Tempera- pending on temperature and material.
tur und Werkstoff.

3. Werkstück von Eindringmittel reinigen. 3. Clean off penetrant fluid from work piece
(z.B. mit Spezialreiniger NPU oder Wasser) (e.g. with special cleaner NPU or water).
Oberfläche trocknen lassen. Allow surface to dry.

4. Den Entwickler „weiß“, hauchdünn auftra- 4. Apply a very thin layer of developer
gen. Nach einer kurzen Trockenzeit tritt „white“. After a short drying time, the
aus den Fehlstellen das Eindringmittel penetrant fluid (e.g. DYE VP 30) emerges
(z.B. DYE VP 30) aus und bildet mit dem from the defective spots and creates a red
weißen Entwickler einen roten Kontrast. contrast to the white developer.

5. Inspektion – rote Linien im weißen Ent- 5. Inspection – red lines on the white devel-
wicklerfeld zeigen Risse oder Überlappun- oper field indicate cracks or overlapping,
gen an, während punktförmige Farbaustrit- while point shaped color patterns can be
te als Poren zu werten sind. rated as blowholes and pores.

008 911 53 BOMAG 787

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 22/39

5. Montage • 5. Assembly

5.1 Montage Allgemein 5.1 Assembly General

Entfetten Sie die Aufnahmebohrung für die Gleitringdich-
tung Pos. 15 in Tragachse Pos. 1. (z.B. LOCTITE 7061)

Degrease and dry the cavities for the face seal item 15 in
the spindle item 1 (e.g. with LOCTITE 7061).

Bild / fig. 34

Kühlen Sie die Außenringe der Kegelrollenlager Pos. 20

in flüssigem Stickstoff auf –180°C ab.

Use nitrogen to cool down the outer rings of tapered

roller bearings item 20 to approx. –180°C.

Bild / fig.. 35

5.2 Montage Abtrieb 5.2 Assembly Output

5.2.1 Montage Abtriebslagerung 5.2.1 Assembly Output Bearings

Setzen Sie die in Stickstoff abgekühlten Außenringe von

den Kegelrollenlagern Pos. 20 in den Stützring Pos. 2
ein. (Prüfen Sie auf richtige axiale Anlage).

After cooling-off with nitrogen, insert outer rings of ta-

pered roller bearings item 20 into supporting ring item 2.
(Check for proper axial seat).

Bild / fig. 36

Montieren Sie die beiden Kegelrollenlager (Pos. 20) in

den Stützring (Pos. 3).

Mount both tapered roller bearing (item 20) into the sup-
porting ring (item 3).

Bild / fig. 37
Abb. ähnlich/ similar in design

788 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.423/39
5. Montage • 5. Assembly

Belasten Sie die beiden Kegelrollenlager Pos. 20 axial

mit Hilfe einer Vorrichtung mit 100 kp.
Lagerung durch 20 Drehungen in einer Richtung eindre-
hen.

Apply axial load of 100 kp to both bearings item 20.

Make use of a device.

Bild / fig. 38
Abb. ähnlich/ similar in design

Messen Sie das Maß zwischen den beiden Innenringen

der Kegelrollenlager Pos. 20 mittels einer Messvorrich-
tung.

Determine dimensions between inner rings of bearing

item 20 with measuring device.

Bild / fig. 39
Abb. ähnlich/ similar in design

Schleifen Sie den Zwischenring Pos. 10 auf Maß. (Ermit-

teltes Maß -0,25 mm).

Grind spacer ring item 10 to measure, i.e. calculated

dimension -0,25 mm.

Bild / fig. 40

Benetzen Sie die Gleitringdichtungs – O-Ringe Pos. 15

und die Aufnahmebohrung der Tragachse Pos. 1 mit
Spiritus.

Wet axial face seal o- rings item 15 and cavity spindle

item 1 with spirit of wine cleaner.

Bild / fig. 41

Drücken Sie die untere Gleitringsichtungshälfte Pos. 15

in die entsprechende Aufnahmebohrung der Tragachse
Pos. 1.
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Install face seal ring halfs item 1 into spindle item 1 un-
der even pressure on the seal surface.
Attention!
Do not use a tool with a sharp edge

Bild / fig. 42

008 911 53 BOMAG 789

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 24/39

5. Montage • 5. Assembly

Versehen Sie die Gleitflächen der Gleitringdichtung Pos.

15 mit einem Ölfilm.

Wet the sliding surfaces of the face seal item 15 with oil.

Bild / fig. 43

Setzen Sie die obere Gleitringdichtungshälfte Pos. 15

auf die untere Gleitringdichtungshälfte.

Mount the upper face seal ring half item 15 onto lower
face seal ring half.

Bild / fig. 44

Montieren Sie den unteren Innenring mit Rollenkranz von

Kegelrollenlager Pos. 20 auf Tragachse Pos. 1.

Mount upper inner ring with roller cage of double tapered

roller bearing item 20 onto spindle item 1.

Bild / fig. 45

Setzen Sie den auf Maß geschliffenen Zwischenring

Pos. 10 auf die Tragachse Pos. 1auf.

Mount the grounded spacer ring item 10 on the spindle

item 1.

Bild / fig. 46

Setzen Sie den gefetteten O-Ring Pos. 43 in die ent-

sprechende Nut im Stützring Pos. 2 ein.

Insert chord item 43 into the o-ring groove of supporting

ring item 2.
Grease chord.

Bild / fig. 47

790 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.425/39
5. Montage • 5. Assembly

Setzen Sie den Stützring Pos. 2 auf das Hohlrad

Pos. 49.

Mount supporting ring item 2 onto ring gear item 49.

Bild / fig. 48

Bestreichen Sie das Gewinde der Zylinderschrauben

Pos. 24 gleichmäßig mit LOCTITE 270 bestreichen.

Evenly apply coat of LOCTITE 270 to threads of socket

head cap screws item 24.

Bild / fig. 49

Zylinderschrauben Pos. 24 in entsprechende Gewinde-

bohrungen von Hohlrad Pos. 49 einsetzen und mit einem
Anzugsdrehmoment von 1000 Nm anziehen.

Install socket head cap screws item 24 into threaded

holes of ring gear item 49 and tighten them to a required
torque of 1000 Nm.

Bild / fig. 50

Montieren Sie das vormontierte Hohlrad mit Stützring

Pos. 49, 2 auf die vormontierte Tragachse Pos. 1.

Install pre-assembled the ring gear with supporting ring

item 49, 2 on spindle item 1.

Bild / fig. 51

Montieren Sie den oberen Innenring mit Rollenkranz des

Kegelrollenlagers Pos. 20 in das Hohlrad Pos. 49.

Mount upper inner ring with roller cage of double tapered

roller bearing item 20 into ring gear item 49.

Bild / fig. 52

008 911 53 BOMAG 791

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 26/39

5. Montage • 5. Assembly

5.2.2 Montage Wellenmutter 5.2.2 Assembly Shaft Nut

Bestreichen Sie das Gewinde der Wellenmutter Pos. 19

gleichmäßig mit LOCTITE 638.

Evenly apply coat of LOCTITE 638 to thread of shaft nut

item 19.

Bild / fig. 53

Montieren Sie die Wellenmutter Pos. 19 mit Ringkerbe

nach oben (sichtbar).

Mount shaft nut item 19 with groove on upper side (visi-

ble).

Bild / fig. 54

ACHTUNG!
Beim Einstellen der Kegelrollenlager ist der Stütz-
ring mehrfach in eine Richtung zu drehen.
- Wellenmutter Pos. 19 – mittels einer Vorrichtung mit
einem Anziehdrehmoment von 1225 daNm anzie-
hen.

ATTENTION!
Rotate the supporting ring repeatedly in one direc-
tion only when setting the tapered roller bearing
Tighten shaft nut item 19 – by using an adequate device
Bild / fig. 55 with a tightening torque of 1225 daNm.

Setzen Sie die Zylinderstifte Pos. 44 ein.

Insert cylindrical dowel pins item 44.

Bild / fig. 56

792 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG18.427/39
5. Montage • 5. Assembly

5.2.3 Montage 5.2.3 Assembly

Planetenstufen/ Planetenstege Planet Stage/ Planet Carrier

Montieren Sie die Scheibe Pos. 42 und den Sicherungs-

ring Pos. 6.

Mount the disk item 42 and the snap ring item 6.

Bild / fig. 57

Montieren Sie den Sicherungsring Pos.6.

Mount the snap ring item 6.

Bild / fig. 58

Bild /fig. 59
Kühlen Sie den Lagerring Pos. 5 in flüssigem Stickstoff auf –180°C ab. Montieren Sie den Lagerring in die Tragachse

Use nitrogen to cool down outer ring of tapered roller bearings item 5 to approx. –180°C and mount outer ring into spindle.

Sichern Sie den Lagerring Pos. 5 mit dem Sicherungs-

ring Pos. 6.

Secure the bearing ring item 5 with the snap ring item 6.

Bild / fig. 60

008 911 53 BOMAG 793

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 28/39

5. Montage • 5. Assembly

Bestreichen Sie die Aufnahmebohrungen der Scheibe

Pos. 41 mit LOCTITE 640.

Evenly apply coat of LOCTITE 640 to the location hole of

disc item 41.

Bild / fig. 61

Montieren Sie die Scheibe Pos. 41.

Mount the disc item 41.

Bild / fig. 62

Drücken Sie das Zylinderrollenlager Pos. 12 aus der

Transportverpackung direkt in die Aufnahmebohrung von
Planetenrad Pos. 11.

Push cylindrical roller bearing item 12 directly out of

transport packing into the locating hole of the planet gear
(item 11).

Bild / fig. 63

Setzen Sie die Anlaufscheibe Pos. 13 ein.

Insert locating ring item 13.

Bild / fig. 64

Setzen Sie den Sicherungsring Pos. 14 ein.

Insert a new snap ring item 14.

Bild / fig. 65

794 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.429/39
5. Montage • 5. Assembly

Setzen Sie die zweite Anlaufscheibe Pos. 13 ein.

Insert 2nd locating ring item 13.

Bild / fig. 66

Drücken Sie das zweite Zylinderrollenlager Pos. 12 aus

der Transportverpackung direkt in die Aufnahmebohrung
von Planetenrad Pos. 11.

Push 2nd cylindrical roller bearing item 12 directly out of

transport packing into the locating hole of the planet gear
item 11.

Bild / fig. 67

Bild /fig. 68
Erwärmen Sie vormontiertes Planetenrad Pos. 11 auf ca. 120°-130°C. Montieren Sie den Sprengring Pos. 8 auf den Pla-
netensteg Pos. 4. Montieren Sie die Planetenräder Pos. 11 auf die Planetenbolzen von Planetensteg Pos. 4.

Heat pre-assembled planet gear item 11 to approx. 120°-130°C. Mount the snap ring item 8 onto the planet stage item 4.
Mount pre-assembled planet gear onto the planetary pin of planet carrier item 4.

Sichern Sie die Planetenräder mit den Sicherungsringen

Pos. 16.

Secure the planet gears with snap ring item 16.

Bild / fig. 69

008 911 53 BOMAG 795

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 30/39

5. Montage • 5. Assembly

Setzen Sie den komplett montierten Planetensteg Pos. 4

in das Getriebe ein.

Install completely pre-assembled planet stage item 4 into

gear box.

Bild / fig. 70

Beachten Sie das die Öffnung des Sprengringes Pos. 8

gegenüber der Nut Tragachse liegt.

Make sure that of the opening of the snap ring item 8 is

is across from the groove of the spindle.

Bild / fig. 71

Setzen Sie den Planetensteg Pos. 53 auf die Verzah-

nung des Sonnenrades Pos. 17.

Insert planet carrier item 53 into internal teeth of sun

gear item 17.

Bild / fig. 72
Abb. ähnlich/ similar in design

Sichern Sie das Sonnenrad mit dem Sicherungsring

Pos. 18.

Secure sun gear with snap ring item 18.

Bild / fig. 73
Abb. ähnlich/ similar in design

796 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.431/39
5. Montage • 5. Assembly

Drücken Sie das Zylinderrollenlager Pos. 55 aus der

Transportverpackung direkt in die Aufnahmebohrung von
Planetenrad Pos. 54.

Push cylindrical roller bearing item 55 directly out of

transport packing into the locating hole of the planet gear
item 54.

Bild / fig. 74
Abb. ähnlich/ similar in design

Erwärmen Sie die vormontierten Planetenräder Pos. 54

auf ca. 120°-130°C. Montieren Sie das vormontierte Pla-
netenrad auf den Planetenbolzen von Planetensteg Pos.
53.

Heat pre-assembled planet gear item 54 to approx. 120°-

130°C. Mount pre-assembled planet gear onto the plane-
tary pin of planet carrier item 53.

Bild / fig. 75
Abb. ähnlich/ similar in design

Sichern Sie die Planetenräder mit den Sicherungsringen

Pos. 58.

Secure the planet gears with snap ring item 58.

Bild / fig. 76
Abb. ähnlich/ similar in design

Setzen Sie den komplett montierten Planetensteg Pos.

53 in das Getriebe.

Lift in the mounted planet carrier item 53 into the gear-

box.

Bild / fig. 77

008 911 53 BOMAG 797

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 32/39

5. Montage • 5. Assembly

Drücken Sie das Zylinderrollenlager Pos. 91 aus der

Transportverpackung direkt in die Aufnahmebohrung von
Planetenrad Pos. 90.

Push cylindrical roller bearing item 91 directly out of

transport packing into the locating hole of the planet gear
item 90.

Bild / fig. 78
Abb. ähnlich/ similar in design

Setzen Sie den Planetensteg Pos. 89 auf die Verzah-

nung der Sonnenradwelle Pos. 88.

Insert planet carrier item 89 into internal teeth of sun

gear shaft item 88.

Bild / fig. 79

Sichern Sie die Sonnenradwelle Pos. 88 mit dem Siche-

rungsring Pos. 59.

Secure sun gear shaft item 88 with snap ring item 59.

Bild / fig. 80

Setzen Sie den vormontierten Planetensteg Pos. 89 in

das Getriebe.

Lift in the preassembled planet carrier item 89 into the

gearbox.

Bild / fig. 81

Setzen Sie die Sonnenradwelle Pos. 87 in das Getriebe

ein.

Install sun gear shaft item 87.

Bild / fig. 82

798 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.433/39
5. Montage • 5. Assembly

Erwärmen Sie die vormontierten Planetenräder Pos. 90

auf ca. 120°-130°C. Montieren Sie das vormontierte Pla-
netenrad auf den Planetenbolzen von Planetensteg Pos.
89.

Heat pre-assembled planet gears item 90 to approx.

120°-130°C. Mount pre-assembled planet gear onto the
planetary pin of planet carrier item 89.

Bild / fig. 83

Sichern Sie die Planetenräder mit den Sicherungsringen

Pos. 92.

Secure the planet gears with snap ring item 92

Bild / fig. 84

5.5.4 Montage Deckel 5.5.4 Assembly Cover

Zylinderrolle Pos. 61 in Deckel Pos. 51 einsetzen.

Install cylindrical roller item 61 into cover item 51.

Bild / fig. 85

Axialspiel prüfen:
Spiel zwischen Anlauffläche der Sonnenradwelle Pos.
87 und der Zylinderrolle Pos. 61 vor der Montage des
Deckels Pos. 51 prüfen. (Sollwert 1-2 mm).

Checking of axial clearance:

Determine clearance between contact face of sun
gear shaft item 87 and cylindrical roller item 61 by
measuring parts prior to assembly of cover item 51.
Bild / fig. 86 (Recommended clearance 1-2 mm).

008 911 53 BOMAG 799

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 34/39

5. Montage • 5. Assembly

Montieren Sie den O-Ring Pos. 66 in die entsprechende

Nut des Deckels Pos. 51.
Fetten Sie den O- Ring ein.

Insert o-ring item 66 into the o-ring groove of cover item

51.
Grease o-ring.

Bild / fig. 87

Bild /fig. 88
Setzen Sie den vormontierten Deckel Pos. 51 mit O-Ring Pos. 66 in den Einpass des Hohlrades Pos. 49 ein und befesti-
gen ihn mit den Schrauben Pos. 67. Ziehen Sie die Schrauben mit erforderlichem Anzugsmoment von 87 Nm an.

Mount the cover item 51 with o-ring item 66 to the ring gear item 49. Tighten screws to a proper torque. of 87 Nm.

Bild /fig. 89
Schrauben Sie die Verschlussschrauben Pos. 69, 70 und 6kt-Schrauben Pos. 121 in den Deckel Pos. 51ein.

Screw the screw plugs item 69, 70 and hex heat bolts item 121 into the cover item.

800 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.435/39
5. Montage • 5. Assembly

5.5.4 Montage Bremse 5.5.4 Assembly Brake

Pressen Sie das Rillenkugellager Pos. 40 auf den Mit-
nehmer Pos. 3.

Press in the ball bearing item 40 onto the coupler.

Bild / fig. 90

Setzen Sie den Mitnehmer Pos. 3 ein.

Mount coupler item 3.

Bild / fig. 91

Legen Sie die Lamellen Pos. 29, 30 in richtiger Reihen-

folge ein. (siehe Ersatzteilzeichnung0/6158/1279/3)

Insert brake disks item 29, 30 in correct order.

(note spare part drawing 0/6158/1279/3)

Bild / fig. 92

Montieren Sie die Quad- und Stützringe Pos. 37, 38 in

den Kolben Pos. 25.

Mount supporting rings and piston seal Pos, 37, 38 into

the piston item 25.

Bild / fig. 93

008 911 53 BOMAG 801

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 36/39

5. Montage • 5. Assembly

Montieren Sie die Quad- und Stützringe Pos. 35, 36 in

die Tragachse Pos. 1.

Mount supporting rings and piston seal Pos, 35, 36 into

spindle item 1.

Bild / fig. 94

Ölen Sie die Dichtfläche ein.

Lubricate the sealing surface.

Bild / fig. 95

Setzen Sie den Kolben Pos. 25 in die Tragachse Pos. 1

ein.

Mount the piston item 25 into the spindle item 1.

Bild / fig. 96
Abb. ähnlich/ similar in design

Setzen Sie die Federn Pos. 31, 32 ein.

Mount pressure springs item 31, 32.

Bild / fig. 97

Setzen Sie die Scheibe Pos. 26 ein.

Mount the disk item 26.

Bild / fig. 98

802 BOMAG 008 911 53

Wheel drive
RDE 77977-01-R/01.08 GFT 110 R3 9279 18.437/39
Bosch Rexroth AG

5. Montage • 5. Assembly

Bild /fig. 99
Pressen Sie mit geeigneter Vorrichtung den vormontierten Kolben Pos. 25 gegen die Federn Pos. 31, 32 und montieren
Sie den Sicherungsring Pos. 28.

Press piston item 25 with suitable fixture against springs item 31, 32 and mount snap ring item 28.

Axialspiel prüfen:

Überprüfen Sie vor dem Einbau der Scheibe Pos. 122

das Axialspiel zwischen Scheibe Pos. 122 und Mitneh-
mer Pos. 3 (Siehe Ersatzteilzeichnung 0/6158/1279/3).

Checking of axial clearance:

Determine clearance between disc item 122 and coupler
item 3 by measuring parts prior to assembly of disc item
122. (See installation drawing 0/6158/1279/3).
Bild / fig. 100

Bild /fig. 101

Abb. ähnlich/ similar in design
Setzen Sie die Scheibe Pos. 122 in den Mitnehmer Pos. 3 ein. Bestreichen Sie die Schraube Pos. 123 mit LOCTITE 270.
Ziehen Sie die Schraube Pos. 123 mit einem Anziehdrehmoment von 51 Nm an. (Siehe Ersatzteilzeichnung
0/6158/1279/3).

Mount the disc item 122 into the coupler item 3. Evenly apply coat of LOCTITE 270 to thread of screws item 123.
Tighten the screws item 123 to the torque 51 Nm. (See spare part drawing 0/6158/1279/3).

008 911 53 BOMAG 803

18.4
RDE 77977-01-R/01.08 GFT 110 R3 9279 WheelAG
Bosch Rexroth drive 38/39

6. Probelauf • 6. Test Run

6.1 Prüfstandsaufbau 6.1 Test set up

Das Getriebe wird in der vorgesehenen Einbaulage aufge- The gearbox shall be mounted in its intended installation
baut und mit einem geeigneten Antriebsmotor angetrieben. position and connected to a suitable driving motor. If the
Wenn das Betriebsverhalten des Getriebetyps bekannt ist, operating performance of the gearbox type is known, it is
kann eine andere Prüflage gewählt werden, wobei die Ra- possible to mount the gearbox in another test position
dialwellendichtringe, bzw. Gleitringdichtungen unter Öl under the condition that the radial face seals and the
stehen müssen (Luftkammerbildung beachten!). axial seal are submerged in oil (check for air chambers!).

6.2 Ölversorgung 6.2 Lubrication

Die Getriebe werden wie in der Einbauzeichnung vorgese- The gear units are to be filled with oil as shown on the
hen mit Öl gefüllt. Bremsen mit separater Ölfüllung sind installation drawing. Brakes, which have separate oil
vor dem Probelauf gemäß Einbauzeichnung ebenfalls mit fillings, shall be filled with oil before test run.
Öl zu befüllen. For oil fill, please use the lubricants listed in the operat-
Zur Ölbefüllung verwenden Sie bitte die in der Betriebsan- ing instructions.
leitung angebenden Schmierstoffe.

6.3 Drehzahl, Laufzeit und 6.3 Speed, Running Time,

Prüflast Test Load
Die Getriebe sind mit Höchstdrehzahl (nmax Getriebe bzw. The gear units are to be operated at max. speed (nmax of
nmax Prüfstand) über 1 Stunde (je ½ Stunde pro Drehrich- gearbox or nmax test bed) under no load for one hour
tung bei Getrieben mit wechselnder Drehrichtung) ohne (half an hour in each direction of rotation in case of re-
Last zu fahren. verse gears).
Hierbei ist die Ölsumpftemperatur am Außendurchmesser Measure oil sump temperatures at outside diameter of
des Hohlrades nach 30, 45 und 60 Minuten zu messen ring gear and note them down after 30, 45 and 60 min-
und zu protokollieren. utes of operation.

6.4 Thermische Werte 6.4 Thermal Parameters

Die Ölsumpftemperatur soll nach Abschluss des The oil sump temperature measured after the 1-hour test
1-stündigen Probelaufs 70°C nicht übersteigen. Die Tem- run shall not exceed 70°C.
peratur nach 30 Minuten bei reduzierter Laufzeit soll die The temperature measured after 30 minutes reduced
Temperatur der Temperaturaufschreibung des ersten Ge- operating time shall not exceed the temperature records
triebes um nicht mehr als 4°C überschreiten. of the first gearbox by more than 4°C.
Die Temperaturen an außenliegenden Lagerstellen (soweit The temperatures measured at the external bearing ar-
zutreffend) sollen die Ölsumpftemperaturen um nicht mehr eas (if applicable) must be not exceed the oil sump tem-
als 10°C übersteigen. perature by more than 10°C.

6.5 Laufgeräusch 6.5 Running Noise

Das Laufgeräusch soll weich und gleichmäßig sein. The running noise under test conditions should be
Es dürfen keine harten, schlagenden oder pfeifende Ge- smooth and steady.
räusche vorhanden sein. Hard, knocking or howling noise produced by the unit is
inadmissible.

6.6 Dichtigkeitsprüfung 6.6 Leakage Testing

Während des Probelaufs sind alle Dichtungen auf Undich- During the test run, make sure to check all seals for
tigkeiten hin zu beobachten, z.B.: leakages, e.g.:
- Ein- und Auslassschrauben - Inlet and drain plugs
- Entlüfter - Vent
- Dichtflächen an Hohlrädern und Deckeln - Sealing faces at ring gears and covers
- Wellendichtungen - Shaft seals

804 BOMAG 008 911 53

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RDE 77977-01-R/01.08 GFT 110 R3 9279 Bosch Rexroth AG 18.439/39
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1MPNCFO
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NFDIBOJTDI7FSXFOEFO4JFEFO4UFVFSCMPDLOJFNBMTBMT(SJGGPEFS4UVGF
4UFMMFO4JFLFJOF(FHFOTUOEFEBSBVGBC
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4JDIFSIFJUTIJOXFJTF
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836 BOMAG 008 911 53

#PTDI3FYSPUI"(
Control valve block #FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
18.5
4JDIFSIFJUTIJOXFJTF

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JN*OUFSOFUVOUFShttp://www.boschrexroth.de/didactic

008 911 53 BOMAG 837

18.5
3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF #PTDI3FYSPUI"(
Control valve block
-JFGFSVNGBOH

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1S®GFO4JFEFO-JFGFSVNGBOHBVG7PMMTUOEJHLFJU
1S®GFO4JFEFO-JFGFSVNGBOHBVGN¨HMJDIF5SBOTQPSUTDIEFO

838 BOMAG 008 911 53

#PTDI3FYSPUI"(
Control valve block #FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
18.5
1SPEVLUCFTDISFJCVOH

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4UFVFSCMPDL[V

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008 911 53 BOMAG 839

18.5
3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF #PTDI3FYSPUI"(
Control valve block
1SPEVLUCFTDISFJCVOH

"CC5ZQTDIJMEBVGWPS+BOVBSIFSHFTUFMMUFO4UFVFSCM¨DLFO
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00005158
Made in Germany

"CC5ZQTDIJMEBVGBC+BOVBSIFSHFTUFMMUFO4UFVFSCM¨DLFO

7920

Made in Germany

"CC5ZQTDIJMEFSBVGBC"QSJMIFSHFTUFMMUFO4UFVFSCM¨DLFONJU"OHBCF
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MNR: R917XXXXX
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;XFDLFOWPO#PTDI3FYSPUI

840 BOMAG 008 911 53

#PTDI3FYSPUI"(
Control valve block #FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
18.5
5SBOTQPSUVOE-BHFSVOH

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XFSEFO

008 911 53 BOMAG 841

18.5
3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF #PTDI3FYSPUI"(
Control valve block
5SBOTQPSUVOE-BHFSVOH

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-FDLBHFTJOEEJF%JDIUVOHFO[VFSOFVFSO

842 BOMAG 008 911 53

#PTDI3FYSPUI"(
Control valve block #FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
18.5
.POUBHF

.POUBHF

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EVSDIIFSBVTTQSJU[FOEFTMPEFS#BVUFJMFOÝ
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1SPEVLUNPOUJFSFOC[X4UFDLFSBOTDIMJFFOPEFS[JFIFO
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4JDIFSO4JFEFO"OMBHFOUFJMHFHFOVOCFBCTJDIUJHUFT8JFEFSFJOTDIBMUFO

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7FSCJOEFO4JFJNNFSEFO&SEVOHTBOTDIMVTTEFT4UFVFSCMPDLTNJUEFN
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7FSXFOEFO4JFBVTTDIMJFMJDIFJO/FU[UFJMNJUTJDIFSFS5SFOOVOH
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7FSMFU[VOHTHFGBISEVSDIGBMTDIF"OTDIMVTTCFMFHVOHPEFSWFSUBVTDIUF
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4UFMMFO4JFTJDIFS EBTTBMMF3PISFVOEPEFS4DIMVDIFBNSJDIUJHFO
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,BCFMTUFDLFS[VEFOKFXFJMJHFO4UFVFSCMPDLNBHOFUFOQS®GFO

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008 911 53 BOMAG 843

18.5
3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF #PTDI3FYSPUI"(
Control valve block
.POUBHF

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844 BOMAG 008 911 53

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008 911 53 BOMAG 845

18.5
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846 BOMAG 008 911 53

#PTDI3FYSPUI"(
Control valve block 18.5
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008 911 53 BOMAG 847

18.5
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848 BOMAG 008 911 53

#PTDI3FYSPUI"(
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18.5
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008 911 53 BOMAG 849

18.5
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Control valve block
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850 BOMAG 008 911 53

#PTDI3FYSPUI"(
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18.5
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008 911 53 BOMAG 851

18.5
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Control valve block
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XFOOFJO"CTFOLFOEFS-BTUOJDIUN¨HMJDIJTU"OBOHFIPCFOFO&JOIFJUFO
E®SGFO4JFPIOFFYUFSOF"CTJDIFSVOHLFJOFTGBMMT*OTUBOEIBMUVOHTBSCFJUFO
EVSDIG®ISFO
4DIBMUFO4JFBMMF1VNQFOBC
4U®U[FO4JF7FSUJLBM[ZMJOEFSNFDIBOJTDIHFHFO"CTJOLFOBC
;VN"VTUBVTDI&JOTBU[[VHFMBTTFOTJOEOVSOFVF CBVHMFJDIFVOEHFQS®GUF
,PNQPOFOUFO &STBU[UFJMFVOE4DINJFSTUPGGFJO&STUBVTS®TUFSRVBMJUU
4UFMMFO4JFTJDIFS EBTTBMMF4DIVU[WPSSJDIUVOHFOVOEJOTCFTPOEFSFBMMF
4DIVU[GVOLUJPOFOEJFEJF4JDIFSIFJUTBCTDIBMUTUSBUFHJFCFFJOUSDIUJHFO
LÖOFOWPSKFEFS8JFEFSJOCFUSJFCOBINFPSEOVOHTHFNJOTUBMMJFSUVOEBVG
'VOLUJPOTU®DIUJHLFJUHFQS®GUTJOE
&OUGFSOFO4JFOBDI&OEFEFS"SCFJUFOBMMF8FSL[FVHFVOE(FSUFWPN
)ZESBVMJLQSPEVLU EJF[VS*OTUBOEIBMUVOHOÜJHXBSFO

852 BOMAG 008 911 53

#PTDI3FYSPUI"(
Control valve block #FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
18.5
*OTUBOEIBMUVOHVOE*OTUBOETFU[VOH

7034*$)5
1FSTPOFOTDIEFOEVSDIOJDIUGVOLUJPOJFSFOEF&STBU[UFJMF
&STBU[UFJMF EJFOJDIUEFOWPO#PTDI3FYSPUIGFTUHFMFHUFOUFDIOJTDIFO
"OGPSEFSVOHFOHFO®HFO L¨OOFO1FSTPOFOTDIEFOWFSVSTBDIFO
7FSXFOEFO4JFOVS0SJHJOBMFSTBU[UFJMFWPO#PTDI3FYSPUI

)*/8&*4
&JOESJOHFOEFS4DINVU[VOE'M®TTJHLFJUFOG®ISFO[V4U¨SVOHFOÝ
%JFTJDIFSF'VOLUJPOEFT4UFVFSCMPDLTJTUEBEVSDIOJDIUNFISHFXISMFJTUFU
"DIUFO4JFCFJBMMFO"SCFJUFOBN4UFVFSCMPDLBVGHS¨UF4BVCFSLFJU
7FSTDIMJFFO4JFBMMFGGOVOHFONJUHFFJHOFUFO4DIVU[FJOSJDIUVOHFO EBNJU
LFJO3FJOJHVOHTNJUUFMJOT4ZTUFNFJOESJOHFOLBOO
CFSQS®GFO4JF PCBMMF%JDIUVOHFOVOE7FSTDIM®TTFEFS4UFDLWFSCJOEVOHFO
GFTUTJU[FO EBNJUCFJEFS3FJOJHVOHLFJOF'FVDIUJHLFJUJOEFO4UFVFSCMPDL
FJOESJOHFOLBOO
4UBVCBCMBHFSVOHFOBVGEFN4UFVFSCMPDLTJOEJOSFHFMNJHFO"CTUOEFO[V
FOUGFSOFO

#FTDIEJHVOHEFS0CFSGMDIFEVSDI-¨TFNJUUFMVOEBHHSFTTJWF
3FJOJHVOHTNJUUFMÝ
"HHSFTTJWF3FJOJHVOHTNJUUFML¨OOFOEJF%JDIUVOHFOEFT4UFVFSCMPDLT
CFTDIEJHFOVOEMBTTFOTJFTDIOFMMFSBMUFSO
7FSXFOEFO4JFOJFNBMT-¨TFNJUUFMPEFSBHHSFTTJWF3FJOJHVOHTNJUUFM
3FJOJHFO4JFEFO4UFVFSCMPDLBVTTDIMJFMJDINJUFJOFNGFVDIUFO5VDIBVT
OJDIUGBTFSOEFN(FXFCF7FSXFOEFO4JFEB[VBVTTDIMJFMJDI8BTTFSVOE
HHGFJONJMEFT3FJOJHVOHTNJUUFM

#FTDIEJHVOHEFS)ZESBVMJLVOE%JDIUVOHFOÝ
%FS8BTTFSESVDLFJOFT)PDIESVDLSFJOJHFSTLBOOEJF)ZESBVMJLVOEEJF
%JDIUVOHFOEFT4UFVFSCMPDLTCFTDIEJHFO%BT8BTTFSWFSESOHUEBTMBVT
EFS)ZESBVMJLVOEEFO%JDIUVOHFO
7FSXFOEFO4JF[VS3FJOJHVOHLFJOFO)PDIESVDLSFJOJHFS

#FHSJGGTEFGJOJUJPO
%FS#FHSJGG*OTUBOEIBMUVOHCF[FJDIOFUOBDI%*/EJF,PNCJOBUJPO
BMMFSUFDIOJTDIFOVOEBENJOJTUSBUJWFO.BOBINFOTPXJF.BOBINFOEFT
.BOBHFNFOUTXISFOEEFT-FCFOT[ZLMVTFJOFS#FUSBDIUVOHTFJOIFJU[VS
&SIBMUVOHEFTGVOLUJPOTGIJHFO;VTUBOEFTPEFSEFS3®DLG®ISVOHJOEJFTFO TP
EBTTTJFEJFHFGPSEFSUF'VOLUJPOFSG®MMFOLBOO
%JFTF.BOBINFOHMJFEFSOTJDIBVGJO
È 8BSUVOH .BOBINFO[VS7FS[¨HFSVOHEFT"CCBVTEFTWPSIBOEFOFO
"COVU[VOHTWPSSBUT

È *OTQFLUJPO .BOBINFO[VS'FTUTUFMMVOHVOE#FVSUFJMVOHEFT*TU[VTUBOEFTFJOFS
#FUSBDIUVOHTFJOIFJUFJOTDIMJFMJDIEFS#FTUJNNVOHEFS6STBDIFOEFS"COVU[VOH
VOEEFN"CMFJUFOEFSOPUXFOEJHFO,POTFRVFO[FOG®SFJOFL®OGUJHF/VU[VOH

È *OTUBOETFU[VOH .BOBINFO[VS3®DLG®ISVOHFJOFS#FUSBDIUVOHTFJOIFJUJO
EFOGVOLUJPOTGIJHFO;VTUBOE NJU"VTOBINFWPO7FSCFTTFSVOHFO

È 7FSCFTTFSVOH ,PNCJOBUJPOBMMFSUFDIOJTDIFOVOEBENJOJTUSBUJWFO
.BOBINFOTPXJF.BOBINFOEFT.BOBHFNFOUT[VS4UFJHFSVOHEFS

008 911 53 BOMAG 853

18.5
3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF #PTDI3FYSPUI"(
Control valve block
*OTUBOEIBMUVOHVOE*OTUBOETFU[VOH

'VOLUJPOTTJDIFSIFJUFJOFS#FUSBDIUVOHTFJOIFJU PIOFEJFWPOJISHFGPSEFSUF
'VOLUJPO[VOEFSO

*OTQFLUJPOVOE8BSUVOH
;JFMWPO*OTQFLUJPOVOE8BSUVOHJTUFT
È EJF'VOLUJPOBMJUUEFT4ZTUFNTNJUTFJOFO"VTHBOHTLFOOHS¨FO[VFSIBMUFO
È EJFTUOEJHF7FSG®HCBSLFJUEFT4ZTUFNT[VTJDIFSO
È 4DIXBDITUFMMFO[VFSLFOOFO
È EJFHFGPSEFSUF-FCFOTEBVFSEFT4ZTUFNT[VFSSFJDIFO

(SVOETU[MJDIFNQGFIMFOXJS FJO*OTQFLUJPOTVOE8BSUVOHTCVDI[VG®ISFO JO

XFMDIFNBMMF"OMBHFOVOETUBOEPSUTQF[JGJTDIFO"SCFJUFOTPXJF*OTQFLUJPOTVOE
8BSUVOHTJOUFSWBMMFEFGJOJFSUTJOEVOEEPLVNFOUJFSUXFSEFO
%JF4UFVFSCM¨DLFTJOECFJ&JOIBMUVOHEFSWPSHFTDISJFCFOFO#FUSJFCTVOE
6NHFCVOHTCFEJOHVOHFOXBSUVOHTGSFJ3FHFMNJHF*OTQFLUJPOTVOE
8BSUVOHTBSCFJUFOGBMMFOEBIFSOJDIUBO
,POUSPMMJFSFO4JFNJOEFTUFOTKFEPDIBMMFESFJ+BISF HFSFDIOFUBC)FSTUFMMEBUVN
EFT4UFVFSCMPDLFT

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BMMF4DISBVCFOVOE"OTDIM®TTFBVGGFTUFO4JU[
BMMF"OTDIMVTTMFJUVOHFOBVG#FTDIEJHVOHFO4PMMUFO#FTDIEJHVOHFO
TJDIUCBSTFJO "OTDIMVTTMFJUVOHFSOFVFSO

#FTUFMMJOGPSNBUJPOFOG®S%JDIUVOHTTU[FGJOEFO4JFJN,BQJUFM
Å&STBU[UFJMFÃBVG4FJUF

%SVDLGM®TTJHLFJUFO
%JF(FCSBVDITFJHFOTDIBGUFOWPO%SVDLGM®TTJHLFJUFOWFSTDIMFDIUFSOTJDINJU
[VOFINFOEFS"MUFSVOH DIFNJTDIFS7FSOEFSVOH
&TCJMEFOTJDI4VSFOVOE
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4UFVFSCMPDLFTG®ISFOL¨OOFO
'PMHFOEF'BLUPSFOCFTDIMFVOJHFOEFO"MUFSVOHTQSP[FTT
È IPIF5FNQFSBUVSFO
È -VGUJOEFS%SVDLGM®TTJHLFJU
È -VGUGFVDIUJHLFJU
È 8BTTFS
È NFUBMMJTDIF,BUBMZTBUPSFO
È IPIFS#FUSJFCTESVDL
È 7FSTDINVU[VOH

#FBDIUFO4JFGPMHFOEF'BVTUSFHFM
"CFJOFS%SVDLGM®TTJHLFJUTUFNQFSBUVSm$WFSEPQQFMUTJDIEJF
"MUFSVOHTHFTDIXJOEJHLFJUQSPm$

È 8FJUFSF BVDIG®S3FYSPUI4UFVFSCM¨DLFHFMUFOEF*OGPSNBUJPOFO[V
%SVDLGM®TTJHLFJUFOBVG.JOFSBM¨MCBTJTGJOEFO4JFJOVOTFSFO%SVDLTDISJGUFO
¾ 3%%SVDLGM®TTJHLFJUFOBVG.JOFSBM¨MCBTJT
¾ 3%%SVDLGM®TTJHLFJUFOBVG.JOFSBM¨MCBTJT

854 BOMAG 008 911 53

#PTDI3FYSPUI"(
Control valve block #FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
18.5
*OTUBOEIBMUVOHVOE*OTUBOETFU[VOH

'FIMGVOLUJPOEVSDI7FSVOSFJOJHVOHEFS%SVDLGM®TTJHLFJU
7FSVOSFJOJHVOHFOEFS%SVDLGM®TTJHLFJUG®ISFOOJDIUOVS[VFSIÏUFN7FSTDIMFJ
VOEL®S[FSFS-FCFOTEBVFSEFT4UFVFSCMPDLFTTPOEFSOBVDI[V'FIMGVOLUJPOFO
%JFTFLÖOFOEJF4JDIFSIFJUVOE;VWFSMTTJHLFJUEFT4UFVFSCMPDLFTOFHBUJW
CFFJOGMVTTFO
'®ISFO4JFEFTIBMCSFHFMNJHEJFJOEFS#FUSJFCTBOMFJUVOHEFS.BTDIJOF
GFTUHFMFHUFO*OTUBOEIBMUVOHTNBOBINFOEVSDIVOEBDIUFO4JFCFJ"SCFJUFOBN
4UFVFSCMPDLBVGHSÜF4BVCFSLFJU
7FSVOSFJOJHVOHFOEFS%SVDLGM®TTJHLFJULÖOFOFOUTUFIFOEVSDI
È 7FSTDIMFJCFJN#FUSJFCEFS.BTDIJOF
NFUBMMJTDIFSVOEOJDIUNFUBMMJTDIFS"CSJFC

È 6OEJDIUJHLFJUFOEFT4UFVFSCMPDLFT
È 7FSTDINVU[VOHFO EJFXISFOEEFS8BSUVOH*OTUBOETFU[VOHFJOHFCSBDIU
XFSEFO
È 7FSXFOEVOHWPOWFSTDINVU[UFS VOHFGJMUFSUFS
%SVDLGM®TTJHLFJUCFJN"VTUBVTDI

/BDIG®MMFO8JFEFSCFG®MMFO
"DIUFO4JFCFJN/BDIG®MMFO8JFEFSCFG®MMFO*ISFS)ZESBVMJLBOMBHFEBSBVG EBTT
4JFFJOF[VMTTJHF%SVDLGM®TTJHLFJU TJFIFÅ5FDIOJTDIFT%BUFOCMBUUÃ
EFSHMFJDIFO
4PSUF EFTHMFJDIFO5ZQTVOEEFTTFMCFO)FSTUFMMFSTWFSXFOEFO
#FJTUBSLFS4DINVU[FJOXJSLVOHC[XCFJWPS[FJUJHFS"MUFSVOHEFS%SVDLGM®TTJHLFJU
NVTTEBT4ZTUFNJOLM5BOLWPSEFS8JFEFSCFG®MMVOHHFSFJOJHUVOEHFTQ®MU
XFSEFO/FVF%SVDLGM®TTJHLFJUNVTTWPSEFN&JOG®MMFOJNNFSFOUTQSFDIFOEEFS
HFGPSEFSUFO3FJOIFJUTLMBTTFHFGJMUFSUXFSEFO EBTJFJN-JFGFS[VTUBOEJOEFS3FHFM
EFSHFGPSEFSUFO3FJOIFJUTLMBTTFOJDIUFOUTQSJDIU-FJUVOHFOVOE4DIMVDIFTJOE
WPSEFN&JOCBV[VTQ®MFO
7FSXFOEFO4JF[VN#FG®MMFOEFT%SVDLGM®TTJHLFJUTCFIMUFSTFJO'JMUFSBHHSFHBU
%BT'JMUFSFMFNFOUNVTTTBVCFSTFJO&OUGFSOFO4JFWPSEFN#FG®MMFOEFT
%SVDLGM®TTJHLFJUTCFIMUFSTLFJOFTGBMMT'JMUFSTJFCFBN&JOG®MMTUVU[FOC[XEFO
'JMUFSFJOTBU[WPO'JMUFSO
%JF'JMUFSGFJOIFJUNVTTNJOEFTUFOTEFSFSGPSEFSMJDIFO3FJOIFJUTLMBTTF
EFT(FTBNUTZTUFNTFOUTQSFDIFO N¨HMJDITUBCFSOPDIGFJOFSTFJO%JF
FJOHFTFU[UF'JMUFSFJOIFJUNVTTEJF"OGPSEFSVOHFOBO'VOLUJPOTTJDIFSIFJUVOE
4UBOE[FJUFSG®MMFO

%FONBYJNBM[VMTTJHFO7FSTDINVU[VOHTHSBEEFS%SVDLGM®TTJHLFJUFSGBISFO
4JFJNÅ5FDIOJTDIFO%BUFOCMBUUÃJN,BQJUFMÅ5FDIOJTDIF%BUFOÃ

#FG®MMFO4JFEFO%SVDLGM®TTJHLFJUTCFIMUFSXFOON¨HMJDI®CFSFJOF
#FG®MMLVQQMVOH N¨HMJDITUBN3®DLMBVGGJMUFS

008 911 53 BOMAG 855

18.5 Control valve block

856 BOMAG 008 911 53

3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF
Control valve block 18.5
#PTDI3FYSPUI"(

%FNPOUBHFVOE"VTUBVTDI

8"3/6/(
7FSMFU[VOHTHFGBISEVSDI%FNPOUBHFVOUFS%SVDL
8FOO4JFEFO%SVDLWPS%FNPOUBHFCFHJOOOJDIUBCTDIBMUFO L¨OOFO4JFTJDI
WFSMFU[FOVOEEFO4UFVFSCMPDL[FSTU¨SFOPEFS"OMBHFOUFJMFCFTDIEJHFO
4DIBMUFO4JFJNNFSEFOSFMFWBOUFO"OMBHFOUFJMESVDLMPT CFWPS4JFEBT
1SPEVLUNPOUJFSFOC[X4UFDLFSBOTDIMJFFOPEFS[JFIFO
4JDIFSO4JFEFO"OMBHFOUFJMHFHFOVOCFBCTJDIUJHUFT8JFEFSFJOTDIBMUFO

7FSMFU[VOHTHFGBISEVSDI%FNPOUBHFVOUFS4QBOOVOH
8FOO4JFEJF4QBOOVOHTWFSTPSHVOHWPS%FNPOUBHFCFHJOOOJDIUBCTDIBMUFO
L¨OOFO4JFTJDIWFSMFU[FOVOEEFO4UFVFSCMPDL[FSTU¨SFOPEFS"OMBHFOUFJMF
CFTDIEJHFO
4DIBMUFO4JFEFOSFMFWBOUFO"OMBHFOUFJMTQBOOVOHTGSFJ CFWPS4JFEBT
1SPEVLUNPOUJFSFO

/PUXFOEJHFT8FSL[FVH
È 8FSL[FVHQBTTFOE[VEFOBVGEFSÅ&JOCBV[FJDIOVOHÃBOHFHFCFOFO
#FGFTUJHVOHFO
È 3FJOJHVOHTNJUUFM"C[JFITUFJOPEFSMTUFJO
È 1FSNBOFOUNBSLFS[VS,FOO[FJDIOVOHEFS4UFVFSCMPDLTDIFJCFO
È 4BVCFSF"VGGBOHXBOOF[VN4BNNFMOWPOBVTMBVGFOEFS%SVDLGM®TTJHLFJU

%FNPOUBHFWPSCFSFJUFO
/FINFO4JFEJF(FTBNUBOMBHFTPBVFS#FUSJFC XJFFTJOEFS(FTBNUBOMFJUVOH
EFS.BTDIJOFCFTDISJFCFOJTU#FSFJUFO4JFBOTDIMJFFOEEJF%FNPOUBHFEFT
4UFVFSCMPDLFTXJFGPMHUWPS

%FNPOUBHFEFT4UFVFSCMPDLFTBVTEFS.BTDIJOF
"OUSJFCTNPUPSBVTTDIBMUFOVOEBMMF7FOUJMFEFT4UFVFSCMPDLFT[VS
%SVDLFOUMBTUVOHCJTJOEJF&OETUFMMVOHFOEVSDITDIBMUFO
"VGGBOHXBOOF[VN4BNNFMOWPOBVTMBVGFOEFS%SVDLGM®TTJHLFJUVOUFSEFO
4UFVFSCMPDLTUFMMFO
"MMF-BTUFOBCTFOLFO
*N4UFVFSCMPDLCFGJOEFUTJDIOPDI%SVDLGM®TTJHLFJUÝ

4UFVFSCMPDLFOUTQSFDIFOEEFS"OHBCFOEFT.BTDIJOFOIFSTUFMMFSTBVTEFS
.BTDIJOFBVTCBVFO
"VTHFCBVUFO4UFVFSCMPDLBVGFJOFTBVCFSF TUBCJMFVOETJDIFSF6OUFSMBHF
TUFMMFO
0GGFOF#PISVOHFOVOE"OTDIM®TTFEFS#MPDLFMFNFOUFWPS4DINVU[FJOUSBH
TDI®U[FO CFJTQJFMTXFJTFEVSDI7FSTDIMJFFONJU,VOTUTUPGGTUPQGFO

008 911 53 BOMAG 857

18.5#PTDI3FYSPUI"(
#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
Control valve block
%FNPOUBHFVOE"VTUBVTDI

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)PDIESVDLSFJOJHFSSFJOJHFO

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3FJOJHVOHTNJUUFMCFOVU[FO EJF,VOTUTUPGGFBOHSFJGFOPEFSEFSFO
&JHFOTDIBGUFOWFSOEFSOLÖOFO .FUBMMFBOHSFJGFOPEFSNJUJIOFOSFBHJFSFO
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,PNQPOFOUFOEFT4UFVFSCMPDLFTUBVTDIFO
6NEFO4UFVFSCMPDL[VEFNPOUJFSFOHFIFO4JFXJFGPMHUWPS
#MPDLFMFNFOUFNJU1FSNBOFOUNBSLFS CFHJOOFOECFJN.POPCMPDLPEFS
&JOHBOHTFMFNFOU EVSDIOVNNFSJFSFO
4UFVFSCMPDLJOTBVCFSF"VGGBOHXBOOFTUFMMFOVN3FTUFIFSBVTMBVGFOEFS
%SVDLGM®TTJHLFJUBVG[VGBOHFO

"CC4UFVFSCMPDLFMFNFOUFEFNPOUJFSFO

'PMHFOEF&MFNFOUFE®SGFO
BVTHFUBVTDIUXFSEFO
%JDIUVOHFO[XJTDIFO
#FUUJHVOHVOE(FIVTF
%JDIUVOHFO[XJTDIFO
.POPCMPDLVOE
4UFVFSCMPDLTDIFJCFO
PQUJPOBM

%SVDLWFOUJMF

'BMMTWPSIBOEFO .VUUFSOBO;VHBOLFSOC[X;ZMJOEFSTDISBVCFOM¨TFOVOE

4DIFJCFOEFNPOUJFSFO

;XJTDIFOEFOFJO[FMOFO#MPDLTFHNFOUFOL¨OOFO"EITJPOTLSGUFXJSLFO

"MMF%JDIUFMFNFOUFFOUGFSOFO
"MMF'MBOTDIGMDIFOWPO"OTDIMVTTQMBUUF &OEQMBUUFVOE4UFVFSCMPDLTDIFJCFO
WPO7FSVOSFJOJHVOHFO 4DINVU[ 'BSCSFTUFOVOE3PTUCFGSFJFO
#FJN4VCFSOEFS'MBOTDIGMDIFO4DINVU[FJOUSBHJOEJF#PISVOHFO
WFSNFJEFO

858 BOMAG 008 911 53

3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF
Control valve block 18.5
#PTDI3FYSPUI"(

%FNPOUBHFVOE"VTUBVTDI

%JDIUGMDIFOG®S03JOHFBOEFS'MBOTDIGMDIFVOEBN'SFJTUJDIEFS
'MBOTDIGMDIFQS®GFOPCTJFVOCFTDIEJHUTJOE#FJ#FTDIEJHVOHFONVTT
EBTKFXFJMJHF#MPDLFMFNFOUEVSDIFJOOFVFTFSTFU[UXFSEFOÝ
03JOHFFOUTQSFDIFOEEFSÅ&STBU[UFJMMJTUFÃJOTUBMMJFSFO
.POUBHFEFSFJO[FMOFO#MPDLFMFNFOUFHFNEFS[VWPSBOHFCSBDIUFO
/VNNFSJFSVOH
;JFIFO4JFEJF.VUUFSOEFS;VHBOLFSEJF;ZMJOEFSDISBVCFOJN6IS[FJHFSTJOO
GFTU"O[JFINPNFOUFFOUTQSFDIFOEÅ&STBU[UFJMMJTUFÃ
4PMMEFS4UFVFSCMPDL[VS*OTUBOETFU[VOHBOEFO)FSTUFMMFS[VS®DLHFTDIJDLU
XFSEFO 4UFVFSCMPDLBOTDIMVTTGMDIFONJUEFONJUHFMJFGFSUFO4DIVU[QMBUUFO
WFSTDIMJFFOPEFSEVSDIHMFJDIXFSUJHF7FSQBDLVOHTDI®U[FO VN
7FSTDINVU[VOHFOVOE#FTDIEJHVOHFO[VWFSNFJEFO

008 911 53 BOMAG 859

18.5#PTDI3FYSPUI"(
#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
Control valve block
&OUTPSHVOH

&OUTPSHVOH

6NXFMUTDIVU[
"DIUMPTFT&OUTPSHFOEFT4UFVFSCMPDLFTVOEEFS%SVDLGM®TTJHLFJULBOO[V
6NXFMUWFSTDINVU[VOHFOG®ISFO
4UFVFSCMPDLSFTUFOUMFFSFOVOEBMT.FUBMMTDISPUUFOUTPSHFO
3FTUFOUMFFSFOCFEFVUFU EBTTEFS4UFVFSCMPDLTPXFJUPSEOVOHTHFNFOUMFFSU
XJSE EBTTLFJOF%SVDLGM®TTJHLFJUNFISIFSBVTUSPQGFOLBOO

#FJN3FTUFOUMFFSFONVTTEFS4UFVFSCMPDLOJDIUHFSFJOJHUXFSEFO

&OUTPSHFO4JFEFO4UFVFSCMPDLVOEEJF%SVDLGM®TTJHLFJUEBIFSOBDIEFO
OBUJPOBMFO#FTUJNNVOHFO*ISFT-BOEFT
&OUTPSHFO4JF%SVDLGM®TTJHLFJUTSFTUFFOUTQSFDIFOEEFOKFXFJMTH®MUJHFO
4JDIFSIFJUTEBUFOCMUUFSOG®SEJFTF%SVDLGM®TTJHLFJUFO
&MFLUSPOJTDIF1SPEVLUFPSEOVOHTHFNFOUTQSFDIFOEEFOHFMUFOEFO
#FTUJNNVOHFOFOUTPSHFO

3FDZDMJOH
%VSDIEFOIPIFO.FUBMMBOUFJML¨OOFOEJF1SPEVLUF®CFSXJFHFOETUPGGMJDI
XJFEFSWFSXFSUFUXFSEFO6NFJOFPQUJNBMF.FUBMMS®DLHFXJOOVOH[VFSSFJDIFO
JTUFJOF%FNPOUBHFJOFJO[FMOF#BVHSVQQFOFSGPSEFSMJDI%JF.FUBMMF EJFJOEFO
FMFLUSJTDIFOVOEFMFLUSPOJTDIFO#BVHSVQQFOFOUIBMUFOTJOE L¨OOFONJUUFMT
TQF[JFMMFS5SFOOWFSGBISFOFCFOGBMMT[VS®DLHFXPOOFOXFSEFO4PGFSOEJF
1SPEVLUF#BUUFSJFOPEFS"LLVNVMBUPSFOFOUIBMUFO TJOEEJFTFWPSEFN3FDZDMJOH
[VFOUGFSOFOVOEN¨HMJDITUEFN#BUUFSJF3FDZDMJOH[V[VG®ISFO

860 BOMAG 008 911 53

3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF
Control valve block #PTDI3FYSPUI"(
18.5
&SXFJUFSVOHVOE6NCBV

&SXFJUFSVOHVOE6NCBV
%FO4UFVFSCMPDLE®SGFO4JFOJDIUVNCBVFO

/BDIVOE6NS®TUVOH
'®SCFTUJNNUF"OXFOEVOHFOLBOOFJOF/BDIC[X6NS®TUVOHEFT
4UFVFSCMPDLFTFSGPSEFSMJDIXFSEFO
4UJNNFO4JFEJF7PSHFIFOTXFJTFNJU#PTDI3FYSPUIBC

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008 911 53 BOMAG 861

18.5#PTDI3FYSPUI"(
#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
Control valve block
'FIMFSTVDIFVOE'FIMFSCFIFCVOH

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¾ 8JF[FJHUTJDIEJF4U¨SVOH

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7FSTDIMVTTTDISBVCFVOEJDIU

862 BOMAG 008 911 53

3%#]#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF
Control valve block #PTDI3FYSPUI"(
18.5
'FIMFSTVDIFVOE'FIMFSCFIFCVOH

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OJDIUPEFSWFS[¨HFSUBVG
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'®S.JOEFTU
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4UFVFS¨MWFSTPSHVOHLMFNNU 4UFVFS¨MWFSTPSHVOHBVTCBVFOVOEEVSDIOFVFFSTFU[FO
7PSTUFVFSWFOUJMFTJOEWFSTDINVU[U 7PSTUFVFSWFOUJMFSOFVFSO
"VTG®ISVOH 6OUFSWFSTPSHVOH 1VNQFOESVDL[VHFSJOH
'®S.JOEFTU1VNQFOESVDLTPSHFO TJFIFÅ5FDIOJTDIFT
IZESBVMJTDIF#FUUJHVOH %BUFOCMBUUÃ
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#FJ7FOUJMFOJN MTUSPNGMJFU[VN7FSCSBVDIFSNJU.JOJNBMESVDL 1VNQFO¨MTUSPNEVSDIIÏFSF%SFI[BIMPEFSHS¨FSF
1BSBMMFMCFUSJFC,FJO XFHFO6OUFSWFSTPSHVOH 1VNQFFSIÏFO C[X7FSCSBVDIFSNFOHFEVSDI
%SVDLC[XLFJOMTUSPN .FOHFOESPTTFMSFEV[JFSFO
BN7FSCSBVDIFS
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008 911 53 BOMAG 863

18.5#PTDI3FYSPUI"(
#FUSJFCTBOMFJUVOH4UFVFSCM¨DLF]3%#
Control valve block
'FIMFSTVDIFVOE'FIMFSCFIFCVOH

4U¨SVOH .¨HMJDIF6STBDIF "CIJMGF

/FVUSBMVNMBVGESVDL[V ,FJOF-PBE4FOTJOH&OUMBTUVOH HJMUOVSG®S.
IPDI . . 41 49

4UFVFSTDIJFCFSOJDIUJO/FVUSBMTUFMMVOH #FJ;VOHF7PSTUFINBQS®GFO TJFIFÅ5FDIOJTDIFT

%BUFOCMBUUÃ
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®CFSQS®GFO

3®DLMBVGESVDL[VIPDI 3®DLMBVGWPOHFNFJOTBNFS3®DLMBVGMFJUVOH
USFOOFO TFQBSBUF3®DLMBVGMFJUVOHWFSXFOEFOPEFS
-FJUVOHTRVFSTDIOJUUWFSHS¨FSO
&JOHBOHTESVDLXBBHFLMFNNU &JOHBOHTFMFNFOUFSOFVFSO
#FXFHVOHBN 4UFVFSTDIJFCFSTUFIUOJDIUJO/FVUSBMTUFMMVOH %SVDLJOEFO4UFVFSEFDLFMO[VIPDI "OTUFVFSVOH
7FSCSBVDIFSUSPU[ ®CFSQS®GFO

/FVUSBMTUFMMVOH
4FLVOES%#VOEJDIUC[X[VOJFESJHFJOHFTUFMMU &JOTUFMMESVDLBN4FLVOES%#QS®GFO
4UFVFSTDIJFCFSIBU[VHSPF-FDLBHF -FDLBHFXFSUFTJFIFÅ5FDIOJTDIFT%BUFOCMBUUÃ
-FDLBHFGSFJFT4FOLCSFNTWFOUJMFJOCBVFO
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HFHFO®CFSEFS3BTULSBGU 'FEFS
[VHSP
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3BTUFJOIFJUFSOFVFSO

#FJ4U¨SVOHFOEVSDI7FSTDINVU[VOHJTU[VTU[MJDI[VS*OTUBOETFU[VOHVOCFEJOHU
EJFMRVBMJUU[V®CFSQS®GFOVOEHFHFCFOFOGBMMTEVSDIHFFJHOFUF.BOBINFO
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'BMMT4JFEFOBVGHFUSFUFOFO'FIMFSOJDIUCFIFCFOLPOOUFO XFOEFO4JFTJDICJUUF
BOFJOFEFS,POUBLUBESFTTFO EJF4JFJN*OUFSOFUVOUFSwww.boschrexroth.com
PEFSJNÅ"OTDISJGUFOWFS[FJDIOJTÃBVG4FJUF

864 BOMAG 008 911 53

Control valve block 18.5

#PTDI3FYSPUI"(
)ZESBVMJDT
;VN&JTFOHJFFS
-PISB.BJO
(FSNBOZ
5FM
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JOGPCSNND!CPTDISFYSPUIEF
XXXCPTDISFYSPUIDPNCSN

{OEFSVOHFOWPSCFIBMUFO
1SJOUFEJO(FSNBOZ
3%#

008 911 53 BOMAG 865

18.5 Control valve block

866 BOMAG 008 911 53

19 Circuit diagrams

008 911 53 BOMAG 867

868 BOMAG 008 911 53
19.1 Hydraulic diagram 571 908 15

008 911 53 BOMAG 869

19.1 Hydraulic diagram 571 908 15

870 BOMAG 008 911 53

Hydraulic diagram 571 908 15 19.1

008 911 53 BOMAG 871

19.1 Hydraulic diagram 571 908 15

872 BOMAG 008 911 53

19.2 Wiring diagram 570 700 35

008 911 53 BOMAG 873

19.2 Wiring diagram 570 700 35

S/N Wiring diagram 570 700 35

S/N 101 570 571 001 ⇔ 101 570 571 006 BC 772 RS-2
S/N 101 570 581 001 ⇔ 101 570 581 020 BC 772 RB-2
S/N 101 570 591 001 ⇔ 101 570 591 006 BC 672 RB-2
S/N 101 570 821 001 ⇔ 101 570 821 004 BC 972 RB-2
S/N 101 570 831 001 ⇔ 101 570 831 014 BC 1172 RB-2
S/N 101 570 921 001 ⇔ 101 570 921 001 BC 772 EB-2
S/N 101 570 931 001 ⇔ 101 570 931 001 BC 672 EB-2

874 BOMAG 008 911 53

Inhaltsverzeichnis: BC 772...1172 RB / TIER III

008 911 53
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing no.
001 vorläufig Stromlaufplan Circuit Diagram
002 vorläufig Versorgung, Zigarettenanzünder supply, cigarette lighter
003 vorläufig Zündschloß, Starter ignition switch, starter
004 vorläufig DEUTZ Steuergerät EDC 7 f. 6 und 8Zylindermot. DEUTZ controller EDC 7 for 6 and 8zylinder engine
005 vorläufig Instrumente indicators
Wiring diagram 570 700 35

006 vorläufig Anzeigen, Störmeldungen monitoring, failure indication

007 vorläufig Fahrpumpen, Radmotoren, Startfreigabe driving pumps, weehl motors, starting release
008 vorläufig Fahrstufen, Bremse, Verzögerungspedal speed ranges, brakes, decelerator device
009 vorläufig Versorgung Steuerung, Warnsummer, Override supply controllers, warning buzzers, override
010 vorläufig Lenkung und Arbeitshydraulik steering and working hydraulic system
011 vorläufig Hupe, Schmieranlage, Tachograph, Sitzfunktionen horn, lubrication systhem, tachograph, seat funktions
012 vorläufig Heizung und Belüftung heating and ventilation
013 vorläufig Schutzbelüftung, Zyklon Abscheider, Klimatronik protected vent. system, cyclone separator, air cond.
014 vorläufig Kabine und Anbauteile cabin and attachmentparts
101 vorläufig Bauteilliste component listing
201 vorläufig Schaltkasten ebox

BOMAG
301 vorläufig Lokalisierungsgrafik Steckverbinder Draufsicht localization graphic connectors top view

03.04.2006
001 001
Werner Stromlaufplan 570 700 35
03.04.2006
19.2

875
circuit diagram 001
Seis
876
Zuleitung Steuerung Pin 54 30/54S 9:2
Zuleitung Steuerung Pin 5660 30/5660S
9:2

2,5qmm
Kabine K30
14:2
19.2

4qmm
geschaltetes "15/54"

2x6qmm
Batteriespannung 30 3:1

6qmm
15/54 X1:6
Zündschloß "15/54" 3:1

6qmm
6qmm
X1:23E X1:391/1 X1:21E X1:25E
Einspeisepunkt für Versorgung
Sicherungespotential 30! 30 30
1 K61 6E 5E
F89 F05 K11
V01 2:8 30A 30A
2 6A 5A 3:14
87
87 87a
X1:391/2 X1:21A
X1:25A
1,5qmm
2x4qmm

Einspeisepunkte für Versorgung

2,5qmm
4qmm
2x6qmm
6qmm
6qmm
Sicherungespotential K11:87!
X1:241 X1:242
X1:31E
X1:33E

0,11A
0,075A
X1:241
11:7
1 86 K61:87a 5:9 F24 K11:87 5:1
5:1
R10
1 220_O
K61 X1:298
F00 250A

057 665 63
2 2,5qmm X1:32E
2 85 X1:243
1x25qmm F122
10A
Anlassehauptleitung: 2x70qmm B+ 3:1 D+ 6:2
Ladeleitung 2x 10qmm oder 1x25qmm X1:32A
X1:81 1
X1:259

BOMAG
+ E21
X1:202
9:13
8:10

G01 2
11 21 31 41 51 61
S01
Batterie X14:6

0,075A
5A
Bei Steckdosenbetrieb je nach Stecker bis 16A möglich!
battery
max. 10A

12 22 32 42 52 62
B+ D+
+ 86 E20 1 2 X1:260 NotAus Schalter
28V/80A + emergancy shut off
G03 G02 K62 XS
24V 30

85 K22 9:6
B W
87a 87
X2:N X2:J EMR
S30 3 X14:7 4:15
W XS
Trennschalter 5:11 4:18
switch battery disconnect
4
X1:70 X1:256
31 31 3:1

2:10 13:10
Zigarettenanzünder Steckdose
cigarette lighter socket

03.04.2006
1 1

008 911 53
Wiring diagram 570 700 35

Werner Versorgung, Zigarettenanzünder 570 700 35

03.04.2006
Seis supply, cigarette lighter 002
2:15 30 30 4:1
2:11 15/54
6qmm
2:6 B+ B+ 4:1 X1:23E
Anlasserhauptleitung 2x70qmm F13
30A

008 911 53
X1:23A

6qmm

Zündstartschalter
012 30 ignition switch
S00
01

50a 15/54

4qmm
1,5qmm

X1:293
Wiring diagram 570 700 35

X1:302

X1:8 X1:9

30
K05
7:2
87 87a

X1:7

BOMAG
2,5qmm
X14:9 X1:371
0,2A

0,2A

86 86
30 50 2 K11 K32
M01
M V47
85 85
1

X1:256 X1:70

2:20 31 31 4:1

2:17 14:6

Starter
starter
Anzugswicklung KHD = 73A
Haltewicklung KHD = 12A

03.04.2006
1 1 570 700 35
Werner Zündschloß, Starter
03.04.2006
19.2

877
Seis ignition switch, starter 003
878
30 30
3:20 13:1
B+ Pedal
3:5 X1:24E 6:7
XS
B124 2:19
19.2

1 + 1 elektronisches Fußpdal Diagnosestecker

F48 F93 elektronic foot pedal diagnosis
86 86 86 X22
80A 25A K15 K146 K60
2 F78
2 S119 H04 1 H70 1
13
X1:24A S118

X4:A
X4:H
X4:G
X4:M
X4:F
X4:K
X4:B
2 2 Fehlertaster Motor
85 85 85
4qmm B46

4qmm
4qmm
14 failure push button engine

Williams Codierung
sw rt ws or gn bl

X1:92
X1:93
X1:94
X1:62
X1:64
X1:65
X1:71
X1:255

X10:B
X10:C
X10:A
X12:A
X12:C
X12:B
X6:1 X1:250
X6:2 X1:244
X6:3 X1:270
X6:4 X1:269
2 3 1 EMR
RPM 2:19
9:2
Option
option

X6:5
X6:6
X6:7
X6:8
X6:9
X6:10

X1:231
X1:232
X1:233
5V EDC 8:2
Handgas
8:2
4x2,5qmm AGND EDC "31" 4x2,5qmm
8:2

Sensor Wasserabscheider
sender water separator
"30"
Fehler EMR
Vers. Meldeleuchte
Glühen
Temperatur
Motoröldruck
"15"
CAN 1H
CAN 1L
CAN 2H
CAN 2L
ISO KLinie

S2 S1

Fehler Motor
failure engine
Wasserabsch.
water separator

X1:235
X1:236
X1:237

XD2.1:3
XD2.1:9
XD2.1:6
XD2.1:5

XD2.1:2
XD2.1:8
XD2.1:11

XD2.1:61
XD2.1:13
XD2.1:10

XD2.1:79
XD2.1:77
XD2.1:33
XD2.1:60
XD2.1:59
XD2.1:30
XD2.1:39
XD2.1:53
XD2.1:35

XD2.1:78
XD2.1:38
XD2.1:20
XD2.1:52
XD2.1:89

XD2.1:22
XD2.1:54
XD2.1:40
XD2.1:34

X27.2:11
X27.2:10
A48 EDC7 Steuerung
4qmm

X17.1:1
X17.1:2
X1:5

XD2.2:28
XD2.2:8
XD2.2:3
XD2.2:7
XD2.2:24
XD2.2:27
XD2.2:32
XD2.2:18
XD2.2:35
XD2.2:26
XD2.2:15
XD2.2:9
XD2.2:10
XD2.2:19
XD2.2:23
XD2.2:34
XD2.2:33
XD2.2:36
XD2.2:25
XD2.3:4
XD2.3:13
XD2.3:6
XD2.3:12
XD2.3:7
XD2.3:3
XD2.3:15
XD2.3:14
XD2.3:16
XD2.3:8
XD2.2:4
XD2.2:5
X1:299

BOMAG
50i
K14 K2
4:4

X27.1:25
X27.1:20
X27.1:19
X27.1:27
X27.1:26
X27.1:33
X27.1:12
X27.1:18
X27.1:24
X27.1:30
X27.1:14
X27.1:13
X27.1:15
X27.1:21
X27.1:23
X27.1:22
X27.1:29
X27.1:28
X27.1:34
X27.1:35
X27.1:37
X27.1:36
X27.1:11
X27.1:42
X27.1:40
X27.1:41
X27.1:39
X27.1:4
X27.1:6
X27.1:7

Y02 2
4qmm 4qmm Y149 Y166 Y151 Y167
3 2 1 2 1 2 1 1 2 3 1 2 3 4 3 2 1 + + + + Y2 1
1 1 85 Y147 Y152
R02 R02 K2 K14 Y148 Y150
R3.1 R3.2
2 2 50 + + + +
B88 B126 B113 B114 B130 B133
B6 B37 B43 B40.1 B40.2 B48 Y15.1 Y15.3 Y15.5 Y15.7 Y15.2 Y15.4 Y15.6 Y15.8

3:20 31 31 5:1

4:2 6:2 6:2 6:3 Injektor B3

jet pump B3
Glühkerze 1 Kraftstofftemperatur Motordrehzahlsensor1 Mag.vent. Flammglühanlage
glow plug 1 fuel temperature sender engine rpm 1 Injektor B2 solenoid valve glow plug system
jet pump B2
Glühkerze 2 EMR Motoröldruck Motordrehzahlsensor 2 Injektor A1 Injektor A3 Injektor A4 Injektor B1
glow plug 2 EMR engine oil pressure sender engine rpm 2
jet pump A1 jet pump A3 jet pump A4 jet pump B1
Kühlmitteltempratur Sensor Ladeluftdruck / Temperatur Injektor A2 Injektor B4
coolant temperature sensor charging air pressure / temperature jet pump A2 jet pump B4

03.04.2006
1 1

008 911 53
Wiring diagram 570 700 35

Werner DEUTZ Steuergerät EDC 7 f. 6 und 8Zylindermot. 570 700 35

03.04.2006
Seis 066_5 DEUTZ controller EDC 7 for 6 and 8zylinder engine 004
2:20 K11:87 K11:87 9:1

X1:29E

F24
15A

008 911 53
X1:29A
2:13 F24 F24 6:1
2:11 K61:87a K61:87a 6:7
X1:294 X1:295 X1:298

5 1 4 3 5 1
Wiring diagram 570 700 35

P00 +
E02 P14 + E22 P02 + E03 P03 + E01 P01 + E46 P12 +
1 1 1 1 1
_t _t n Q
2 2 2 2 2
G G G G

Modul 1
module 1
Modul 2
module 2
Modul 3
module 3
3 2 4 1 5 3 4

BOMAG
X1:300 X1:303 X1:301 X1:296
X1:291 X1:148 X1:292 X1:228

X14:8

X5:1

1 2
B53 1 1
R04 R03

2 2
X1:299 W X1:229
2:8
31 31
4:20 6:1

Kühlmitteltemperatur Motordrehzahl Tankanzeige

collant temperature trancducer, motor speed level gauge

Hydrauliköltemperatur Betriebsstundenzähler Voltmeter

hydraulic oil temperature engine hour meter volt meter

03.04.2006
1 1 570 700 35
Werner Instrumente
03.04.2006
19.2

879
Seis indicators 005
880
F24 F24
5:20 9:1
D+ ESX 9:15 Abschmieren
2:9 11:2
Lüfter 1.GANG
12:14 30 30 9:7
19.2

K133 K48 2.GANG 9:7

9:9 7:3
87 87a 87 87a
X1:101 X1:104
X1:89 X1:84 X1:90 X1:91 X1:123

X1:125
X1:126

X1:124

rt
rt
ws/vi
br/rt
br
br/sw
sw
vi

vi
ws/bl
br/or
br
ws/vi
or X1:102 X1:105 or
1 2 0/3a 4 8 A15 A15 16 11 17 18 9

6 3 7 5 20 19 14 15 12 13 10

bl
bl
gr

sw
br/or

ws/rt

ws/gr
ws/br
ws/br
ws/gr

ws/gn
ws/gn

X1:106

X1:115
X1:119

X1:118
X1:121

X1:120
X1:122

X1:87 X1:88 X1:85 X1:86

X1:392/2 V02 2 1 X1:392/1 X1:397/1 1 2 V07 X1:397/2
X0:18 X0:45
Fehler
X1:394/2 V04 2 1 X1:394/1 X1:398/1 1 2 V08 X1:398/2
X1:109 X1:117

X0:52 X0:50 X1:108 X1:116

Fehler
X1:393/2 V03 2 1 X1:393/1 X1:399/1 1 2 V09 X1:399/2

20s
Fehler
X0:19 X0:13
X1:111

X1:395/2 V05 2 1 X1:395/1 X1:400/1 1 2 V10 X1:400/2

Steuerung
Gaspedal
X0:11 X0:10
Pedal X1:401/1 1 2 V11 X1:401/2
X1:112

X1:82 X1:83 4:19 X0:6 Fehler

D+
X1:403/1 1 2 V13 X1:403/2
X1:113

X1:114

X0:36 X0:51

ESX
X14:10 X1:210

BOMAG
5:20 K61:87a K61:87a 14:11
15

20s
20s
2min
K113

Kühlmitteltemperatur
collant temperature
Motoröldruck
engine oil pressure
Kühlmittelfüllstand
coolant tank
Luftfilter rechts
air cleaner rh.
Luftfilter links
air cleaner lh.
120s anzugsverzögert
120s switch on delay
K15 30 K60 30
4:12 4:14
X1:110
87a 87 87a 87 Verteilergetriebe
power takeoff gear
Hydrauliköl min.
hydraulic oil min.
Hydrauliköltemp.
hydraulic oil temp.
Diff.drucksch.
pressure. diff.
Diff.drucksch.
pressure. diff.
Diff.drucksch.
pressure. diff.
Diff.drucksch.
pressure diff.
Diff.drucksch.
pressure diff.
Bremsdruck
brake pressure
Verschmutzungssensor
contamination sensor

X1:103
30 30
3 3 3 3 1 1 3 K113 2 2 2 2 2 1 +
K146 B55 B03 B116 B129 B24 B20 B121 B122 B22 B21 B42 B05
4:13 6:11 B19
Q P P B25 P P Q P
87a 87 4 4 4 4 2 2 4 87 87a 1 1 1 1 1 2

X14:11

X1:181
X1:182
X1:182
X1:191
X1:191

X1:181

X1:183
X1:187
X1:185
X1:186
X1:183

31
X1:184
X1:184

X1:205

5:20 31 7:1
Speisepumpe Speisepumpe Zwischengetr.
6:14
Speisepumpe Speisepumpe

Rücklauffilter nur BC 972 RB

return flow filter only acc. to BC 972 RB

Modul 1: Motorfunktionen Modul 2: Maschinenfunktionen

module 1: engine functions module 2: maschine functions

19.04.2006
1 1

008 911 53
Wiring diagram 570 700 35

Werner Anzeigen, Störmeldungen 570 700 35

19.04.2006
Seis monitoring, failure indication 006
DEC 1 8:4
X1:338 X1:262 S04:12 8:10
X1:335 2 1
X1:46/2 X1:46/1
X9:4 X9:1 FM6

008 911 53
1
R32 X1:42/1
1k
2

1 1
R33 1 R34 R35 1 FM2
2k 1k 3k3 2
2 2 2

Fahrtrichtungsschalter nicht belegt X1:42/2

switch, travel direction V0R 33 13 24 44 not used
S31 X1:336
34 14 23 43
Wiring diagram 570 700 35

X9:5 X9:6 X9:3 X9:2

X1:339

X1:340 X1:337

Richtung
AGND
8,5V
Ain

X1:412/1 X1:413/1

X0:1
13 9

X0:32
X0:23
X0:29

1 1
V23 V25 K77 K77 ESX Steuerung
9:17 9:17
2 2 14 10

X0:22
X0:21
X0:46
X0:47
X0:48
X0:43

X1:412/2 X1:413/2

BOMAG
Vorwärts

Rückwärts
vorne Links
hinten Links

vorne rechts
hinten rechts

br nicht bei
X1:221 X1:223 X1:135 X1:157
V38 BC 672772
not used for
rt BC 672772

X1:149 X1:153 X1:131 X1:133 X1:155

200 ... 600mA
200 ... 600mA
200 ... 600mA
200 ... 600mA

86 86 H14
K05 K48 + 1 1 1 1 1 1 1 1
V34 Y17 V35 Y17 V32 Y16 V33 Y16 Y132 Y133 Y134 Y135

85 85 2 2 2 2 2 2 2 2

1,08A
1,08A
1,08A
1,08A

X1:70 X1:70 X1:188

X1:222 X1:224 X1:136 X1:158
31 X1:154 X1:132 X1:134 X1:156
6:20 31 8:1
TandemPumpe TandemPumpe TandemPumpe TandemPumpe
3:9 6:14 rechts 2 rechts 4 links 1 links 3 Prop. Ventil Rad vorne li. Prop. Ventil Rad hinten re.
prop. valve weehl front lh. prop. valve weehl rear rh.
stromlos = qmax stromlos = qmax
Prop. Ventil Rad vorne re.
Ventile Fahrpumpe rückwärts Ventile Fahrpumpe vorwärts prop. valve weehl front rh.
solenoid valves, travel direction backw. solenoid valves, travel direction forw.
stromlos = qmax
Warnsummer Rückwärtsfahrt stromlos = Rückwärtsfahrt nicht aktiv stromlos = Vorwärtsfahrt nicht aktiv
buzzer, back up alarm strom = Rückwärtsfahrt aktiv strom = Vorwärtsfahrt aktiv
Prop. Ventil Rad hinten li.
prop. valve weehl rear lh.
stromlos = qmax

03.04.2006
1 1 570 700 35
Werner Fahrpumpen, Radmotoren, Startfreigabe
03.04.2006
19.2

881
Seis driving pumps, weehl motors, starting release 1 007
882
F25 9:1

X1:343 X1:261
19.2

31 X1:358
S01
2:17
Aktivierung Verzögerungspedal X1:357
32
enable decelerator pedal 7:19 S04:12 X1:41/2
X1:262 23
S02
12 123
S160 0 1 43 23 Bremsschalter 1 S02 Schalter Fahrstufen
S04 brake switch FM1 switch speed ranges
01
2 24
11 Komplett 872 701 02
44 24
X1:41/1
Verzögerungspedal

X40:6
X40:2
X13:3
5V EDC DEC 1
X13:1
X13:2

4:8 7:19 decelerator pedal R20 R21 R22 R23

1 k_O 1 k_O 1 k_O 1 k_O
Nur für BC 671771 RB/RS
only acc. to BC 671771 RB/RS

bl gr
KD1 KD2
S161

ws
sw
rt
ge
gn
vi
or
bei Option
Schalter Fahrstufen
switch speed ranges

X3:B
acc.to option
X40:3

decelerator pedal

Verbindung entfällt
connection not applied

X40:1
Fahrtverzögerungspedal
X1:359
X1:263

X42:5
X42:6
X41:11
X41:6
X41:4 X39:B
X41:3 X39:C
X41:5 X39:A
X41:1 X40:4
X41:2 X40:5
S04:11
8:11
Zusatzelektronik
A78

Bremse
high=Bremse auf
8,5V
AGND
Fahrstufen
additional electronic

X41:9

X42:1
X41:8

X42:2
X42:4
X41:10

X41:12
X0:1
X0:7

BOMAG
X0:23

X0:40
ESX Steuerung
X36:1
X0:62

X0:61
1

X3:C
R43

X3:A
499 _O
2
Handgas 5 k_O K77
4:8 8 7 S04:11

Bremse
AGND EDC X36:2 S120
4:8 9:17 8:10 X1:170
1./2. Fahrstufe

1 X1:151
R44

1,25A
1,25A

499 _O
1 2 Y04 1 Y03 1
H81 X36:3 V31 V37
2 2 2

X1:234
Nur für BC 671771 RB/RS
only acc. to BC 671771 RB/RS

31 X1:152 X1:192
7:20 31 9:1

Meldeleuchte Verzögerungsfunktion Magnetventil Bremse Stufenumschaltung

indicator light decelerator device solenoid valve brake Speed range selection
stromlos = Brmse zu
Handgas
strom = Bremse auf
hand throttle
Nur für Option Verzögerungspedal
only acc. to option decelerator device

03.04.2006
1 1

008 911 53
Wiring diagram 570 700 35

Werner Fahrstufen, Bremse, Verzögerungspedal 570 700 35

03.04.2006
Seis speed ranges, brakes, decelerator device 1 008
K11:87 K11:87 11:1
5:20

X1:35E

F25
10A

008 911 53
X1:35A
F25 F25 10:1
8:20
2:19 30/54S 2,5qmm 6:6 ESX

2:19 30/5660S 4qmm

X1:26E
F24
6:20 X1:27E
RPM F84
4:8
10A

F67
30A X1:26A
30
K90
X1:27A
X1:257 9:4

2,5qmm
Elektronik
87 87a
Wiring diagram 570 700 35

X1:66
X2:H
X1:67
X2:G
S01

X2:U

5x0,75qmm
Leistung
2:17
22
X1:349
X1:349
X1:349

X1:258 X1:404/2 X1:405/2

X1:207
+UE/Dios
+UB/Dios
+UB/Dios

Drehzahl
CAN2
CAN2+
RxD
TxD
+ + + + + +

1x0,75qmm
2 2
V14 V15
1 1

X0:5
X0/1:3
X0/1:9

X0:4

X0:16
X0/1:10

X0:56
X0:57
X0:59
X0:60
X0:33
X0:53

X0:58

X0:28
X0:54
ESX Steuerung X1:404/1 X1:405/1 ESX Dios Modul

X0:2
X0:24
X0:25
X0:3
X0:44
1. Gang 2. Gang Summer
X0/1:11
X0/1:4

BOMAG
6:19 1.GANG
2.GANG
6:19
GND/Dios

X1:402/1 X1:410/1 X1:411/1 1

Relais Override
Motorabstellung
V42
Gehäuse Dios Modul

1 1 1 2
V12 V21 V22
2 2 2 KLIMA
GND für Knotenaddresse Dios

X1:402/2 X1:410/2 X1:411/2

X35:1
K90 86 K22 86 86 + K77/1 86 K77 86
H07
0,7A

K133
X1:185
X1:186

X1:184

85 85 85 X35:2 85 85

0,075
0,075
0,075
0,021A
0,021A

31 X1:70 X1:70 X1:70 X1:70 X1:70 X1:70

8:20 31 10:1

9:17 2:17 6:10

10:4 8:11
10:4 7:6
Lampentest Warnsummer
warning buzzer 10:4 7:5

10:4

03.04.2006
1 1 570 700 35
Werner Versorgung Steuerung, Warnsummer, Override
03.04.2006
19.2

883
Seis supply controllers, warning buzzers, override 1 009
884
F25 X15:A
9:20
X1:349
1=Links /2=Rechts Schild/Schaufel 1=senken / 2=heben 3=schließen / 4=öffnen
1=left /2=right blade/shovel 1=let down / 2=lift 3=close / 4=open
1
19.2

BR/BN
1 1 3 Achse 3/4 mit Kontakten
S71 1 S70 4 1 3 1015 nur bei Schaufel
axle 3/4 with contacts B08
1 2 2 Vorrüstung Lenkrad 3 2 4
2 preassembling steering 2 4 1015 only acc. to shovel X15:B
JoyStick
weehl 2
sieht Metall wenn Lehne unten

joystick X1:363
Initiator Armlehne

3 2 5 4 7 6 1 3 2 5 4 6 7 1 14 13 12 15 11 10 16 8 9
SW/BK
BL/BU

X2:A X2:B

X2:V

X1:346
X1:345
X1:344
X1:347
X1:348
X1:343
X1:321
X1:325
X1:326
X1:324
X1:323
X1:322
X1:330
X1:329
X1:328
X1:331
X1:332
X1:327
X1:352
X1:351
X1:350
X1:353
X1:354
X1:334
X1:333
CAN Bus LED display
CAN bus LED display X1:63

X1:44/2 X1:45/2 X1:47/2 + P18 X1:61

2 X1:43/2 2 2
FM4 2 FM5 FM7 X1:68
1 FM3 1 1
1 057 664 08

X1:44/1 X1:43/1 X1:45/1 X1:47/1 X1:69

X15:C
AGND F1 F2
8,5V

lenken
CAN+
CAN

links
rechts
lenken
AGND
8,5V
heben/
senken
senken
heben
auf/zu
schließen
öffnen
Schwim.
Lehne

links
rechts
X0:1
X0/1:1

X0:9

X0:8
X0/1:2

X0:15
X0:31
X0:17
X0:12

X0:14
X0:41

X0:39
X0:30
X0:35
X0:37

X0:38
X0:23
X0:27
X0:26

ESX Steuerung X0:34 ESX Dios Modul

BOMAG
X0:64
X0:49
X0:20
X0:42
X0:63
X0:65
X0:66
X0:67
X0:68
X0:55
X0/1:5
X0/1:6

9:15

20 19 2 R36 1 Gehäuse
housing

heben
K77/1 47_O 390 mA

senken

lenken li

lenken re.

X1:406/2
Schwimmst.
9:15
öffnen/Dios

0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA

14 13 2 R38 1
schließen/Dios

K77/1 47_O 390 mA

X1:407/2
9:15 R40
10 9 2 1
K77/1 47_O 390 mA
X1:141 X1:143 X1:364

X1:408/2
9:15 R42 X1:137 X1:139
8 7 2 1 X1:159 X1:161 X1:163 X1:165

X1:409/2
K77/1 47_O 390 mA Y92 1 Y93 1 Y108 1 Y109 1 Y102 1 Y102 1 Y111 1 Y110 1
2 2 2 2 1,08A
1,08A

2 2
2 2 2 2 2 2

V19
V16
V17

V18
X1:189
X1:181
X1:182
X1:183
X1:187
X1:188

1 1 1 1
X1:160 X1:162 X1:164 X1:166 X1:138 X1:140 X1:142 X1:144
31
9:20 31 11:1

Lenken rechts Schild senken

steering right let down blade

X1:409/1
X1:406/1
X1:407/1

X1:408/1
Lenken links Schwimmstellung Schaufel schließen
floating position close shovel
steering left
Schwimmstellung Schaufel öffnen
Schild heben
lift blade floating position open shovel

03.04.2006
1 1

008 911 53
Wiring diagram 570 700 35

Werner Lenkung und Arbeitshydraulik 570 700 35

03.04.2006
Seis steering and working hydraulic system 010
9:20 K11:87 K11:87 13:1
Abschmieren
6:19
X1:30E X1:34E X1:31E

F16 F23 F29

008 911 53
10A 15A 15A

X1:172
X1:30A X1:34A X1:31A

X1:171 Zusatzanzeige Geschwindigkeit

additional speedometer X1:341 X1:245

3A
X31:A
X34:4 1 2 86 30 S25 23
4 (+) K13
LA 15 K13
E04 1 E04 1 11:14
M08
P09 85 87 87a 24
M 8 (S) 2 2
Wiring diagram 570 700 35

Zentralschmieranlage
central lubrication system 3 () X1:246
Z 31 X31:B X31:C X1:355

X34:3 5

X33:1
X33:2
X11:1 X21:1
7,5A

+ sw
M10 R06
X30:A M
B7 A2 ge

X1:173
X1:174
K13:87
2,5A

14:19
X1:248 X28:1 Versorgung über F89
X1:356 Signalhörner Kabine
X1:241 A1 A3
br sw
2:13
23 1

BOMAG
S27 B15 3
8 S29 23
X28:3 B3 A5 S03 2 ge
Taster Schmieranlage X30:C R06
4 P09 V46
switch, lubrication system 24 X28:4
B52 bl 2 ws
4 6 1 9 1 24 br
B4 A6
X1:272 X28:2
A16

Initiator Schmierkolben
proximity switch lubrication piston
Lieferumfang GRAMMER
delivery equipment GRAMMER

X30:B 7 8 9 2 X11:2 X21:2

Im Lenkjoystick
in steering joystick

X1:190 X1:191 X1:364 X1:256

X1:342
10:20 31 31 13:1

11:16

Sensor Radmotor HL Tachograph Sitz mit Kompressor und Schalter

sensor wheelmotor rear lh. tachograph Im Lenkjoystick drivers seat with compressor and switch
in steering joystick
Tachomodul Sitzheizung
tacho controller Taster Signalhorn heating, drivers seat
Option Tachograph push buttonwarning horn
option tachograph

03.04.2006
1 1 570 700 35
Werner Hupe, Schmieranlage, Tachograph, Sitzfunktionen
03.04.2006
19.2

885
Seis horn, lubrication systhem, tachograph, seat funktions 011
886
K32:30 K32:87
14:2 14:3
F41:4
14:8
19.2

F40 G F90 F F02 F

Box 2 Box 2 Box 1
10A
7 5A
6 10A
6

X1:374
X1:265
2,5 qmm

123 13 31 42 24
1 2 3 12 11 13 14 16
Stufenschalter Frischluft
switch, fresh air
S44
5 7 11 3 1 10 14 32 41 23

Regel aus = 0,2A S28 X1:266 X1:267 X1:268

E30 Kleine Stufe = 0,3A
mittleter Stufe = 0,5A
große Stufe = 1A 1 1
Power Stufe = 1,7A R26 R27
Heizung Anlaufstrom beim Start = 4,2A
22 Ohm
10 Ohm

Heating
Schaltuhr Heizung 2 6 8 9 4 12 2 2
heater timer Lüfter
6:6
X1:373
10 9 5 6 8 7 4 15
X1:377

BOMAG
X8:1

2,5 qmm
15/54
30
87a
in

X1:375
X1:226
A53 n
1
Y14
max. 0,75A

20s; n kleiner 1300 1/min

2 20s; rpm lower 1300 1/min
X1:227 8s; n=0 1/min
8s; rpm=0 1/min S +
X1:376
M17 M

X8:2

15/54

K31
14:1
Kraftstoffpumpe Überwachung Lüfter Frischluft Lüfter
fuel pump heating unit monitoring blower blower fresh air

03.04.2006
1 1

008 911 53
Wiring diagram 570 700 35

Werner Heizung und Belüftung 570 700 35

03.04.2006
Seis heating and ventilation 012
30
4:19
F24
9:6 Raumtemperatursensor
K11:87 sensor ambient temperature
11:20
X1:36E
Ausblastemperatursensor
F33 sensor outlet temperature X1:20E

008 911 53
X1:28E X1:22E X1:33E
10A
F50
F123 F94 F31 15A
X1:36A
10A
B29 B118 X1:20A
X1:28A X1:22A X1:33A
30 + +
K62

wird durch D+ aktiviert

2:10 nicht belegt
87 87a not used X1:253 X1:383 X1:381
Versorgung für Schutzbelüftungsanlage

Bel.
X1:251 X1:249

X23:1
X24:1

X23:2
X24:2

15/54
D+
Absicherung und Verkabelung nach Angabe X25:B X25:A
Hersteller der Schutzbelüftungsanlage
supply for protected ventilation system ge rt
Lüftermodul
Wiring diagram 570 700 35

X26:6
X26:7
fuse and wiring acc. to supplier PWM +

X26:13
X26:12
X26:14
blower module

X26:1
X27:1

X26:3
X27:3
X26:5

X27:2
of protected ventilation system

X26:4
A65 Klimatronik X27:4 A53

M+ M

X26:2
X26:10
X26:11
X26:9
X26:8
br gn sw
X25:C
1

31
V43 X1:247

Ventil
2 X1:129
Kupplung

1
B117 _t Thermostat Vereisungsschutz
X22:1 X22:2 thermostat antiicing device
X1:252 2
optional
X1:130 E37 +

BOMAG
optional X1:127 2
X1:146
X7:6 X18:1 VD V36
1
4 Druckschalter

3A
pressure switch
B75 P
LP 3 HP
X29:1 X19:1 X1:414/2
or X7:5 X18:2
+ Y138 1 2 X1:147
X1:201
M26 M V26 X14:4 X17:1
0,42A

2 1
sw 2 1
X1:414/1
X19:2
X1: X29:2 V48 Y15
1 2
X1:382
1,75A

X1:70 X1:272 X1:128

X1:205 X14:5 X17:2
11:20 31 31 14:1

Zyklon Abscheider Magnetventil Heizen Magnetkupplung Verdampferlüfter

cyclone separator solenid valve heating magnetic clutch blower evaporator

Zusatzausrüstung Klimatronik KONVEKTA

Option klimatronic KONVEKTA

03.04.2006
1 1 570 700 35
Werner Schutzbelüftung, Zyklon Abscheider, Klimatronik
03.04.2006
19.2

887
Seis protected vent. system, cyclone separator, air cond. 013
888
K30 K13:87
2:19 2x6qmm
11:16
19.2

X1:2 X1:1

2x6qmm
12:9 K32:30

30
K32
3:16
87
K32:87
12:19
H A B X1:372 X1:372
F49 F27 F28
10A
Box 2 8 F66 H F85 D F42 E F41 D F99 G F86 E F125 B F98 C Box 1 1 Box 1 2
10A 10A
Box 1 8 Box 1 4 Box 2 5 Box 2 4 Box 1 7 Box 1 5 Box 2 2 Box 2 3
15A 20A 10A 10A 15A 15A 10A 10A

F41:4
12:9 + 123 3 2 1 012 7 2
F126 S22
01
S16 2A
S53 1 1 2 S45 1 S38 1 S137 1 S26 1 S128 1
01
S20 5 1 8 5 S21 5 4
ws
5 3 4 5 5 5 5 Kamera 5
camera
X1:145 15 J S 86

X1:72
P32
K61:87a

1,5A
Impulsgeber

Spannungswandler
voltage transformer
X7:1 X7:2 6:9 gn A57 Interval switch
2,5A

+24 +12 E56 4 31 31b

24V E16 1 E23 1 E25 1 E29 1 1 1

BOMAG
X1:378
B11

2,9A
2,9A
2,9A
0,6A
2,9A
12V
2 2 2 2 2 sw 2

Rundumkennleuchte
rotary beacon
U01 E32
A12 15 53a 31b 53
2,5A

31b
53
53a

+ + B51 E17 1 P15 3 R77 R77 R77 R77 + +

E24 1 E26 1 E29 1 + E57 1 1
V 1 1 1 1

2,9A
M04 M M06 M M05 M M07 M B28

2,9A
2,9A
0,6A
2,9A
B51 31
2 2,9A 2 2 2 2
Radio 2 2 2 2 Bildschirm 31 31 2

X1:150
1,7A
1,7A
1,7A
1,7A
7,9A
2,5A
3,3A
2,5A

radio monitor
K31
12:19 Scheinwerfer vorn X7:3 X7:4 Spiegelheizung Wischer vorn Wischer hinten Signalhorn
2x6qmm
head lights front mirror heating wiper, front wiper, rear warning horn

X1:3 X1:4 Scheinwerfer links/rechts Innenleuchten 1 1 Wascherpumpe Wascherpumpe

head lights lh./rh. inside light, cabin E28 E27 washer pump washer pump
2,9A 2,9A

X1:189
X1:189
2 2

31 X1:190 X1:190 31
13:20

Scheinwerfer Motorraum
head lights, engine area

Arbeitsscheinwerfer hinten
working head lights, rear

03.04.2006
1 1

008 911 53
Wiring diagram 570 700 35

Werner Kabine und Anbauteile 570 700 35

03.04.2006
Seis cabin and attachmentparts 014
Name Bl. Pf. Benennung title TYP
A12

A15
014
Wiring diagram 570 700 35
A15 006
006
2
7
13
Radio
Ueberwachungsmodul
Ueberwachungsmodul
Radio
monitoring module
monitoring module
19.2
A16 011 9 Elektronik Tachograph Electronic system, tachograph
A48 004 9 Elektronische Motorsteuerung Electronic engine management
A53 012 14 Modul Luefterueberwachung Modul blower monitoring
A53 013 18 Modul Luefterueberwachung Modul blower monitoring
A57 014 14 Intervallschalter Scheibenwischer Interval switch, wiper
A65 013 14 Steuerung Klimatronik Controller klimatronic
A78 008 3 Zusatzelektronik Additional control unit

B03 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B05 006 18 Druckschalter Bremse Pressure switch, brake
B08 010 19 Naeherungsinitiator Fahrhebel ’0’Stell. Proximity switch, travel lever ’0’ pos. max. 1,08A
Seis
19.04.2006
Werner
19.04.2006

B11 014 19 Signalhorn Warning horn 2,5A

B15 011 6 Aufnehmer Geschwindigkeit Transducer, speed
B19 006 19 Magnetsensor Verschmutzung Magnetic sensor, contamination
B20 006 13 Temperaturschalter Hydraulikoel Temperature switch, hydraulic oil
B21 006 17 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B22 006 16 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B24 006 12 Schwimmerschalter Hydraulikoel Float switch, hydraulic oil
B25 006 11 Druckschalter Ruecklauffilter Pressure switch, return flow filter
B28 014 20 Signalhorn Warning horn 2,5A
B29 013 14 Raumthermostat Room thermostat
B42 006 17 Differenzdruckschalter Hydraulikoel Hydraulic oil pressure differential switch
B51 014 2 Lautsprecher Radio Speaker radio
B51 014 3 Lautsprecher Radio Speaker radio
B52 011 4 Naeherungsinitiator Schmierkolben Proximity switch, lubrication piston
B53 005 6 Temperaturgeber Kuehlmittel Temperature switch, collant
B55 006 3 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B75 013 16 Kuehlmitteldruck coolant pressure
B88 004 5 Druckgeber Motoroel Sender, engine oil pressure
B113 004 7 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 004 8 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B116 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner
B117 013 15 Thermostat Klimaanlage Thermostar, air conditioning
B118 013 15 Temperaturfühler Auslaß Temperature sender outlet
B121 006 15 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B122 006 15 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B124 004 3 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 004 6 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B129 006 12 Druckschalter Verteilergetriebe pressure switch power takeoff gear
B130 004 9 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
component listing

B133 004 11 Sensor Ladeluftdruck / temperatur sesnor charging air prssure / temperature
Bauteilliste

E01 005 14 Beleuchtung Tankanzeige Illumination, level gauge

E02 005 5 Beleuchtung Temperaturanzeige Illumination, temperature gauge
E03 005 10 Beleuchtung Drehzahlmesser Illumination, rpm meter
E04 011 10 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E04 011 11 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E16 014 4 Scheinwerfer links Head light, lh. 55W
E17 014 4 Scheinwerfer rechts Head light, rh. 55W
E20 002 12 Zigarettenanzuender Cigarette lighter
E21 002 12 Beleuchtung Zigarettenanzuender Illumination, cigarette lighter
E22 005 7 Beleuchtung Temperaturanzeige Hydr.oel Illumination, temp. gauge, hydraulic oil
E23 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E24 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E25 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E26 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E27 014 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E28 014 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E29 014 7 Innenleuchte Kabine Inside light, cabin 15W
E29 014 8 Innenleuchte Kabine Inside light, cabin 15W
E30 012 3 Heizgeraet Heating unit
E32 014 8 Kennleuchte Warning light 70W
E37 013 18 Klimaverdampfer Air conditioning, evaporator
E46 005 15 Beleuchtung Voltmeter Illumination volt meter
E56 014 9 Scheinwerfer Motorraum rechts Head light, engine area rh. 55W
E57 014 9 Scheinwerfer Motorraum links Head light, engine area lh. 55W
ESX 006 9 Elektronisches Steuergeraet Electronic system, control unit
ESX 007 12 Elektronisches Steuergeraet Electronic system, control unit
ESX 008 10 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 5 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 18 Elektronisches Steuergeraet Electronic system, control unit
ESX 010 8 Elektronisches Steuergeraet Electronic system, control unit max. 1,08A
ESX 010 18 Elektronisches Steuergeraet Electronic system, control unit 0,2A

F00 002 2 Hauptsicherung Batterie Fuse, main, battery 250A

F02 012 12 Ersatzsicherung Fuse, spare 10A
F05 002 15 Sicherung Steckdose Fuse, socket 30A
F13 003 9 Sicherung Startschalter Fuse, starter switch 30A
F16 011 4 Sicherung Zentralschmieranlage Fuse, central lubrication system 10A
1

F23 011 14 Sicherung Signalhorn Fuse, warning horn 15A

F24 005 5 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A
F25 009 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F27 014 16 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 10A
F28 014 18 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 10A
11

F29 011 18 Sicherung Kompressor Sitzverstell. Fuse, compr., seat height adjustm. 15A
F31 013 6 Sicherung Kabinenluefter Fuse, cabin ventilator 10A
F33 013 9 Sicherung Klimageraet Fuse, air conditioning 10A
F40 012 3 Sicherung Kabinenheizung Fuse, heating unit cab 10A
570 700 35

F41 014 8 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A

F42 014 7 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F48 004 2 Sicherung Gluehanlage Fuse, glow plug system 80A
F49 014 1 Sicherung Spannungswandler Fuse, voltage transformer 10A
F50 013 19 Sicherung Klimageraet Fuse, air conditioning 15A
101

F66 014 4 Sicherung Scheinwerfer vorne Fuse, head light front 15A
F67 009 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 30A
008 911
F84 53 009 13 Sicherung Steuerung (Klemme 54) BOMAG
Fuse, controller (Pin 54) 10A 889
Name Bl. Pf. Benennung title TYP

19.2 F85
F86
F89
014
014
002
6
10
12
Sicherung, Scheinwerfer vorne
Sicherung, Scheinwerfer hinten
Sicherung, Zigarettenanzuender
Fuse, head light front
Fuse, head lights rear
Fuse, cigarette lighter
20A
Wiring diagram 570 700 35
15A
30A
F90 012 8 Sicherung, Ansteuerung Fuse, actuation 5A
F93 004 4 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F94 013 3 Sicherung Schutzbelueftung Fuse, protected ventilation syst.
F98 014 13 Sicherung Spiegelheizung fuse,mirror heating 10A
F99 014 9 Sicherung Motorraumbeleuchtung fuse, illumination engine area 15A
FM1 008 13 Platinensicherung Multifuse 0,2A
FM2 007 19 Platinensicherung Multifuse 0,2A
FM3 010 8 Platinensicherung Multifuse 0,2A
FM4 010 4 Platinensicherung Multifuse 0,2A
FM5 010 11 Platinensicherung Multifuse 0,2A
FM6 007 7 Platinensicherung Multifuse 0,2A
Seis
19.04.2006
Werner
19.04.2006

FM7 010 13 Platinensicherung Multifuse 0,2A

F122 002 17 Sicherung EMR Fuse, EMR 10A
F123 013 2 Sicherung Schutzbelüftungsanlage Fuse, protected ventilation system
F125 014 11 Vorsicherung prefusing 10A
F126 014 11 Sicherung Rückfahrkamera Fuse, back up camera system 2A

G01 002 2 Batterie Battery

G02 002 5 Generator Generator 28V/80A
G03 002 2 Batterie Battery

H04 004 10 Meldeleuchte Betriebsstoerung Indicator light, breakdown

H07 009 13 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0,2A
H14 007 4 Warnsummer Rueckwaertsfahrt Backup alarm buzzer max. 2,5A
H70 004 11 Anzeige Wasser im Diesel Indicator water in fuel
H81 008 5 Meldeleuchte Verzögerungsfunktion Indicator light, decelerator device

K05 007 2 Relais Startstrom Relay, starting current BOSCHW

K11 003 14 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K13 011 14 Relais Signalhorn Relay, warning horn BOSCHW
K14 004 4 Relais Vorgluehen Relay, glow plug system K2DEUTZ
K15 004 12 Relais Gluehen beim Start Relay, glowing during starting BOSCHW
K22 009 6 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K32 003 16 Relais Kabine Relay, cabin BOSCHL
K48 007 3 Relais Fahrhebel 0Stellung Relay, travel lever 0position BOSCHW
K60 004 14 Relais Motoroeldruck Relay, engine oil pressure BOSCHW
K61 002 8 Relais Ladekontrolle Relay, charge control BOSCHW
K62 002 10 Relais D+ Relay, D+ BOSCHW
K77 009 17 Relais Override Relay, override SDS/SF4
K90 009 4 Relais, Meldeleuchte Stoerung SPS Relay, indicat.light brake down SPS BOSCHW
component listing

K113 006 11 Zeitrelais Timing relay BOSCHW

K133 009 9 Relais Test Relay, test BOSCHW
Bauteilliste

K146 004 13 Relais Kühlmitteltemperatur relay, coolant temperature BOSCHW

K77/1 009 15 Relais Override Relay, override SDS/SF4

M01 003 9 Starter Starter

M04 014 15 Scheibenwischermotor vorne Windscreen wiper motor, front 190W
M05 014 17 Scheibenwischermotor hinten Windscreen wiper motor, rear max 3,3A
M06 014 16 Scheibenwaschermotor vorne Windscreen washer motor, front 60W
M07 014 18 Scheibenwaschermotor hinten Windscreen washer motor, rear 60W
M08 011 3 Zentralschmieranlage Central lubrication system max. 3A
M10 011 18 Kompressor Fahrersitzhoehenverstellung Compr., operator’s seat height adjustm. 7,5A
M17 012 18 Zusatzluefter Additional blower max. 0,75A
M24 013 10 Stellmotor Luftklappe adjusting motor air inlet flap
M26 013 6 Zyklon Abscheider cyclone separator 3A

P00 005 12 Betriebsstundenzaehler Operating hour meter

P01 005 15 Tankanzeige Level gauge
P02 005 7 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil
P03 005 11 Drehzahlmesser Rpm meter
P09 011 10 Frequenz und Geschwindigkeitsanzeige Frequency and Speedometer
P09 011 10 Frequenz und Geschwindigkeitsanzeige Frequency and Speedometer
P12 005 16 Voltmeter Volt meter
P14 005 6 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
P15 014 11 BCM 03 Bildschirm BCM 03 terminal
P18 010 16 Diagnose Diagnostics max. 1,08A
P32 014 12 Kamera Rückraumüberwachung Camera, back up monitoring

R02 004 2 Gluehkerze Glow plug

R02 004 2 Gluehkerze Glow plug
R03 005 15 Geber Tankanzeige Sender, level gauge
R04 005 8 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
R06 011 19 Heizung Fahrersitz Heating, operator’s seat
R06 011 19 Heizung Fahrersitz Heating, operator’s seat
R10 002 7 Parallelwiderstand Parallel resistor 220 OHM
R20 008 15 Widerstand Resistor 1 KOHM
R21 008 15 Widerstand Resistor 1 KOHM
R22 008 16 Widerstand Resistor 1 KOHM
R23 008 17 Widerstand Resistor 1 KOHM
2

R26 012 17 Widerstand Resistor 22 OHM

R27 012 18 Widerstand Resistor 10 OHM
R32 007 5 Widerstand Resistor 1 kOhm
R33 007 5 Widerstand Resistor 2 kOhm
R34 007 6 Widerstand Resistor 1 kOhm
11

R35 007 8 Widerstand Resistor 3,3 kOhm

R36 010 5 Widerstand Resistor 47 OHM
R38 010 5 Widerstand Resistor 47 OHM
R40 010 5 Widerstand Resistor 47 OHM
570 700 35

R42 010 5 Widerstand Resistor 47 OHM

R43 008 7 Widerstand Resistor 499Ohm
R44 008 7 Widerstand Resistor 499Ohm
R77 014 12 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
R77 014 13 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
102

R77 014 13 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W

R77 014 14 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
890 BOMAG 008 911 53
Name Bl. Pf. Benennung title TYP
S00

S01
003
Wiring diagram 570 700 35
S01 002
002
9
17
17
Startschalter
Schalter NOT AUS
Schalter NOT AUS
Starter switch
Switch, emergency off
Switch, emergency off
MERIT
NOTAUSH 19.2
S02 008 16 Fahrstufenschalter Switch, speed range selector
S02 008 19 Fahrstufenschalter Switch, speed range selector
S03 011 14 Taster Signalhorn Push button, warning horn
S04 008 10 Bremsschalter Switch, brake
S16 014 5 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 014 14 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 18 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S22 014 16 Schalter Scheibenwascher vorne Switch, windscreen washer, front
S25 011 19 Schalter Fahrersitzheizung Switch, heating, operator’s seat
S26 014 10 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
S27 011 3 Taster Zentralschmieranlage Push botton, central lubrication system
Seis
19.04.2006
Werner
19.04.2006

S28 012 8 Schalter Kabinenheizung Switch, cabin heating

S29 011 18 Schalter Fahrersitz Hoehenverstellung Switch, operator’s seat height adjustm.
S30 002 2 Batterietrennschalter Switch, battery disconnect
S31 007 5 Schalter Fahrtrichtung Switch, travel direction
S38 014 8 Schalter Kennleuchte Switch, warning light
S44 012 17 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 4 Schalter Arbeitsbeleuchtung Switch, working lights
S70 010 10 Schalter Schubsschild Switch, dozer blade WAGO
S71 010 3 Schalter Lenkung Switch, steering max. 1,08A
S118 004 18 Schalter Fehlerdiagnose Switch, fault diagnosis
S119 004 6 Elektronisches Fusspedal Electronic foot pedal
S120 008 7 Schalter Motordrehzahl Switch, engine speed 5 kOhm
S128 014 13 Schalter Spiegelheizung Switch, mirror heating
S137 014 9 Schalter Motorraumbeleuchtung Switch, illumination engine area
S160 008 4 Schalter Aktivierung Verzögerungspedal Switch, enable decelerator pedal
S161 008 6 Verzögerungspedal decelerator pedal

U01 014 1 Spannungswandler Voltage transformer

V01 002 7 Diode Diode WAGO

V02 006 7 Diode Diode WAGO
V03 006 7 Diode Diode WAGO
V04 006 7 Diode Diode WAGO
V05 006 7 Diode Diode WAGO
V07 006 12 Diode Diode WAGO
V08 006 12 Diode Diode WAGO
V09 006 12 Diode Diode WAGO
V10 006 12 Diode Diode WAGO
component listing

V11 006 12 Diode Diode WAGO

V12 009 7 Diode Diode WAGO
Bauteilliste

V13 006 12 Diode Diode WAGO

V14 009 14 Diode Diode Wago
V15 009 15 Diode Diode Wago
V16 010 2 Diode Diode WAGO
V17 010 3 Diode Diode WAGO
V18 010 2 Diode Diode WAGO
V19 010 2 Diode Diode WAGO
V21 009 9 Diode Diode WAGO
V22 009 10 Diode Diode WAGO
V23 007 2 Diode Diode WAGO
V25 007 3 Diode Diode WAGO
V26 013 14 Diode Diode WAGO
V31 008 10 Diode Diode Lütze
V32 007 9 Diode Diode Lütze
V33 007 11 Diode Diode Lütze
V34 007 5 Diode Diode Lütze
V35 007 7 Diode Diode Lütze
V36 013 19 Diode Diode FE5B
V37 008 13 Diode Diode Lütze
V38 007 2 Diode Diode FE5B KabeldiodeDiode
V42 009 13 Diode (A2) Diode (A2) Diodenmodul
V43 013 6 Diode (A3) Diode (A3) Diodenmodul
V46 011 15 Diode (A6) Diode (A6) Diodenmodul
V47 003 12 Diode (A7) Diode (A7) Diodenmodul
V48 013 15 Diode (A8) Diode (A8) Diodenmodul

X0/1:1 010 18 DIOS STECKER Dios connector

X0/1:2 010 18 DIOS STECKER Dios connector
X0/1:3 009 18 DIOS STECKER Dios connector
X0/1:4 009 19 DIOS STECKER Dios connector
X0/1:5 010 18 DIOS STECKER Dios connector
X0/1:6 010 19 DIOS STECKER Dios connector
X0/1:9 009 19 DIOS STECKER Dios connector
X0/1:10 009 19 DIOS STECKER Dios connector
X0/1:11 009 18 DIOS STECKER Dios connector
X0:1 007 10 ESX STECKER esx connector
X0:1 008 13 ESX STECKER esx connector
3

X0:1 010 7 ESX STECKER esx connector

X0:2 009 4 ESX STECKER esx connector
X0:3 009 9 ESX STECKER esx connector
X0:4 009 10 ESX STECKER esx connector
X0:5 009 11 ESX STECKER esx connector
11

X0:6 006 9 ESX STECKER esx connector

X0:7 008 14 ESX STECKER esx connector
X0:8 010 3 ESX STECKER esx connector
X0:9 010 7 ESX STECKER esx connector
570 700 35

X0:10 006 10 ESX STECKER esx connector

X0:11 006 9 ESX STECKER esx connector
X0:12 010 14 ESX STECKER esx connector
X0:13 006 10 ESX STECKER esx connector
X0:14 010 6 ESX STECKER esx connector
103

X0:15 010 7 ESX STECKER esx connector

X0:16 009 4 ESX STECKER esx connector
008 911
X0:17 53 010 13 ESX STECKER BOMAG
esx connector 891
Name Bl. Pf. Benennung title TYP

19.2 X0:18
X0:19
X0:20
006
006
010
9
9
8
ESX STECKER
ESX STECKER
ESX STECKER
esx connector
esx connector
esx connector
Wiring diagram 570 700 35
X0:21 007 10 ESX STECKER esx connector
X0:22 007 8 ESX STECKER esx connector
X0:23 007 11 ESX STECKER esx connector
X0:23 008 13 ESX STECKER esx connector
X0:23 010 8 ESX STECKER esx connector
X0:24 009 6 ESX STECKER esx connector
X0:25 009 7 ESX STECKER esx connector
X0:26 010 17 ESX STECKER esx connector
X0:27 010 16 ESX STECKER esx connector
X0:28 009 6 ESX STECKER esx connector
X0:29 007 19 ESX STECKER esx connector
Seis
19.04.2006
Werner
19.04.2006

X0:30 010 10 ESX STECKER esx connector

X0:31 010 12 ESX STECKER esx connector
X0:32 007 7 ESX STECKER esx connector
X0:33 009 9 ESX STECKER esx connector
X0:34 010 13 ESX STECKER esx connector
X0:35 010 11 ESX STECKER esx connector
X0:36 006 9 ESX STECKER esx connector
X0:37 010 15 ESX STECKER esx connector
X0:38 010 5 ESX STECKER esx connector
X0:39 010 5 ESX STECKER esx connector
X0:40 008 10 ESX STECKER esx connector
X0:41 010 11 ESX STECKER esx connector
X0:42 010 9 ESX STECKER esx connector
X0:43 007 19 ESX STECKER esx connector
X0:44 009 13 ESX STECKER esx connector
X0:45 006 10 ESX STECKER esx connector
X0:46 007 14 ESX STECKER esx connector
X0:47 007 16 ESX STECKER esx connector
X0:48 007 17 ESX STECKER esx connector
X0:49 010 7 ESX STECKER esx connector
X0:50 006 10 ESX STECKER esx connector
X0:51 006 10 ESX STECKER esx connector
X0:52 006 9 ESX STECKER esx connector
X0:53 009 9 ESX STECKER esx connector
X0:54 009 13 ESX STECKER esx connector
X0:55 010 16 ESX STECKER esx connector
X0:56 009 7 ESX STECKER esx connector
X0:57 009 8 ESX STECKER esx connector
X0:58 009 8 ESX STECKER esx connector
component listing

X0:59 009 8 ESX STECKER esx connector

X0:60 009 9 ESX STECKER esx connector
Bauteilliste

X0:61 008 10 ESX STECKER esx connector

X0:62 008 14 ESX STECKER esx connector
X0:63 010 11 ESX STECKER esx connector
X0:64 010 6 ESX STECKER esx connector
X0:65 010 14 ESX STECKER esx connector
X0:66 010 15 ESX STECKER esx connector
X0:67 010 15 ESX STECKER esx connector
X0:68 010 16 ESX STECKER esx connector
X1: 013 2 Wago Zentralelektrik Wago ebox
X1:1 014 7 Wago Zentralelektrik Wago ebox
X1:2 014 7 Wago Zentralelektrik Wago ebox
X1:3 014 2 Wago Zentralelektrik Wago ebox
X1:4 014 2 Wago Zentralelektrik Wago ebox
X1:5 004 20 Wago Zentralelektrik Wago ebox
X1:6 002 17 Wago Zentralelektrik Wago ebox
X1:7 003 9 Wago Zentralelektrik Wago ebox
X1:8 003 9 Wago Zentralelektrik Wago ebox
X1:9 003 9 Wago Zentralelektrik Wago ebox
X1:61 010 18 Wago Zentralelektrik Wago ebox
X1:62 004 15 Wago Zentralelektrik Wago ebox
X1:63 010 18 Wago Zentralelektrik Wago ebox
X1:64 004 16 Wago Zentralelektrik Wago ebox
X1:65 004 16 Wago Zentralelektrik Wago ebox
X1:66 009 10 Wago Zentralelektrik Wago ebox
X1:67 009 11 Wago Zentralelektrik Wago ebox
X1:68 010 18 Wago Zentralelektrik Wago ebox
X1:69 010 18 Wago Zentralelektrik Wago ebox
X1:70 002 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 003 16 Wago Zentralelektrik Wago ebox
X1:70 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 009 4 Wago Zentralelektrik Wago ebox
X1:70 009 6 Wago Zentralelektrik Wago ebox
X1:70 009 9 Wago Zentralelektrik Wago ebox
X1:70 009 13 Wago Zentralelektrik Wago ebox
X1:70 009 15 Wago Zentralelektrik Wago ebox
X1:70 009 17 Wago Zentralelektrik Wago ebox
4

X1:70 013 6 Wago Zentralelektrik Wago ebox

X1:71 004 17 Wago Zentralelektrik Wago ebox
X1:72 014 11 Wago Zentralelektrik Wago ebox
X1:81 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:82 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
11

X1:83 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:84 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:85 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:86 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
570 700 35

X1:87 006 2 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:88 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:89 006 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:90 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:91 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
104

X1:92 004 12 Wago Zentralelektrik Wago ebox

X1:93 004 13 Wago Zentralelektrik Wago ebox
892 X1:94 004 14 Wago Zentralelektrik BOMAG
Wago ebox 008 911 53
Name Bl. Pf. Benennung title TYP
X1:101

X1:103
006
Wiring diagram 570 700 35
X1:102 006
006
7
9
5
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO EBOX
WAGO EBOX
WAGO EBOX
19.2
X1:104 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:105 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:106 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:108 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:109 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:110 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:111 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:112 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:113 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:114 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:115 006 14 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
19.04.2006
Werner
19.04.2006

X1:116 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:117 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:118 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:119 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:120 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:121 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:122 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:123 006 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:124 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:125 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:126 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:127 013 13 Wago Zentralelektrik Wago ebox
X1:128 013 13 Wago Zentralelektrik Wago ebox
X1:129 013 15 Wago Zentralelektrik Wago ebox
X1:130 013 15 Wago Zentralelektrik Wago ebox
X1:131 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:132 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:133 007 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:134 007 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:135 007 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:136 007 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:137 010 11 Wago Zentralelektrik Wago ebox
X1:138 010 11 Wago Zentralelektrik Wago ebox
X1:139 010 12 Wago Zentralelektrik Wago ebox
X1:140 010 12 Wago Zentralelektrik Wago ebox
X1:141 010 18 Wago Zentralelektrik Wago ebox
X1:142 010 18 Wago Zentralelektrik Wago ebox
X1:143 010 19 Wago Zentralelektrik Wago ebox
X1:144 010 19 Wago Zentralelektrik Wago ebox
component listing

X1:145 014 9 Wago Zentralelektrik Wago ebox

X1:146 013 15 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:147 013 15 Wago Zentralelektrik Wago ebox

X1:148 005 8 Wago Zentralelektrik Wago ebox
X1:149 007 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:150 014 10 Wago Zentralelektrik Wago ebox
X1:151 008 10 Wago Zentralelektrik Wago ebox
X1:152 008 10 Wago Zentralelektrik Wago ebox
X1:153 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:154 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:155 007 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:156 007 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:157 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:158 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:159 010 6 Wago Zentralelektrik Wago ebox
X1:160 010 6 Wago Zentralelektrik Wago ebox
X1:161 010 7 Wago Zentralelektrik Wago ebox
X1:162 010 7 Wago Zentralelektrik Wago ebox
X1:163 010 8 Wago Zentralelektrik Wago ebox
X1:164 010 8 Wago Zentralelektrik Wago ebox
X1:165 010 9 Wago Zentralelektrik Wago ebox
X1:166 010 9 Wago Zentralelektrik Wago ebox
X1:170 008 14 Wago Zentralelektrik Wago ebox
X1:171 011 4 Wago Zentralelektrik Wago ebox
X1:172 011 3 Wago Zentralelektrik Wago ebox
X1:173 011 3 Wago Zentralelektrik Wago ebox
X1:174 011 4 Wago Zentralelektrik Wago ebox
X1:181 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:181 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:181 010 14 Wago Zentralelektrik Wago ebox
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:182 010 15 Wago Zentralelektrik Wago ebox
X1:183 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:183 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:183 010 15 Wago Zentralelektrik Wago ebox
X1:184 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:184 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:184 009 18 Wago Zentralelektrik Wago ebox
5

X1:185 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:185 009 19 Wago Zentralelektrik Wago ebox
X1:186 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:186 009 19 Wago Zentralelektrik Wago ebox
X1:187 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
11

X1:187 010 16 Wago Zentralelektrik Wago ebox

X1:188 007 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:188 010 16 Wago Zentralelektrik Wago ebox
X1:189 010 14 Wago Zentralelektrik Wago ebox
570 700 35

X1:189 014 9 Wago Zentralelektrik Wago ebox

X1:189 014 9 Wago Zentralelektrik Wago ebox
X1:190 011 6 Wago Zentralelektrik Wago ebox
X1:190 014 10 Wago Zentralelektrik Wago ebox
X1:190 014 11 Wago Zentralelektrik Wago ebox
105

X1:191 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:191 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
008 911
X1:19153 011 7 Wago Zentralelektrik BOMAG
Wago ebox 893
Name Bl. Pf. Benennung title TYP

19.2 X1:192
X1:201
X1:202
008
013
002
14
15
7
Wago Zentralelektrik
Wago Zentralelektrik
WAGO ZENTRALELEKTRIK
Wago ebox
Wago ebox
WAGO EBOX
Wiring diagram 570 700 35
X1:205 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:205 013 15 Wago Zentralelektrik Wago ebox
X1:207 009 4 Wago Zentralelektrik Wago ebox
X1:20A 013 19 Sika Klemme fuse terminal
X1:20E 013 19 Sika Klemme fuse terminal
X1:210 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:21A 002 12 Sika Klemme fuse terminal
X1:21E 002 12 Sika Klemme fuse terminal
X1:221 007 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:222 007 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:223 007 16 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
19.04.2006
Werner
19.04.2006

X1:224 007 16 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:226 012 3 Wago Zentralelektrik Wago ebox
X1:227 012 3 Wago Zentralelektrik Wago ebox
X1:228 005 15 Wago Zentralelektrik Wago ebox
X1:229 005 15 Wago Zentralelektrik Wago ebox
X1:22A 013 3 Sika Klemme fuse terminal
X1:22E 013 3 Sika Klemme fuse terminal
X1:231 004 6 Wago Zentralelektrik Wago ebox
X1:232 004 6 Wago Zentralelektrik Wago ebox
X1:233 004 7 Wago Zentralelektrik Wago ebox
X1:234 008 5 Wago Zentralelektrik Wago ebox
X1:235 004 6 Wago Zentralelektrik Wago ebox
X1:236 004 6 Wago Zentralelektrik Wago ebox
X1:237 004 7 Wago Zentralelektrik Wago ebox
X1:23A 003 9 Sika Klemme fuse terminal
X1:23E 002 3 Sika Klemme fuse terminal
X1:23E 003 9 Sika Klemme fuse terminal
X1:241 002 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:242 002 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:243 002 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:244 004 10 Wago Zentralelektrik Wago ebox
X1:245 011 19 Wago Zentralelektrik Wago ebox
X1:246 011 19 Wago Zentralelektrik Wago ebox
X1:247 013 15 Wago Zentralelektrik Wago ebox
X1:248 011 3 Wago Zentralelektrik Wago ebox
X1:249 013 10 Wago Zentralelektrik Wago ebox
X1:24A 004 4 Sika Klemme fuse terminal
X1:24E 004 4 Sika Klemme fuse terminal
X1:250 004 10 Wago Zentralelektrik Wago ebox
component listing

X1:251 013 9 Wago Zentralelektrik Wago ebox

X1:252 013 13 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:253 013 17 Wago Zentralelektrik Wago ebox

X1:255 004 18 Wago Zentralelektrik Wago ebox
X1:256 002 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:256 003 12 Wago Zentralelektrik Wago ebox
X1:256 011 15 Wago Zentralelektrik Wago ebox
X1:257 009 13 Wago Zentralelektrik Wago ebox
X1:258 009 13 Wago Zentralelektrik Wago ebox
X1:259 002 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:25A 002 15 Sika Klemme fuse terminal
X1:25E 002 15 Sika Klemme fuse terminal
X1:260 002 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:261 008 10 Wago Zentralelektrik Wago ebox
X1:262 007 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:262 008 10 Wago Zentralelektrik Wago ebox
X1:263 008 10 Wago Zentralelektrik Wago ebox
X1:265 012 18 Wago Zentralelektrik Wago ebox
X1:266 012 17 Wago Zentralelektrik Wago ebox
X1:267 012 18 Wago Zentralelektrik Wago ebox
X1:268 012 19 Wago Zentralelektrik Wago ebox
X1:269 004 11 Wago Zentralelektrik Wago ebox
X1:26A 009 13 Sika Klemme fuse terminal
X1:26E 009 13 Sika Klemme fuse terminal
X1:270 004 11 Wago Zentralelektrik Wago ebox
X1:272 011 3 Wago Zentralelektrik Wago ebox
X1:272 013 9 Wago Zentralelektrik Wago ebox
X1:27A 009 7 Sika Klemme fuse terminal
X1:27E 009 7 Sika Klemme fuse terminal
X1:28A 013 2 Sika Klemme fuse terminal
X1:28E 013 2 Sika Klemme fuse terminal
X1:291 005 7 Wago Zentralelektrik Wago ebox
X1:292 005 11 Wago Zentralelektrik Wago ebox
X1:293 003 10 Wago Zentralelektrik Wago ebox
X1:294 005 5 Wago Zentralelektrik Wago ebox
X1:295 005 7 Wago Zentralelektrik Wago ebox
X1:296 005 15 Wago Zentralelektrik Wago ebox
X1:298 002 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:298 005 11 Wago Zentralelektrik Wago ebox
6

X1:299 004 20 Wago Zentralelektrik Wago ebox

X1:299 005 5 Wago Zentralelektrik Wago ebox
X1:29A 005 5 Sika Klemme fuse terminal
X1:29E 005 5 Sika Klemme fuse terminal
X1:300 005 7 Wago Zentralelektrik Wago ebox
11

X1:301 005 11 Wago Zentralelektrik Wago ebox

X1:302 003 13 Wago Zentralelektrik Wago ebox
X1:303 005 8 Wago Zentralelektrik Wago ebox
X1:30A 011 4 Sika Klemme fuse terminal
570 700 35

X1:30E 011 4 Sika Klemme fuse terminal

X1:31A 011 18 Sika Klemme fuse terminal
X1:31E 002 17 SIKA KLEMME fuse terminal
X1:31E 011 18 Sika Klemme fuse terminal
X1:321 010 6 Wago Zentralelektrik Wago ebox
106

X1:322 010 8 Wago Zentralelektrik Wago ebox

X1:323 010 7 Wago Zentralelektrik Wago ebox
894 X1:324 010 7 Wago Zentralelektrik BOMAG
Wago ebox 008 911 53
Name Bl. Pf. Benennung title TYP
X1:325

X1:327
010
Wiring diagram 570 700 35
X1:326 010
010
6
7
11
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago ebox
Wago ebox
Wago ebox
19.2
X1:328 010 11 Wago Zentralelektrik Wago ebox
X1:329 010 10 Wago Zentralelektrik Wago ebox
X1:32A 002 17 Sika Klemme fuse terminal
X1:32E 002 17 Sika Klemme fuse terminal
X1:330 010 10 Wago Zentralelektrik Wago ebox
X1:331 010 11 Wago Zentralelektrik Wago ebox
X1:332 010 11 Wago Zentralelektrik Wago ebox
X1:333 010 14 Wago Zentralelektrik Wago ebox
X1:334 010 14 Wago Zentralelektrik Wago ebox
X1:335 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:336 007 9 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
19.04.2006
Werner
19.04.2006

X1:337 007 7 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:338 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:339 007 5 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:33A 013 6 Sika Klemme fuse terminal
X1:33E 002 17 SIKA KLEMME fuse terminal
X1:33E 013 6 Sika Klemme fuse terminal
X1:340 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:341 011 18 Wago Zentralelektrik Wago ebox
X1:342 011 18 Wago Zentralelektrik Wago ebox
X1:343 008 4 Wago Zentralelektrik Wago ebox
X1:343 010 5 Wago Zentralelektrik Wago ebox
X1:344 010 4 Wago Zentralelektrik Wago ebox
X1:345 010 4 Wago Zentralelektrik Wago ebox
X1:346 010 3 Wago Zentralelektrik Wago ebox
X1:347 010 5 Wago Zentralelektrik Wago ebox
X1:348 010 5 Wago Zentralelektrik Wago ebox
X1:349 009 18 Wago Zentralelektrik Wago ebox
X1:349 009 19 Wago Zentralelektrik Wago ebox
X1:349 009 19 Wago Zentralelektrik Wago ebox
X1:349 010 17 Wago Zentralelektrik Wago ebox
X1:34A 011 14 Sika Klemme fuse terminal
X1:34E 011 14 Sika Klemme fuse terminal
X1:350 010 13 Wago Zentralelektrik Wago ebox
X1:351 010 12 Wago Zentralelektrik Wago ebox
X1:352 010 12 Wago Zentralelektrik Wago ebox
X1:353 010 13 Wago Zentralelektrik Wago ebox
X1:354 010 13 Wago Zentralelektrik Wago ebox
X1:355 011 19 Wago Zentralelektrik Wago ebox
X1:356 011 14 Wago Zentralelektrik Wago ebox
component listing

X1:357 008 17 Wago Zentralelektrik Wago ebox

X1:358 008 13 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:359 008 14 Wago Zentralelektrik Wago ebox

X1:35A 009 2 Sika Klemme fuse terminal
X1:35E 009 2 Sika Klemme fuse terminal
X1:363 010 15 Wago Zentralelektrik Wago ebox
X1:364 010 19 Wago Zentralelektrik Wago ebox
X1:364 011 14 Wago Zentralelektrik Wago ebox
X1:36A 013 9 Sika Klemme fuse terminal
X1:36E 013 9 Sika Klemme fuse terminal
X1:371 003 16 Wago Zentralelektrik Wago ebox
X1:372 014 19 Wago Zentralelektrik Wago ebox
X1:372 014 20 Wago Zentralelektrik Wago ebox
X1:373 012 15 Wago Zentralelektrik Wago ebox
X1:374 012 15 Wago Zentralelektrik Wago ebox
X1:375 012 3 Wago Zentralelektrik Wago ebox
X1:376 012 3 Wago Zentralelektrik Wago ebox
X1:377 012 19 Wago Zentralelektrik Wago ebox
X1:378 014 10 Wago Zentralelektrik Wago ebox
X1:381 013 19 Wago Zentralelektrik Wago ebox
X1:382 013 18 Wago Zentralelektrik Wago ebox
X1:383 013 17 Wago Zentralelektrik Wago ebox
X1:391/1 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:391/2 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:392/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:392/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:393/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:393/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:394/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:394/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:395/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:395/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:397/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:397/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:398/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:398/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:399/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:399/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:400/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
7

X1:400/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:401/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:401/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:402/1 009 7 Wago Zentralelektrik Wago ebox
X1:402/2 009 7 Wago Zentralelektrik Wago ebox
11

X1:403/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:403/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:404/1 009 14 Wago Zentralelektrik Wago ebox
X1:404/2 009 14 Wago Zentralelektrik Wago ebox
570 700 35

X1:405/1 009 15 Wago Zentralelektrik Wago ebox

X1:405/2 009 15 Wago Zentralelektrik Wago ebox
X1:406/1 010 2 Wago Zentralelektrik Wago ebox
X1:406/2 010 2 Wago Zentralelektrik Wago ebox
X1:407/1 010 3 Wago Zentralelektrik Wago ebox
107

X1:407/2 010 3 Wago Zentralelektrik Wago ebox

X1:408/1 010 2 Wago Zentralelektrik Wago ebox
008 911 53
X1:408/2 010 2 Wago Zentralelektrik BOMAG
Wago ebox 895
Name Bl. Pf. Benennung title TYP

19.2 X1:409/1
X1:409/2
X1:41/1
010
010
008
2
2
13
Wago Zentralelektrik
Wago Zentralelektrik
WAGO ZENTRALELEKTRIK
Wago ebox
Wago ebox
WAGO EBOX
Wiring diagram 570 700 35
X1:41/2 008 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:410/1 009 9 Wago Zentralelektrik Wago ebox
X1:410/2 009 9 Wago Zentralelektrik Wago ebox
X1:411/1 009 10 Wago Zentralelektrik Wago ebox
X1:411/2 009 10 Wago Zentralelektrik Wago ebox
X1:412/1 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:412/2 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:413/1 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:413/2 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:414/1 013 14 Wago Zentralelektrik Wago ebox
X1:414/2 013 14 Wago Zentralelektrik Wago ebox
Seis
19.04.2006
Werner
19.04.2006

X1:42/1 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:42/2 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:43/1 010 8 Wago Zentralelektrik Wago ebox
X1:43/2 010 8 Wago Zentralelektrik Wago ebox
X1:44/1 010 4 Wago Zentralelektrik Wago ebox
X1:44/2 010 4 Wago Zentralelektrik Wago ebox
X1:45/1 010 11 Wago Zentralelektrik Wago ebox
X1:45/2 010 11 Wago Zentralelektrik Wago ebox
X1:46/1 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:46/2 007 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:47/1 010 13 Wago Zentralelektrik Wago ebox
X1:47/2 010 13 Wago Zentralelektrik Wago ebox
X2:A 010 18 Datenschnittstelle data interface
X2:B 010 18 Datenschnittstelle data interface
X2:G 009 11 Datenschnittstelle data interface
X2:H 009 10 Datenschnittstelle data interface
X2:J 002 11 Datenschnittstelle data interface
X2:N 002 11 Datenschnittstelle data interface
X2:U 009 11 Datenschnittstelle data interface
X2:V 010 15 Datenschnittstelle data interface
X3:A 008 3 Stecker Handgas connector hand throttle
X3:B 008 2 Stecker Handgas connector hand throttle
X3:C 008 2 Stecker Handgas connector hand throttle
X4:A 004 15 EMR Diagnose EMRdiagnosis
X4:B 004 17 EMR Diagnose EMRdiagnosis
X4:F 004 16 EMR Diagnose EMRdiagnosis
X4:G 004 16 EMR Diagnose EMRdiagnosis
X4:H 004 15 EMR Diagnose EMRdiagnosis
X4:K 004 17 EMR Diagnose EMRdiagnosis
component listing

X4:M 004 16 EMR Diagnose EMRdiagnosis

X5:1 005 7 Deutsch Stecker Senso Deutsch Connector sensor
Bauteilliste

X6:1 004 10 Wago Zentralelektrik Wago ebox

X6:2 004 10 Wago Zentralelektrik Wago ebox
X6:3 004 11 Wago Zentralelektrik Wago ebox
X6:4 004 11 Wago Zentralelektrik Wago ebox
X6:5 004 15 Wago Zentralelektrik Wago ebox
X6:6 004 15 Wago Zentralelektrik Wago ebox
X6:7 004 16 Wago Zentralelektrik Wago ebox
X6:8 004 16 Wago Zentralelektrik Wago ebox
X6:9 004 16 Wago Zentralelektrik Wago ebox
X6:10 004 17 Wago Zentralelektrik Wago ebox
X7:1 014 9 Stecker Rops connector on rops
X7:2 014 9 Stecker Rops connector on rops
X7:3 014 9 Stecker Rops connector on rops
X7:4 014 9 Stecker Rops connector on rops
X7:5 013 16 Stecker Rops connector on rops
X7:6 013 16 Stecker Rops connector on rops
X8:1 012 3 Pumpenstecker Kabine connector pump cabin;
X8:2 012 3 Pumpenstecker Kabine connector pump cabin;
X9:1 007 5 Stecker Schalter Rich connector direction switch
X9:2 007 9 Stecker Schalter Rich connector direction switch
X9:3 007 7 Stecker Schalter Rich connector direction switch
X9:4 007 5 Stecker Schalter Rich connector direction switch
X9:5 007 5 Stecker Schalter Rich connector direction switch
X9:6 007 6 Stecker Schalter Rich connector direction switch
XS 002 15 Steckdose Socket
X10:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X10:B 004 6 AMP Stecker Gaspedal AMP connector throttle
X10:C 004 6 AMP Stecker Gaspedal AMP connector throttle
X11:1 011 18 Schnittstelle Sitz connector drivers seat
X11:2 011 18 Schnittstelle Sitz connector drivers seat
X12:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X12:B 004 8 AMP Stecker Gaspedal AMP connector throttle
X12:C 004 7 AMP Stecker Gaspedal AMP connector throttle
X13:1 008 17 Stecker Stufenschalte connector speed range switch
X13:2 008 18 Stecker Stufenschalte connector speed range switch
X13:3 008 14 Stecker Stufenschalte connector speed range switch
X14:4 013 15 Stecker Motor connector engine
8

X14:5 013 16 Stecker Motor connector engine

X14:6 002 6 Motorschnittstelle engine interface
X14:7 002 6 Motorschnittstelle engine interface
X14:8 005 7 Motorschnittstelle engine interface
X14:9 003 9 Motorschnittstelle engine interface
11

X14:10 006 12 Stecker Motor connector engine

X14:11 006 12 Stecker Motor connector engine
X15:A 010 18 Stecker Lehne links connector arm rest lh.
X15:B 010 18 Stecker Lehne links connector arm rest lh.
570 700 35

X15:C 010 19 Stecker Lehne links connector arm rest lh.

X17:1 013 16 Stecker Klimakupplung connector clima clutch
X17:2 013 16 Stecker Klimakupplung connector clima clutch
X18:1 013 16 Stecker Druckschalter connector pressure switch
X18:2 013 16 Stecker Druckschalter connector pressure switch
108

X19:1 013 13 Stecker Heizventil connector heating valve

X19:2 013 13 Stecker Heizventil connector heating valve
896 X21:1 011 19 Schnittstelle Sitz BOMAG
connector drivers seat 008 911 53
Name Bl. Pf. Benennung title TYP
X21:2

X22:2
011
Wiring diagram 570 700 35
X22:1 013
013
19
10
11
Schnittstelle Sitz
Stecker Luftklappe
Stecker Luftklappe
connector drivers seat
connector air flap
connector air flap
19.2
X23:1 013 14 Stecker Sensor connector sensor
X23:2 013 14 Stecker Sensor connector sensor
X24:1 013 15 Stecker Sensor connector sensor
X24:2 013 15 Stecker Sensor connector sensor
X25:A 013 19 Stecker Lüfter connector blower
X25:B 013 18 Stecker Lüfter connector blower
X25:C 013 18 Stecker Lüfter connector blower
X26:1 013 9 Stecker Klimasteuerun connector climacontrol
X26:2 013 9 Stecker Klimasteuerun connector climacontrol
X26:3 013 11 Stecker Klimasteuerun connector climacontrol
X26:4 013 10 Stecker Klimasteuerun connector climacontrol
Seis
19.04.2006
Werner
19.04.2006

X26:5 013 16 Stecker Klimasteuerun connector climacontrol

X26:6 013 12 Stecker Klimasteuerun connector climacontrol
X26:7 013 12 Stecker Klimasteuerun connector climacontrol
X26:8 013 15 Stecker Klimasteuerun connector climacontrol
X26:9 013 13 Stecker Klimasteuerun connector climacontrol
X26:10 013 10 Stecker Klimasteuerun connector climacontrol
X26:11 013 11 Stecker Klimasteuerun connector climacontrol
X26:12 013 13 Stecker Klimasteuerun connector climacontrol
X26:13 013 13 Stecker Klimasteuerun connector climacontrol
X26:14 013 13 Stecker Klimasteuerun connector climacontrol
X27:1 013 14 Stecker Klimasteuerun connector climacontrol
X27:2 013 14 Stecker Klimasteuerun connector climacontrol
X27:3 013 15 Stecker Klimasteuerun connector climacontrol
X27:4 013 15 Stecker Klimasteuerun connector climacontrol
X28:1 011 6 Stecker Radsensor connector wheel sensor
X28:2 011 6 Stecker Radsensor connector wheel sensor
X28:3 011 7 Stecker Radsensor connector wheel sensor
X28:4 011 7 Stecker Radsensor connector wheel sensor
X29:1 013 6 Stecker Zyklon Connector cyclone
X29:2 013 6 Stecker Zyklon Connector cyclone
X30:A 011 6 Verbindungsstecker Se connector sensor
X30:B 011 6 Verbindungsstecker Se connector sensor
X30:C 011 7 Verbindungsstecker Se connector sensor
X31:A 011 11 Verbindungsstecker An connector gauge
X31:B 011 9 Verbindungsstecker An connector gauge
X31:C 011 10 Verbindungsstecker An connector gauge
X33:1 011 4 Schmieranlage lubrication system
X33:2 011 4 Schmieranlage lubrication system
X34:1 011 4 Schmieranlage lubrication system
component listing

X34:2 011 4 Schmieranlage lubrication system

X34:3 011 3 Schmieranlage lubrication system
Bauteilliste

X34:4 011 3 Schmieranlage lubrication system

X34:5 011 4 Schmieranlage lubrication system
X35:1 009 13 Stecker Warnsummer connector warning buzzer
X35:2 009 13 Stecker Warnsummer connector warning buzzer
X36:1 008 7 Stecker Poti connector potentiometer
X36:2 008 6 Stecker Poti connector potentiometer
X36:3 008 7 Stecker Poti connector potentiometer
X39:A 008 7 Stecker Deceleratorpe connector decelerator pedal
X39:B 008 6 Stecker Deceleratorpe connector decelerator pedal
X39:C 008 6 Stecker Deceleratorpe connector decelerator pedal
X40:1 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:2 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:3 008 9 Stecker Deceleratorpe connector decelerator pedal
X40:4 008 7 Stecker Deceleratorpe connector decelerator pedal
X40:5 008 8 Stecker Decelelratorp connector decelerator pedal
X40:6 008 7 Stecker Deceleratorpe connector decelerator pedal
X41:1 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:2 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:3 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:4 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:5 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:6 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:8 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:9 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:10 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:11 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:12 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X42:1 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:2 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:4 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:5 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:6 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X17.1:1 004 2 2pol SPT 2pole SPT
X17.1:2 004 2 2pol SPT 2pole SPT
X27.1:4 004 18 Motor / 42pol EPC engine / 42pole EPC
X27.1:6 004 19 Motor / 42pol EPC engine / 42pole EPC
X27.1:7 004 19 Motor / 42pol EPC engine / 42pole EPC
9

X27.1:11 004 14 Motor / 42pol EPC engine / 42pole EPC

X27.1:12 004 6 Motor / 42pol EPC engine / 42pole EPC
X27.1:13 004 8 Motor / 42pol EPC engine / 42pole EPC
X27.1:14 004 8 Motor / 42pol EPC engine / 42pole EPC
X27.1:15 004 9 Motor / 42pol EPC engine / 42pole EPC
11

X27.1:18 004 7 Motor / 42pol EPC engine / 42pole EPC

X27.1:19 004 5 Motor / 42pol EPC engine / 42pole EPC
X27.1:20 004 4 Motor / 42pol EPC engine / 42pole EPC
X27.1:21 004 10 Motor / 42pol EPC engine / 42pole EPC
570 700 35

X27.1:22 004 11 Motor / 42pol EPC engine / 42pole EPC

X27.1:23 004 10 Motor / 42pol EPC engine / 42pole EPC
X27.1:24 004 7 Motor / 42pol EPC engine / 42pole EPC
X27.1:25 004 4 Motor / 42pol EPC engine / 42pole EPC
X27.1:26 004 5 Motor / 42pol EPC engine / 42pole EPC
109

X27.1:27 004 5 Motor / 42pol EPC engine / 42pole EPC

X27.1:28 004 11 Motor / 42pol EPC engine / 42pole EPC
008 911 53
X27.1:29 004 11 Motor / 42pol EPC BOMAG
engine / 42pole EPC 897
Name Bl. Pf. Benennung title TYP

19.2 X27.1:30
X27.1:33
X27.1:34
004
004
004
7
6
12
Motor / 42pol EPC
Motor / 42pol EPC
Motor / 42pol EPC
engine / 42pole EPC
engine / 42pole EPC
engine / 42pole EPC
Wiring diagram 570 700 35
X27.1:35 004 12 Motor / 42pol EPC engine / 42pole EPC
X27.1:36 004 14 Motor / 42pol EPC engine / 42pole EPC
X27.1:37 004 13 Motor / 42pol EPC engine / 42pole EPC
X27.1:39 004 17 Motor / 42pol EPC engine / 42pole EPC
X27.1:40 004 16 Motor / 42pol EPC engine / 42pole EPC
X27.1:41 004 16 Motor / 42pol EPC engine / 42pole EPC
X27.1:42 004 15 Motor / 42pol EPC engine / 42pole EPC
X27.2:10 004 3 12pol EPC 12pole EPC
X27.2:11 004 3 12pol EPC 12pole EPC
XD2.1:2 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:3 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
Seis
19.04.2006
Werner
19.04.2006

XD2.1:5 004 18 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH

XD2.1:6 004 18 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:8 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:9 004 5 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:10 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:11 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:13 004 11 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:20 004 14 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:22 004 10 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:30 004 10 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:33 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:34 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:35 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:38 004 11 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:39 004 13 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:40 004 15 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:52 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:53 004 15 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:54 004 12 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:59 004 8 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:60 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:61 004 8 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:77 004 6 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:78 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:79 004 6 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:89 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.2:3 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:4 004 19 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:5 004 19 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
component listing

XD2.2:7 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH

XD2.2:8 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
Bauteilliste

XD2.2:9 004 8 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH

XD2.2:10 004 8 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:15 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:18 004 6 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:19 004 9 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:23 004 10 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:24 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:25 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:26 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:27 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:28 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:32 004 6 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:33 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:34 004 10 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:35 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:36 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.3:3 004 15 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:4 004 12 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:6 004 13 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:7 004 14 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:8 004 18 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:12 004 14 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:13 004 12 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:14 004 16 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:15 004 16 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:16 004 17 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH

Y02 004 19 Magnetventil Flammgluehanlage Solenoid valve, glow plug system 18W
Y03 008 14 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector
Y04 008 10 Magnetventil Bremse Solenoid valve, brake 1,25A
Y14 012 3 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 013 16 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 1,75A
Y16 007 10 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y16 007 12 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y17 007 6 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y17 007 8 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y92 010 6 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. max. 1,1A
10

Y93 010 7 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. max. 1,1A
Y102 010 11 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A
Y102 010 12 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A
Y108 010 8 Magnetventil Schaufel Heben solenoid valve, lifting shovel max. 1,1A
Y109 010 9 Magnetventil Schaufel Senken solenoid valve, let down shovel max. 1,1A
11

Y110 010 19 Magnetventil Schaufel oeffnen solenoid valve, open shovel max. 1,1A
Y111 010 18 Magnetventil Schaufel Schließen solenoid valve, close shovel max. 1,1A
Y132 007 14 Magnetventil Radmotor vorn links Solenoid valve, wheel motor front lh. max. 0,6A
Y133 007 16 Magnetventil Radmotor vorn rechts Solenoid valve, wheel motor front rh. max. 0,6A
570 700 35

Y134 007 17 Magnetventil Radmotor hinten links Solenoid valve, wheel motor rear lh. max. 0,6A
Y135 007 19 Magnetventil Radmotor hinten rechts Solenoid valve, wheel motor rear rh. max. 0,6A
Y138 013 13 Magnetveentil Heizung Solenoid valve, heating unit 0,42A
Y147 004 12 Injektor A1 jet pump A1
Y148 004 14 Injektor A2 jet pump A2
110

Y149 004 13 Injektor A3 jet pump A3

Y150 004 17 Injektor B1 jet pump B1
898 Y151 004 16 Injektor B2 BOMAG
jet pump B2 008 911 53
Name Bl. Pf. Benennung title TYP

Seis
19.04.2006
Y152

Y167
004 16 Injektor B3
Wiring diagram 570 700 35
Y166 004 14 Injektor A4
004 18 Injektor B4
jet pump B3
jet pump A4
jet pump B4
19.2
Werner
19.04.2006
component listing
Bauteilliste
11
11
570 700 35
111

008 911 53 BOMAG 899

008 911 53 BOMAG 900
404

402
408

394
400
403
405
406
407
409
414

392
398

393
395
396
397
399
412

401
410
413
415

391
411

K77 K77
H07

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
057 513 10

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
057 664 11 057 664 11
057 564 17

057 564 37
057 564 22 057 564 30
057 564 23
1x6qmm
1x6qmm

Seis

153 131 1x6qmm

Versorgung Kabine 1
Werner

154 132
155 133 1x6qmm Versorgung Kabine 1x6qmm
2
03.04.2006
03.04.2006

156 134
K11

157 135 1x6qmm Masse Kabine 3

158 136
057 543 08

1x6qmm Masse Kabine 4

159 137
160 138 Masse Schutzbelüftung 5
161 139
057 564 29

162 140 6
163 141
164 142 7
165 143
1x2,5qmm
1x4qmm

1x6qmm
1x6qmm

166 144 8
057 564 35

167 145 9
K05

168 146
15A
169 147 Klimatronik Konvekta 1x1,5qmm F50 20
170 148 Zigarettenanzünder + 30A
171 149 1x1,5qmm F89 21
Tachograph / BC 672 EB
057 564 19
K22

172 150 Schutzbelüftung 22

173 151
30A
174 152 Zündschloß 1x6qmm 1x6qmm
F13 23
187 181 25A
188 182 EDC7 Steuerung (30) 2x2,5qmm F93 24
189 183 30A
Steckdose 1x2,5qmm F05 25
190 184
10A
191 185 Prozessor Steuerung 1x2,5qmm 1x2,5qmm
F84 26
192 186
K113 K13

30A
206 201 Leistung Steuerung 5x0,75qmm F67 27 1x4qmm
207 202
Schutzbelüftung
208 203 28
209 204 15A
Instrumente 1x1,5qmm
K90

F24 29
210 205
Schmieranlage + 10A
226 221 1x1,5qmm F16 30
Tachograph / BC 672 EB
227 222 15A
Fahrersitz 1x1,5qmm F29 31 1x2,5qmm
228 223
K48

10A
229 224 EDC7 Steuerung (15) 1x1,5qmm F122 32
230 225
K11

10A
235 231 Zykon Abscheider 1x1,5qmm F31 33 1x2,5qmm
236 232 15A
K61

Signalhörner 1x1,5qmm F23 34

237 233
238 234 10A
Fahren und Bremse 1x1,5qmm F25 35
257 241 10A
258 242 Klimatronik Konvekta 1x1,5qmm F33
057 268 42

36
K62

259 243
260 244 37
261 245 45 41
262 246 45 41
K133

263 247 46 42
264 248 46 42

ebox
265 249 47 43
057 564 25

266 250 47 43
057 564 36

Schaltkasten
057 564 21

267 251 48 44
057 543 12

1 2 1 2 1 2 1 2
1 2 1 2 1 2 1 2

268 252 48 44
057 564 38

269 253 61
270 254
K15

62
271 255
057 500 57

63
057 664 96

272 256 64
K146

300 291 65
301 292 66
302 292
293 67
K60

303 294 68
304 295 69
305 296 70
306 297 71
307 298 72

057 565 39
308 299 84 81
343 321 85 82

057 565 36
057 668 71

344 322 86 83
057 564 24

345 323 92 87
346 324 93 88
347 325 94 89
348 326 95 90
349 327 96 91
057 564 26

350 328 104 101

057 565 40
351 329 105 102

057 565 38
352 330 106 103
353 331 115 107
354 332 116 108
355 333 117 109
356 334 118 110
X2:AV

357 335 119 111

358 336 119 111
057 555 96

359 337 120 112

360 338 121 113
361 339 122 114

057 565 37
362 340 125 123
363 341 126 124

057 565 35
364 342
129 127
data interface

375 371 130 128

Datenschnittstelle

376 372
377 373 6 1
378 374 7 2
057 556 04 (Kappe/cap)

057 665 63
383 381 8 3

057 665 61
384 382 9 4

X6:1..10
057 555 98

10 5

1
X6
2 R42 1 2 R10 1
47_O 220_O
2 R40 1 2 R27 1
47_O 10_O

1
057 564 43

057 199 46
diagnosis EMR
Diagnose EMR
X4:
2 R38 1 2 R26 1
47_O 22_O
2 R36 1 2 2 2 2 2 2 2 2
LU Motor
47_O
P18
8 7 6 5 4 3 2 1

057 664 03
1 1
1 1 1 1 1 1

LU Motor

570 700 35
057 664 08

V48
V47
V46
V45
V44
V43
V42
V41

201
057 665 62
Wiring diagram 570 700 35 19.2
008 911 53
Wiring diagram 570 700 35

X28
X4
X2
X17

X1
X30
X15
X3
X11
X35
X7 X21
X18
X13 X39
X23 X9
X26 X12 X40
X0
X19 X27 X10
X16 X31 X42 X36

BOMAG
X22 X41
X29 X24 X8
X14 X18
X17 X27.1 X25

X27.2
D2.1

X33
D2.2 D2.3
X34

03.04.2006
1 1 570 700 35
Werner Lokalisierungsgrafik Steckverbinder Draufsicht
03.04.2006
19.2

901
Seis localization graphic connectors top view 301
902
19.2

X18

X29

X23
X31 X11 X15 X13
X16 X41
X21
X4 X42
X36
X2 X19 X15 X26 X9
X0
X27

X24
X18 X22
X1

X30 X25 X12 X39

X35
X3 X10 X40

D2.2 X34
X17 X27.1
D2.1 X27.2

BOMAG
D2.3 X33

X14

X28

03.04.2006
1 1

008 911 53
Wiring diagram 570 700 35

Werner Lokalisierungsgrafik Steckverbinder Seitenansicht 570 700 35

03.04.2006
Seis localization graphic connectors side view 302
19.3 Wiring diagram 570 700 37

008 911 53 BOMAG 903

19.3 Wiring diagram 570 700 37

S/N Wiring diagram 570 700 37

S/N 101 570 571 007 ⇔ 101 570 571 011 BC 772 RS-2
S/N 101 570 581 021 ⇔ 101 570 581 034 BC 772 RB-2
S/N 101 570 591 007 ⇔ 101 570 591 008 BC 672 RB-2
S/N 101 570 821 005 ⇔ 101 570 821 007 BC 972 RB-2
S/N 101 570 831 015 ⇔ 101 570 831 021 BC 1172 RB-2
S/N 101 570 921 002 ⇔ 101 570 921 002 BC 772 EB-2

904 BOMAG 008 911 53

Inhaltsverzeichnis: BC 772...1172 RB / TIER III

006 vorläufig Anzeigen, Störmeldungen monitoring, failure indication

BOMAG
301 vorläufig Lokalisierungsgrafik Steckverbinder Draufsicht localization graphic connectors top view

28.08.2006
001 001
Werner Stromlaufplan 570 700 37
28.08.2006
19.3

905
circuit diagram 001
Seis
906
Zuleitung Steuerung Pin 54 30/54S 9:2
Zuleitung Steuerung Pin 5660 30/5660S
9:2

2,5qmm
Kabine K30
14:2
19.3

4qmm
geschaltetes "15/54"

2x6qmm
Batteriespannung 30 3:1

6qmm
15/54 X1:6
Zündschloß "15/54" 3:1

Einspeisepunkte für Versorgung

2,5qmm
4qmm
2x6qmm
6qmm
6qmm
Sicherungespotential K11:87!
X1:241 X1:242
X1:31E
X1:33E

0,11A
0,075A
X1:241
11:7
1 86 K61:87a 5:9 F24 K11:87 5:1
5:1
R10
1 220_O
K61 X1:298
F00 250A

057 665 63
2 2,5qmm X1:32E
2 85 X1:243
1x25qmm F122
10A
Anlassehauptleitung: 2x70qmm B+ 3:1 D+ 6:2
Ladeleitung 2x 10qmm oder 1x25qmm X1:32A
X1:81 1
X1:259

BOMAG
+ E21
X1:202
9:13
8:10

G01 2
11 21 31 41 51 61
S01
Batterie X14:6

0,075A
5A
Bei Steckdosenbetrieb je nach Stecker bis 16A möglich!
battery
max. 10A

2:10 13:10
Zigarettenanzünder Steckdose
cigarette lighter socket

28.08.2006
1 1

008 911 53
Wiring diagram 570 700 37

Werner Versorgung, Zigarettenanzünder 570 700 37

28.08.2006
Seis supply, cigarette lighter 002
2:15 30 30 4:1
2:11 15/54
6qmm
2:6 B+ B+ 4:1 X1:23E
Anlasserhauptleitung 2x70qmm F13
30A

008 911 53
X1:23A

6qmm

Zündstartschalter
012 30 ignition switch
S00
01

50a 15/54

4qmm
1,5qmm

X1:293
Wiring diagram 570 700 37

X1:302

X1:8 X1:9

30
K05
7:2
87 87a

X1:7

BOMAG
2,5qmm
X14:9 X1:371
0,2A

0,2A

86 86
30 50 2 K11 K32
M01
M V47
85 85
1

X1:256 X1:70

2:20 31 31 4:1

2:17 14:6

Starter
starter
Anzugswicklung KHD = 73A
Haltewicklung KHD = 12A

28.08.2006
1 1 570 700 37
Werner Zündschloß, Starter
28.08.2006
19.3

907
Seis ignition switch, starter 003
908
30 30
3:20 13:1
B+ Pedal
3:5 X1:24E 6:7
XS
B124 2:19
19.3

1 + 1 elektronisches Fußpdal Diagnosestecker

F48 F93 elektronic foot pedal diagnosis
86 86 86 X22
80A 25A K15 K146 K60
2 F78
2 S119 H04 1 H70 1
13
X1:24A S118

X4:A
X4:H
X4:G
X4:M
X4:F
X4:K
X4:B
2 2 Fehlertaster Motor
85 85 85
4qmm B46

4qmm
4qmm
14 failure push button engine

Williams Codierung
sw rt ws or gn bl

X1:92
X1:93
X1:94
1
R24

X1:62
X1:64
X1:65
X1:71
2 X1:255

X10:B
X10:C
X10:A
X12:A
X12:C
X12:B
X6:1 X1:250
X6:2 X1:244
X6:3 X1:270
X6:4 X1:269
10 kOhm
2 3 1 EMR
RPM 2:19
9:2
Option
option

X6:5
X6:6
X6:7
X6:8
X6:9
X6:10

X1:231
X1:232
X1:233
5V EDC 8:2
Handgas
8:2
4x2,5qmm Dachkurve AGND EDC "31" 4x2,5qmm
8:2

Sensor Wasserabscheider
sender water separator
"30"
Fehler EMR
Vers. Meldeleuchte
Glühen
Temperatur
Motoröldruck
"15"
CAN 1H
CAN 1L
CAN 2H
CAN 2L
ISO KLinie

S2 S1

Fehler Motor
failure engine
Wasserabsch.
water separator

X1:235
X1:236
X1:237

XD2.1:3
XD2.1:9
XD2.1:6
XD2.1:5

XD2.1:2
XD2.1:8
XD2.1:11

XD2.1:61
XD2.1:13
XD2.1:10

XD2.1:79
XD2.1:77
XD2.1:33
XD2.1:60
XD2.1:59
XD2.1:30
XD2.1:39
XD2.1:53
XD2.1:35

XD2.1:62
XD2.1:29
XD2.1:78
XD2.1:38
XD2.1:20
XD2.1:52
XD2.1:89

XD2.1:22
XD2.1:54
XD2.1:40
XD2.1:34

X27.2:11
X27.2:10
A48 EDC7 Steuerung
4qmm

X17.1:1
X17.1:2
X1:5

BOMAG
50i
K14 K2
4:4

3:20 31 31 5:1

4:2 6:2 6:2 6:3 Injektor B3

28.08.2006
1 1

008 911 53
Wiring diagram 570 700 37

Werner DEUTZ Steuergerät EDC 7 f. 6 und 8Zylindermot. 570 700 37

28.08.2006
Seis 066_7 DEUTZ controller EDC 7 for 6 and 8zylinder engine 004
2:20 K11:87 K11:87 9:1

X1:29E

F24
15A

008 911 53
X1:29A
2:13 F24 F24 6:1
2:11 K61:87a K61:87a 6:7
X1:294 X1:295 X1:298

5 1 4 3 5 1
Wiring diagram 570 700 37

P00 +
E02 P14 + E22 P02 + E03 P03 + E01 P01 + E46 P12 +
1 1 1 1 1
_t _t n Q
2 2 2 2 2
G G G G

Modul 1
module 1
Modul 2
module 2
Modul 3
module 3
3 2 4 1 5 3 4

BOMAG
X1:300 X1:303 X1:301 X1:296
X1:291 X1:148 X1:292 X1:228

X14:8

X5:1

1 2
B53 1 1
R04 R03

2 2
X1:299 W X1:229
2:8
31 31
4:20 6:1

Kühlmitteltemperatur Motordrehzahl Tankanzeige

collant temperature trancducer, motor speed level gauge

Hydrauliköltemperatur Betriebsstundenzähler Voltmeter

hydraulic oil temperature engine hour meter volt meter

28.08.2006
1 1 570 700 37
Werner Instrumente
28.08.2006
19.3

909
Seis indicators 005
910
F24 F24
5:20 9:1
D+ ESX 9:15 Abschmieren
2:9 11:2
Lüfter 1.GANG
12:14 30 30 9:7
19.3

K133 K48 2.GANG 9:7

9:9 7:3
87 87a 87 87a
X1:101 X1:104
X1:89 X1:84 X1:90 X1:91 X1:123

X1:125
X1:126

X1:124

rt
rt
ws/vi
br/rt
br
br/sw
sw
vi

vi
ws/bl
br/or
br
ws/vi
or X1:102 X1:105 or
1 2 0/3a 4 8 A15 A15 16 11 17 18 9

6 3 7 5 20 19 14 15 12 13 10

bl
bl
gr

sw
br/or

ws/rt

ws/gr
ws/br
ws/br
ws/gr

ws/gn
ws/gn

X1:106

X1:115
X1:119

X1:118
X1:121

X1:120
X1:122

X1:87 X1:88 X1:85 X1:86

X1:392/2 V02 2 1 X1:392/1 X1:397/1 1 2 V07 X1:397/2
X0:18 X0:45
Fehler
X1:394/2 V04 2 1 X1:394/1 X1:398/1 1 2 V08 X1:398/2
X1:109 X1:117

X0:52 X0:50 X1:108 X1:116

Fehler
X1:393/2 V03 2 1 X1:393/1 X1:399/1 1 2 V09 X1:399/2

20s
Fehler
X0:19 X0:13
X1:111

X1:395/2 V05 2 1 X1:395/1 X1:400/1 1 2 V10 X1:400/2

Steuerung
Gaspedal
X0:11 X0:10
Pedal X1:401/1 1 2 V11 X1:401/2
X1:112

X1:82 X1:83 4:19 X0:6 Fehler

D+
X1:403/1 1 2 V13 X1:403/2
X1:113

X1:114

X0:36 X0:51

ESX
X14:10 X1:210

BOMAG
5:20 K61:87a K61:87a 14:11
15

20s
20s
2min
K113

X1:103
30 30
3 3 3 3 1 1 3 K113 2 2 2 2 2 1 +
K146 B55 B03 B116 B129 B24 B20 B121 B122 B22 B21 B42 B05
4:13 6:11 B19
Q P P B25 P P Q P
87a 87 4 4 4 4 2 2 4 87 87a 1 1 1 1 1 2

X14:11

X1:181
X1:182
X1:182
X1:191
X1:191

X1:181

X1:183
X1:187
X1:185
X1:186
X1:183

31
X1:184
X1:184

X1:205

5:20 31 7:1
Speisepumpe Speisepumpe Zwischengetr.
6:14
Speisepumpe Speisepumpe

Rücklauffilter nur BC 972 RB

return flow filter only acc. to BC 972 RB

Modul 1: Motorfunktionen Modul 2: Maschinenfunktionen

module 1: engine functions module 2: maschine functions

28.08.2006
1 1

008 911 53
Wiring diagram 570 700 37

Werner Anzeigen, Störmeldungen 570 700 37

28.08.2006
Seis monitoring, failure indication 006
DEC 1 8:4
X1:338 X1:262 S04:12 8:10
X1:335 2 1
X1:46/2 X1:46/1
X9:4 X9:1 FM6

008 911 53
1
R32 X1:42/1
1k
2

1 1
R33 1 R34 R35 1 FM2
2k 1k 3k3 2
2 2 2

Fahrtrichtungsschalter nicht belegt X1:42/2

switch, travel direction V0R 33 13 24 44 not used
S31 X1:336
34 14 23 43
Wiring diagram 570 700 37

X9:5 X9:6 X9:3 X9:2

X1:339

X1:340 X1:337

Richtung
AGND
8,5V
Ain

X1:412/1 X1:413/1

X0:1
13 9

X0:32
X0:23
X0:29

1 1
V23 V25 K77 K77 ESX Steuerung
9:17 9:17
2 2 14 10

X0:22
X0:21
X0:46
X0:47
X0:48
X0:43

X1:412/2 X1:413/2

BOMAG
Vorwärts

Rückwärts
vorne Links
hinten Links

vorne rechts
hinten rechts

br nicht bei
X1:221 X1:223 X1:135 X1:157
V38 BC 672772
not used for
rt BC 672772

X1:149 X1:153 X1:131 X1:133 X1:155

200 ... 600mA
200 ... 600mA
200 ... 600mA
200 ... 600mA

86 86 H14
K05 K48 + 1 1 1 1 1 1 1 1
V34 Y17 V35 Y17 V32 Y16 V33 Y16 Y132 Y133 Y134 Y135

85 85 2 2 2 2 2 2 2 2

1,08A
1,08A
1,08A
1,08A

X1:70 X1:70 X1:188

28.08.2006
1 1 570 700 37
Werner Fahrpumpen, Radmotoren, Startfreigabe
28.08.2006
19.3

911
Seis driving pumps, weehl motors, starting release 1 007
912
F25 9:1

X1:343 X1:261
19.3

X40:6
X40:2
X13:3
5V EDC DEC 1
X13:1
X13:2

4:8 7:19 decelerator pedal R20 R21 R22 R23

1 k_O 1 k_O 1 k_O 1 k_O
Nur für BC 671771 RB/RS
only acc. to BC 671771 RB/RS

bl gr
KD1 KD2
S161

ws
sw
rt
ge
gn
vi
or
bei Option
Schalter Fahrstufen
switch speed ranges

X3:B
acc.to option
X40:3

decelerator pedal

Verbindung entfällt
connection not applied

X40:1
Fahrtverzögerungspedal
X1:359
X1:263

X42:5
X42:6
X41:11
X41:6
X41:4 X39:B
X41:3 X39:C
X41:5 X39:A
X41:1 X40:4
X41:2 X40:5
S04:11
8:11
Zusatzelektronik
A78

Bremse
high=Bremse auf
8,5V
AGND
Fahrstufen
additional electronic

X41:9

X42:1
X41:8

X42:2
X42:4
X41:10

X41:12
X0:1
X0:7

BOMAG
X0:23

X0:40
ESX Steuerung
X36:1
X0:62

X0:61
1

X3:C
R43

X3:A
499 _O
2
Handgas 5 k_O K77
4:8 8 7 S04:11

Bremse
AGND EDC X36:2 S120
4:8 9:17 8:10 X1:170
1./2. Fahrstufe

1 X1:151
R44

1,25A
1,25A

499 _O
1 2 Y04 1 Y03 1
H81 X36:3 V31 V37
2 2 2

X1:234
Nur für BC 671771 RB/RS
only acc. to BC 671771 RB/RS

31 X1:152 X1:192
7:20 31 9:1

Meldeleuchte Verzögerungsfunktion Magnetventil Bremse Stufenumschaltung

28.08.2006
1 1

008 911 53
Wiring diagram 570 700 37

Werner Fahrstufen, Bremse, Verzögerungspedal 570 700 37

28.08.2006
Seis speed ranges, brakes, decelerator device 1 008
K11:87 K11:87 11:1
5:20

X1:35E

F25
10A

008 911 53
X1:35A
F25 F25 10:1
8:20
2:19 30/54S 2,5qmm 6:6 ESX

2:19 30/5660S 4qmm

X1:26E
F24
6:20 X1:27E
RPM F84
4:8
10A

F67
30A X1:26A
30
K90
X1:27A
X1:257 9:4

2,5qmm
Elektronik
87 87a
Wiring diagram 570 700 37

X1:66
X2:H
X1:67
X2:G
S01

X2:U

5x0,75qmm
Leistung
2:17
22
X1:349
X1:349
X1:349

X1:258 X1:404/2 X1:405/2

X1:207
+UE/Dios
+UB/Dios
+UB/Dios

Drehzahl
CAN2
CAN2+
RxD
TxD
+ + + + + +

1x0,75qmm
2 2
V14 V15
1 1

X0:5
X0/1:3
X0/1:9

X0:4

X0:16
X0/1:10

X0:56
X0:57
X0:59
X0:60
X0:33
X0:53

X0:58

X0:28
X0:54
ESX Steuerung X1:404/1 X1:405/1 ESX Dios Modul

X0:2
X0:24
X0:25
X0:3
X0:44
1. Gang 2. Gang Summer
X0/1:11
X0/1:4

BOMAG
6:19 1.GANG
2.GANG
6:19
GND/Dios

X1:402/1 X1:410/1 X1:411/1 1

Relais Override
Motorabstellung
V42
Gehäuse Dios Modul

1 1 1 2
V12 V21 V22
2 2 2 KLIMA
GND für Knotenaddresse Dios

X1:402/2 X1:410/2 X1:411/2

X35:1
K90 86 K22 86 86 + K77/1 86 K77 86
H07
0,7A

K133
X1:185
X1:186

X1:184

85 85 85 X35:2 85 85

0,075
0,075
0,075
0,021A
0,021A

31 X1:70 X1:70 X1:70 X1:70 X1:70 X1:70

8:20 31 10:1

9:17 2:17 6:10

10:4 8:11
10:4 7:6
Lampentest Warnsummer
warning buzzer 10:4 7:5

10:4

28.08.2006
1 1 570 700 37
Werner Versorgung Steuerung, Warnsummer, Override
28.08.2006
19.3

913
Seis supply controllers, warning buzzers, override 1 009
914
F25 X15:A
9:20
X1:349
1=Links /2=Rechts Schild/Schaufel 1=senken / 2=heben 3=schließen / 4=öffnen
1=left /2=right blade/shovel 1=let down / 2=lift 3=close / 4=open
1
19.3

joystick X1:363
Initiator Armlehne

3 2 5 4 7 6 1 3 2 5 4 6 7 1 14 13 12 15 11 10 16 8 9
SW/BK
BL/BU

X2:A X2:B

X2:V

X1:44/2 X1:45/2 X1:47/2 + P18 X1:61

2 X1:43/2 2 2
FM4 2 FM5 FM7 X1:68
1 FM3 1 1
1 057 664 08

X1:44/1 X1:43/1 X1:45/1 X1:47/1 X1:69

X15:C
AGND F1 F2
8,5V

lenken
CAN+
CAN

links
rechts
lenken
AGND
8,5V
heben/
senken
senken
heben
auf/zu
schließen
öffnen
Schwim.
Lehne

links
rechts
X0:1
X0/1:1

X0:9

X0:8
X0/1:2

X0:15
X0:31
X0:17
X0:12

X0:14
X0:41

X0:39
X0:30
X0:35
X0:37

X0:38
X0:23
X0:27
X0:26

ESX Steuerung X0:34 ESX Dios Modul

BOMAG
X0:64
X0:49
X0:20
X0:42
X0:63
X0:65
X0:66
X0:67
X0:68
X0:55
X0/1:5
X0/1:6

9:15

20 19 2 R36 1 Gehäuse
housing

heben
K77/1 47_O 390 mA

senken

lenken li

lenken re.

X1:406/2
Schwimmst.
9:15
öffnen/Dios

0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA

14 13 2 R38 1
schließen/Dios

K77/1 47_O 390 mA

X1:407/2
9:15 R40
10 9 2 1
K77/1 47_O 390 mA
X1:141 X1:143 X1:364

X1:408/2
9:15 R42 X1:137 X1:139
8 7 2 1 X1:159 X1:161 X1:163 X1:165

X1:409/2
K77/1 47_O 390 mA Y92 1 Y93 1 Y108 1 Y109 1 Y102 1 Y102 1 Y111 1 Y110 1
2 2 2 2 1,08A
1,08A

2 2
2 2 2 2 2 2

V19
V16
V17

V18
X1:189
X1:181
X1:182
X1:183
X1:187
X1:188

1 1 1 1
X1:160 X1:162 X1:164 X1:166 X1:138 X1:140 X1:142 X1:144
31
9:20 31 11:1

Lenken rechts Schild senken

steering right let down blade

X1:409/1
X1:406/1
X1:407/1

X1:408/1
Lenken links Schwimmstellung Schaufel schließen
floating position close shovel
steering left
Schwimmstellung Schaufel öffnen
Schild heben
lift blade floating position open shovel

28.08.2006
1 1

008 911 53
Wiring diagram 570 700 37

Werner Lenkung und Arbeitshydraulik 570 700 37

28.08.2006
Seis steering and working hydraulic system 010
9:20 K11:87 K11:87 13:1
Abschmieren
6:19
X1:30E X1:34E X1:31E

F16 F23 F29

008 911 53
10A 15A 15A

X1:172
X1:30A X1:34A X1:31A

X1:171 Zusatzanzeige Geschwindigkeit

additional speedometer X1:341 X1:245

3A
X31:A
X34:4 1 2 86 30 S25 23
4 (+) K13
LA 15 K13
E04 1 E04 1 11:14
M08
P09 85 87 87a 24
M 8 (S) 2 2
Wiring diagram 570 700 37

Zentralschmieranlage
central lubrication system 3 () X1:246
Z 31 X31:B X31:C X1:355

X34:3 5

X33:1
X33:2
X11:1 X21:1
7,5A

+ sw
M10 R06
X30:A M
B7 A2 ge

X1:173
X1:174
K13:87
2,5A

14:19
X1:248 X28:1 Versorgung über F89
X1:356 Signalhörner Kabine
X1:241 A1 A3
br sw
2:13
23 1

BOMAG
S27 B15 3
8 S29 23
X28:3 B3 A5 S03 2 ge
Taster Schmieranlage X30:C R06
4 P09 V46
switch, lubrication system 24 X28:4
B52 bl 2 ws
4 6 1 9 1 24 br
B4 A6
X1:272 X28:2
A16

Initiator Schmierkolben
proximity switch lubrication piston
Lieferumfang GRAMMER
delivery equipment GRAMMER

X30:B 7 8 9 2 X11:2 X21:2

Im Lenkjoystick
in steering joystick

X1:190 X1:191 X1:364 X1:256

X1:342
10:20 31 31 13:1

11:16

Sensor Radmotor HL Tachograph Sitz mit Kompressor und Schalter

28.08.2006
1 1 570 700 37
Werner Hupe, Schmieranlage, Tachograph, Sitzfunktionen
28.08.2006
19.3

915
Seis horn, lubrication systhem, tachograph, seat funktions 011
916
K32:30 K32:87
14:2 14:3
F41:4
14:8
19.3

F40 G F90 F F02 F

Box 2 Box 2 Box 1
10A
7 5A
6 10A
6

X1:374
X1:265
2,5 qmm

123 13 31 42 24
1 2 3 12 11 13 14 16
Stufenschalter Frischluft
switch, fresh air
S44
5 7 11 3 1 10 14 32 41 23

Regel aus = 0,2A S28 X1:266 X1:267 X1:268

E30 Kleine Stufe = 0,3A
mittleter Stufe = 0,5A
große Stufe = 1A 1 1
Power Stufe = 1,7A R26 R27
Heizung Anlaufstrom beim Start = 4,2A
22 Ohm
10 Ohm

Heating
Schaltuhr Heizung 2 6 8 9 4 12 2 2
heater timer Lüfter
6:6
X1:373
10 9 5 6 8 7 4 15
X1:377

BOMAG
X8:1

2,5 qmm
15/54
30
87a
in

X1:375
X1:226
A53 n
1
Y14
max. 0,75A

20s; n kleiner 1300 1/min

2 20s; rpm lower 1300 1/min
X1:227 8s; n=0 1/min
8s; rpm=0 1/min S +
X1:376
M17 M

X8:2

15/54

K31
14:1
Kraftstoffpumpe Überwachung Lüfter Frischluft Lüfter
fuel pump heating unit monitoring blower blower fresh air

28.08.2006
1 1

008 911 53
Wiring diagram 570 700 37

Werner Heizung und Belüftung 570 700 37

28.08.2006
Seis heating and ventilation 012
30
4:19
F24
9:6 Raumtemperatursensor
K11:87 sensor ambient temperature
11:20
X1:36E
Ausblastemperatursensor
F33 sensor outlet temperature X1:20E

008 911 53
X1:28E X1:22E X1:33E
10A
F50
F123 F94 F31 15A
X1:36A
10A
B29 B118 X1:20A
X1:28A X1:22A X1:33A
30 + +
K62

wird durch D+ aktiviert

2:10 nicht belegt
87 87a not used X1:253 X1:383 X1:381
Versorgung für Schutzbelüftungsanlage

Bel.
X1:251 X1:249

X23:1
X24:1

X23:2
X24:2

15/54
D+
Absicherung und Verkabelung nach Angabe X25:B X25:A
Hersteller der Schutzbelüftungsanlage
supply for protected ventilation system ge rt
Lüftermodul
Wiring diagram 570 700 37

X26:6
X26:7
fuse and wiring acc. to supplier PWM +

X26:13
X26:12
X26:14
blower module

X26:1
X27:1

X26:3
X27:3
X26:5

X27:2
of protected ventilation system

X26:4
A65 Klimatronik X27:4 A53

M+ M

X26:2
X26:10
X26:11
X26:9
X26:8
br gn sw
X25:C
1

31
V43 X1:247

Ventil
2 X1:129
Kupplung

1
B117 _t Thermostat Vereisungsschutz
X22:1 X22:2 thermostat antiicing device
X1:252 2
optional
X1:130 E37 +

BOMAG
optional X1:127 2
X1:146
X7:6 X18:1 VD V36
1
4 Druckschalter

3A
pressure switch
B75 P
LP 3 HP
X29:1 X19:1 X1:414/2
or X7:5 X18:2
+ Y138 1 2 X1:147
X1:201
M26 M V26 X14:4 X17:1
0,42A

2 1
sw 2 1
X1:414/1
X19:2
X1: X29:2 V48 Y15
1 2
X1:382
1,75A

X1:70 X1:272 X1:128

X1:205 X14:5 X17:2
11:20 31 31 14:1

Zyklon Abscheider Magnetventil Heizen Magnetkupplung Verdampferlüfter

cyclone separator solenid valve heating magnetic clutch blower evaporator

Zusatzausrüstung Klimatronik KONVEKTA

Option klimatronic KONVEKTA

28.08.2006
1 1 570 700 37
Werner Schutzbelüftung, Zyklon Abscheider, Klimatronik
28.08.2006
19.3

917
Seis protected vent. system, cyclone separator, air cond. 013
918
K30 K13:87
2:19 2x6qmm
11:16
19.3

X1:2 X1:1

2x6qmm
12:9 K32:30

F41:4
12:9 + 123 3 2 1 012 7 2
F126 S22
01
S16 2A
S53 1 1 2 S45 1 S38 1 S137 1 S26 1 S128 1
01
S20 5 1 8 5 S21 5 4
ws
5 3 4 5 5 5 5 Kamera 5
camera
X1:145 15 J S 86

X1:72
P32
K61:87a

1,5A
Impulsgeber

Spannungswandler
voltage transformer
X7:1 X7:2 6:9 gn A57 Interval switch
2,5A

+24 +12 E56 4 31 31b

24V E16 1 E23 1 E25 1 E29 1 1 1

BOMAG
X1:378
B11

2,9A
2,9A
2,9A
0,6A
2,9A
12V
2 2 2 2 2 sw 2

Rundumkennleuchte
rotary beacon
U01 E32
A12 15 53a 31b 53
2,5A

31b
53
53a

+ + B51 E17 1 P15 3 R77 R77 R77 R77 + +

E24 1 E26 1 E29 1 + E57 1 1
V 1 1 1 1

2,9A
M04 M M06 M M05 M M07 M B28

2,9A
2,9A
0,6A
2,9A
B51 31
2 2,9A 2 2 2 2
Radio 2 2 2 2 Bildschirm 31 31 2

X1:150
1,7A
1,7A
1,7A
1,7A
7,9A
2,5A
3,3A
2,5A

radio monitor
K31
12:19 Scheinwerfer vorn X7:3 X7:4 Spiegelheizung Wischer vorn Wischer hinten Signalhorn
2x6qmm
head lights front mirror heating wiper, front wiper, rear warning horn

X1:3 X1:4 Scheinwerfer links/rechts Innenleuchten 1 1 Wascherpumpe Wascherpumpe

head lights lh./rh. inside light, cabin E28 E27 washer pump washer pump
2,9A 2,9A

X1:189
X1:189
2 2

31 X1:190 X1:190 31
13:20

Scheinwerfer Motorraum
head lights, engine area

Arbeitsscheinwerfer hinten
working head lights, rear

28.08.2006
1 1

008 911 53
Wiring diagram 570 700 37

Werner Kabine und Anbauteile 570 700 37

28.08.2006
Seis cabin and attachmentparts 014
Name Bl. Pf. Benennung title TYP
A12

A15
014
Wiring diagram 570 700 37
A15 006
006
2
7
13
Radio
Ueberwachungsmodul
Ueberwachungsmodul
Radio
monitoring module
monitoring module
19.3
A16 011 9 Elektronik Tachograph Electronic system, tachograph
A48 004 9 Elektronische Motorsteuerung Electronic engine management
A53 012 14 Modul Luefterueberwachung Modul blower monitoring
A53 013 18 Modul Luefterueberwachung Modul blower monitoring
A57 014 14 Intervallschalter Scheibenwischer Interval switch, wiper
A65 013 14 Steuerung Klimatronik Controller klimatronic
A78 008 3 Zusatzelektronik Additional control unit

B03 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B05 006 18 Druckschalter Bremse Pressure switch, brake
B08 010 19 Naeherungsinitiator Fahrhebel ’0’Stell. Proximity switch, travel lever ’0’ pos. max. 1,08A
Seis
28.08.2006
Werner
28.08.2006

B11 014 19 Signalhorn Warning horn 2,5A

B133 004 11 Sensor Ladeluftdruck / temperatur sesnor charging air prssure / temperature
Bauteilliste

E01 005 14 Beleuchtung Tankanzeige Illumination, level gauge

F00 002 2 Hauptsicherung Batterie Fuse, main, battery 250A

F23 011 14 Sicherung Signalhorn Fuse, warning horn 15A

F41 014 8 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A

19.3 F85
F86
F89
014
014
002
6
10
12
Sicherung, Scheinwerfer vorne
Sicherung, Scheinwerfer hinten
Sicherung, Zigarettenanzuender
Fuse, head light front
Fuse, head lights rear
Fuse, cigarette lighter
20A
Wiring diagram 570 700 37
15A
30A
F90 012 8 Sicherung, Ansteuerung Fuse, actuation 5A
F93 004 4 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F94 013 3 Sicherung Schutzbelueftung Fuse, protected ventilation syst.
F98 014 13 Sicherung Spiegelheizung fuse,mirror heating 10A
F99 014 9 Sicherung Motorraumbeleuchtung fuse, illumination engine area 15A
FM1 008 13 Platinensicherung Multifuse 0,2A
FM2 007 19 Platinensicherung Multifuse 0,2A
FM3 010 8 Platinensicherung Multifuse 0,2A
FM4 010 4 Platinensicherung Multifuse 0,2A
FM5 010 11 Platinensicherung Multifuse 0,2A
FM6 007 7 Platinensicherung Multifuse 0,2A
Seis
28.08.2006
Werner
28.08.2006

FM7 010 13 Platinensicherung Multifuse 0,2A

G01 002 2 Batterie Battery

G02 002 5 Generator Generator 28V/80A
G03 002 2 Batterie Battery

H04 004 10 Meldeleuchte Betriebsstoerung Indicator light, breakdown

K05 007 2 Relais Startstrom Relay, starting current BOSCHW

K113 006 11 Zeitrelais Timing relay BOSCHW

K133 009 9 Relais Test Relay, test BOSCHW
Bauteilliste

K146 004 13 Relais Kühlmitteltemperatur relay, coolant temperature BOSCHW

K77/1 009 15 Relais Override Relay, override SDS/SF4

M01 003 9 Starter Starter

P00 005 12 Betriebsstundenzaehler Operating hour meter

R02 004 2 Gluehkerze Glow plug

R24 004 5 Widerstand Resistor 10 kOHM

R26 012 17 Widerstand Resistor 22 OHM
R27 012 18 Widerstand Resistor 10 OHM
R32 007 5 Widerstand Resistor 1 kOhm
R33 007 5 Widerstand Resistor 2 kOhm
11

R34 007 6 Widerstand Resistor 1 kOhm

R35 007 8 Widerstand Resistor 3,3 kOhm
R36 010 5 Widerstand Resistor 47 OHM
R38 010 5 Widerstand Resistor 47 OHM
570 700 37

R40 010 5 Widerstand Resistor 47 OHM

R42 010 5 Widerstand Resistor 47 OHM
R43 008 7 Widerstand Resistor 499Ohm
R44 008 7 Widerstand Resistor 499Ohm
R77 014 12 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
102

R77 014 13 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W

R77 014 13 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
920 R77 014 14 Widerstandsheizung Aussenspiegel BOMAG
Resistor heating outside mirror 40W 008 911 53
Name Bl. Pf. Benennung title TYP

Wiring
S00 diagram
003 9
S01
570 700 37
Startschalter
002 17 Schalter NOT AUS
Starter switch
Switch, emergency off
MERIT
NOTAUSH
19.3
S01 002 17 Schalter NOT AUS Switch, emergency off
S02 008 16 Fahrstufenschalter Switch, speed range selector
S02 008 19 Fahrstufenschalter Switch, speed range selector
S03 011 14 Taster Signalhorn Push button, warning horn
S04 008 10 Bremsschalter Switch, brake
S16 014 5 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 014 14 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 18 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S22 014 16 Schalter Scheibenwascher vorne Switch, windscreen washer, front
S25 011 19 Schalter Fahrersitzheizung Switch, heating, operator’s seat
S26 014 10 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
Seis
28.08.2006
Werner
28.08.2006

S27 011 3 Taster Zentralschmieranlage Push botton, central lubrication system

S28 012 8 Schalter Kabinenheizung Switch, cabin heating
S29 011 18 Schalter Fahrersitz Hoehenverstellung Switch, operator’s seat height adjustm.
S30 002 2 Batterietrennschalter Switch, battery disconnect
S31 007 5 Schalter Fahrtrichtung Switch, travel direction
S38 014 8 Schalter Kennleuchte Switch, warning light
S44 012 17 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 4 Schalter Arbeitsbeleuchtung Switch, working lights
S70 010 10 Schalter Schubsschild Switch, dozer blade WAGO
S71 010 3 Schalter Lenkung Switch, steering max. 1,08A
S118 004 18 Schalter Fehlerdiagnose Switch, fault diagnosis
S119 004 6 Elektronisches Fusspedal Electronic foot pedal
S120 008 7 Schalter Motordrehzahl Switch, engine speed 5 kOhm
S128 014 13 Schalter Spiegelheizung Switch, mirror heating
S137 014 9 Schalter Motorraumbeleuchtung Switch, illumination engine area
S160 008 4 Schalter Aktivierung Verzögerungspedal Switch, enable decelerator pedal
S161 008 6 Verzögerungspedal decelerator pedal

U01 014 1 Spannungswandler Voltage transformer

V01 002 7 Diode Diode WAGO

V10 006 12 Diode Diode WAGO

V11 006 12 Diode Diode WAGO
Bauteilliste

V12 009 7 Diode Diode WAGO

V13 006 12 Diode Diode WAGO
V14 009 14 Diode Diode Wago
V15 009 15 Diode Diode Wago
V16 010 2 Diode Diode WAGO
V17 010 3 Diode Diode WAGO
V18 010 2 Diode Diode WAGO
V19 010 2 Diode Diode WAGO
V21 009 9 Diode Diode WAGO
V22 009 10 Diode Diode WAGO
V23 007 2 Diode Diode WAGO
V25 007 3 Diode Diode WAGO
V26 013 14 Diode Diode WAGO
V31 008 10 Diode Diode Lütze
V32 007 9 Diode Diode Lütze
V33 007 11 Diode Diode Lütze
V34 007 5 Diode Diode Lütze
V35 007 7 Diode Diode Lütze
V36 013 19 Diode Diode FE5B
V37 008 13 Diode Diode Lütze
V38 007 2 Diode Diode FE5B KabeldiodeDiode
V42 009 13 Diode (A2) Diode (A2) Diodenmodul
V43 013 6 Diode (A3) Diode (A3) Diodenmodul
V46 011 15 Diode (A6) Diode (A6) Diodenmodul
V47 003 12 Diode (A7) Diode (A7) Diodenmodul
V48 013 15 Diode (A8) Diode (A8) Diodenmodul

X0/1:1 010 18 DIOS STECKER Dios connector

X0:1 008 13 ESX STECKER esx connector

X0:1 010 7 ESX STECKER esx connector
X0:2 009 4 ESX STECKER esx connector
X0:3 009 9 ESX STECKER esx connector
X0:4 009 10 ESX STECKER esx connector
11

X0:5 009 11 ESX STECKER esx connector

X0:6 006 9 ESX STECKER esx connector
X0:7 008 14 ESX STECKER esx connector
X0:8 010 3 ESX STECKER esx connector
570 700 37

X0:9 010 7 ESX STECKER esx connector

X0:10 006 10 ESX STECKER esx connector
X0:11 006 9 ESX STECKER esx connector
X0:12 010 14 ESX STECKER esx connector
X0:13 006 10 ESX STECKER esx connector
103

X0:14 010 6 ESX STECKER esx connector

X0:15 010 7 ESX STECKER esx connector
008 911
X0:16 53 009 4 ESX STECKER BOMAG
esx connector 921
Name Bl. Pf. Benennung title TYP

19.3 X0:17
X0:18
X0:19
010
006
006
13
9
9
ESX STECKER
ESX STECKER
ESX STECKER
esx connector
esx connector
esx connector
Wiring diagram 570 700 37
X0:20 010 8 ESX STECKER esx connector
X0:21 007 10 ESX STECKER esx connector
X0:22 007 8 ESX STECKER esx connector
X0:23 007 11 ESX STECKER esx connector
X0:23 008 13 ESX STECKER esx connector
X0:23 010 8 ESX STECKER esx connector
X0:24 009 6 ESX STECKER esx connector
X0:25 009 7 ESX STECKER esx connector
X0:26 010 17 ESX STECKER esx connector
X0:27 010 16 ESX STECKER esx connector
X0:28 009 6 ESX STECKER esx connector
Seis
28.08.2006
Werner
28.08.2006

X0:29 007 19 ESX STECKER esx connector

X0:30 010 10 ESX STECKER esx connector
X0:31 010 12 ESX STECKER esx connector
X0:32 007 7 ESX STECKER esx connector
X0:33 009 9 ESX STECKER esx connector
X0:34 010 13 ESX STECKER esx connector
X0:35 010 11 ESX STECKER esx connector
X0:36 006 9 ESX STECKER esx connector
X0:37 010 15 ESX STECKER esx connector
X0:38 010 5 ESX STECKER esx connector
X0:39 010 5 ESX STECKER esx connector
X0:40 008 10 ESX STECKER esx connector
X0:41 010 11 ESX STECKER esx connector
X0:42 010 9 ESX STECKER esx connector
X0:43 007 19 ESX STECKER esx connector
X0:44 009 13 ESX STECKER esx connector
X0:45 006 10 ESX STECKER esx connector
X0:46 007 14 ESX STECKER esx connector
X0:47 007 16 ESX STECKER esx connector
X0:48 007 17 ESX STECKER esx connector
X0:49 010 7 ESX STECKER esx connector
X0:50 006 10 ESX STECKER esx connector
X0:51 006 10 ESX STECKER esx connector
X0:52 006 9 ESX STECKER esx connector
X0:53 009 9 ESX STECKER esx connector
X0:54 009 13 ESX STECKER esx connector
X0:55 010 16 ESX STECKER esx connector
X0:56 009 7 ESX STECKER esx connector
X0:57 009 8 ESX STECKER esx connector
component listing

X0:58 009 8 ESX STECKER esx connector

X0:59 009 8 ESX STECKER esx connector
Bauteilliste

X0:60 009 9 ESX STECKER esx connector

X0:61 008 10 ESX STECKER esx connector
X0:62 008 14 ESX STECKER esx connector
X0:63 010 11 ESX STECKER esx connector
X0:64 010 6 ESX STECKER esx connector
X0:65 010 14 ESX STECKER esx connector
X0:66 010 15 ESX STECKER esx connector
X0:67 010 15 ESX STECKER esx connector
X0:68 010 16 ESX STECKER esx connector
X1: 013 2 Wago Zentralelektrik Wago ebox
X1:1 014 7 Wago Zentralelektrik Wago ebox
X1:2 014 7 Wago Zentralelektrik Wago ebox
X1:3 014 2 Wago Zentralelektrik Wago ebox
X1:4 014 2 Wago Zentralelektrik Wago ebox
X1:5 004 20 Wago Zentralelektrik Wago ebox
X1:6 002 17 Wago Zentralelektrik Wago ebox
X1:7 003 9 Wago Zentralelektrik Wago ebox
X1:8 003 9 Wago Zentralelektrik Wago ebox
X1:9 003 9 Wago Zentralelektrik Wago ebox
X1:61 010 18 Wago Zentralelektrik Wago ebox
X1:62 004 15 Wago Zentralelektrik Wago ebox
X1:63 010 18 Wago Zentralelektrik Wago ebox
X1:64 004 16 Wago Zentralelektrik Wago ebox
X1:65 004 16 Wago Zentralelektrik Wago ebox
X1:66 009 10 Wago Zentralelektrik Wago ebox
X1:67 009 11 Wago Zentralelektrik Wago ebox
X1:68 010 18 Wago Zentralelektrik Wago ebox
X1:69 010 18 Wago Zentralelektrik Wago ebox
X1:70 002 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 003 16 Wago Zentralelektrik Wago ebox
X1:70 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 009 4 Wago Zentralelektrik Wago ebox
X1:70 009 6 Wago Zentralelektrik Wago ebox
X1:70 009 9 Wago Zentralelektrik Wago ebox
X1:70 009 13 Wago Zentralelektrik Wago ebox
X1:70 009 15 Wago Zentralelektrik Wago ebox
4

X1:70 009 17 Wago Zentralelektrik Wago ebox

X1:70 013 6 Wago Zentralelektrik Wago ebox
X1:71 004 17 Wago Zentralelektrik Wago ebox
X1:72 014 11 Wago Zentralelektrik Wago ebox
X1:81 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
11

X1:82 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:83 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:84 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:85 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
570 700 37

X1:86 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:87 006 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:88 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:89 006 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:90 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
104

X1:91 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:92 004 12 Wago Zentralelektrik Wago ebox
922 X1:93 004 13 Wago Zentralelektrik BOMAG
Wago ebox 008 911 53
Name Bl. Pf. Benennung title TYP
X1:94

X1:102
004
Wiring diagram 570 700 37
X1:101 006
006
14
7
9
Wago Zentralelektrik
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
Wago ebox
WAGO EBOX
WAGO EBOX
19.3
X1:103 006 5 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:104 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:105 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:106 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:108 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:109 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:110 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:111 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:112 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:113 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:114 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
28.08.2006
Werner
28.08.2006

X1:115 006 14 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:116 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:117 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:118 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:119 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:120 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:121 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:122 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:123 006 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:124 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:125 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:126 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:127 013 13 Wago Zentralelektrik Wago ebox
X1:128 013 13 Wago Zentralelektrik Wago ebox
X1:129 013 15 Wago Zentralelektrik Wago ebox
X1:130 013 15 Wago Zentralelektrik Wago ebox
X1:131 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:132 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:133 007 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:134 007 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:135 007 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:136 007 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:137 010 11 Wago Zentralelektrik Wago ebox
X1:138 010 11 Wago Zentralelektrik Wago ebox
X1:139 010 12 Wago Zentralelektrik Wago ebox
X1:140 010 12 Wago Zentralelektrik Wago ebox
X1:141 010 18 Wago Zentralelektrik Wago ebox
X1:142 010 18 Wago Zentralelektrik Wago ebox
X1:143 010 19 Wago Zentralelektrik Wago ebox
component listing

X1:144 010 19 Wago Zentralelektrik Wago ebox

X1:145 014 9 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:146 013 15 Wago Zentralelektrik Wago ebox

X1:147 013 15 Wago Zentralelektrik Wago ebox
X1:148 005 8 Wago Zentralelektrik Wago ebox
X1:149 007 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:150 014 10 Wago Zentralelektrik Wago ebox
X1:151 008 10 Wago Zentralelektrik Wago ebox
X1:152 008 10 Wago Zentralelektrik Wago ebox
X1:153 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:154 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:155 007 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:156 007 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:157 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:158 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:159 010 6 Wago Zentralelektrik Wago ebox
X1:160 010 6 Wago Zentralelektrik Wago ebox
X1:161 010 7 Wago Zentralelektrik Wago ebox
X1:162 010 7 Wago Zentralelektrik Wago ebox
X1:163 010 8 Wago Zentralelektrik Wago ebox
X1:164 010 8 Wago Zentralelektrik Wago ebox
X1:165 010 9 Wago Zentralelektrik Wago ebox
X1:166 010 9 Wago Zentralelektrik Wago ebox
X1:170 008 14 Wago Zentralelektrik Wago ebox
X1:171 011 4 Wago Zentralelektrik Wago ebox
X1:172 011 3 Wago Zentralelektrik Wago ebox
X1:173 011 3 Wago Zentralelektrik Wago ebox
X1:174 011 4 Wago Zentralelektrik Wago ebox
X1:181 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:181 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:181 010 14 Wago Zentralelektrik Wago ebox
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:182 010 15 Wago Zentralelektrik Wago ebox
X1:183 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:183 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:183 010 15 Wago Zentralelektrik Wago ebox
X1:184 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:184 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
5

X1:184 009 18 Wago Zentralelektrik Wago ebox

X1:185 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:185 009 19 Wago Zentralelektrik Wago ebox
X1:186 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:186 009 19 Wago Zentralelektrik Wago ebox
11

X1:187 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:187 010 16 Wago Zentralelektrik Wago ebox
X1:188 007 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:188 010 16 Wago Zentralelektrik Wago ebox
570 700 37

X1:189 010 14 Wago Zentralelektrik Wago ebox

X1:189 014 9 Wago Zentralelektrik Wago ebox
X1:189 014 9 Wago Zentralelektrik Wago ebox
X1:190 011 6 Wago Zentralelektrik Wago ebox
X1:190 014 10 Wago Zentralelektrik Wago ebox
105

X1:190 014 11 Wago Zentralelektrik Wago ebox

X1:191 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
008 911
X1:19153 006 15 WAGO ZENTRALELEKTRIK BOMAG
WAGO EBOX 923
Name Bl. Pf. Benennung title TYP

19.3 X1:191
X1:192
X1:201
011
008
013
7
14
15
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago ebox
Wago ebox
Wago ebox
Wiring diagram 570 700 37
X1:202 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:205 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:205 013 15 Wago Zentralelektrik Wago ebox
X1:207 009 4 Wago Zentralelektrik Wago ebox
X1:20A 013 19 Sika Klemme fuse terminal
X1:20E 013 19 Sika Klemme fuse terminal
X1:210 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:21A 002 12 Sika Klemme fuse terminal
X1:21E 002 12 Sika Klemme fuse terminal
X1:221 007 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:222 007 14 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
28.08.2006
Werner
28.08.2006

X1:223 007 16 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:224 007 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:226 012 3 Wago Zentralelektrik Wago ebox
X1:227 012 3 Wago Zentralelektrik Wago ebox
X1:228 005 15 Wago Zentralelektrik Wago ebox
X1:229 005 15 Wago Zentralelektrik Wago ebox
X1:22A 013 3 Sika Klemme fuse terminal
X1:22E 013 3 Sika Klemme fuse terminal
X1:231 004 6 Wago Zentralelektrik Wago ebox
X1:232 004 6 Wago Zentralelektrik Wago ebox
X1:233 004 7 Wago Zentralelektrik Wago ebox
X1:234 008 5 Wago Zentralelektrik Wago ebox
X1:235 004 6 Wago Zentralelektrik Wago ebox
X1:236 004 6 Wago Zentralelektrik Wago ebox
X1:237 004 7 Wago Zentralelektrik Wago ebox
X1:23A 003 9 Sika Klemme fuse terminal
X1:23E 002 3 Sika Klemme fuse terminal
X1:23E 003 9 Sika Klemme fuse terminal
X1:241 002 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:242 002 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:243 002 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:244 004 10 Wago Zentralelektrik Wago ebox
X1:245 011 19 Wago Zentralelektrik Wago ebox
X1:246 011 19 Wago Zentralelektrik Wago ebox
X1:247 013 15 Wago Zentralelektrik Wago ebox
X1:248 011 3 Wago Zentralelektrik Wago ebox
X1:249 013 10 Wago Zentralelektrik Wago ebox
X1:24A 004 4 Sika Klemme fuse terminal
X1:24E 004 4 Sika Klemme fuse terminal
component listing

X1:250 004 10 Wago Zentralelektrik Wago ebox

X1:251 013 9 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:252 013 13 Wago Zentralelektrik Wago ebox

X1:253 013 17 Wago Zentralelektrik Wago ebox
X1:255 004 18 Wago Zentralelektrik Wago ebox
X1:256 002 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:256 003 12 Wago Zentralelektrik Wago ebox
X1:256 011 15 Wago Zentralelektrik Wago ebox
X1:257 009 13 Wago Zentralelektrik Wago ebox
X1:258 009 13 Wago Zentralelektrik Wago ebox
X1:259 002 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:25A 002 15 Sika Klemme fuse terminal
X1:25E 002 15 Sika Klemme fuse terminal
X1:260 002 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:261 008 10 Wago Zentralelektrik Wago ebox
X1:262 007 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:262 008 10 Wago Zentralelektrik Wago ebox
X1:263 008 10 Wago Zentralelektrik Wago ebox
X1:265 012 18 Wago Zentralelektrik Wago ebox
X1:266 012 17 Wago Zentralelektrik Wago ebox
X1:267 012 18 Wago Zentralelektrik Wago ebox
X1:268 012 19 Wago Zentralelektrik Wago ebox
X1:269 004 11 Wago Zentralelektrik Wago ebox
X1:26A 009 13 Sika Klemme fuse terminal
X1:26E 009 13 Sika Klemme fuse terminal
X1:270 004 11 Wago Zentralelektrik Wago ebox
X1:272 011 3 Wago Zentralelektrik Wago ebox
X1:272 013 9 Wago Zentralelektrik Wago ebox
X1:27A 009 7 Sika Klemme fuse terminal
X1:27E 009 7 Sika Klemme fuse terminal
X1:28A 013 2 Sika Klemme fuse terminal
X1:28E 013 2 Sika Klemme fuse terminal
X1:291 005 7 Wago Zentralelektrik Wago ebox
X1:292 005 11 Wago Zentralelektrik Wago ebox
X1:293 003 10 Wago Zentralelektrik Wago ebox
X1:294 005 5 Wago Zentralelektrik Wago ebox
X1:295 005 7 Wago Zentralelektrik Wago ebox
X1:296 005 15 Wago Zentralelektrik Wago ebox
X1:298 002 11 WAGO ZENTRALELEKTRIK WAGO EBOX
6

X1:298 005 11 Wago Zentralelektrik Wago ebox

X1:299 004 20 Wago Zentralelektrik Wago ebox
X1:299 005 5 Wago Zentralelektrik Wago ebox
X1:29A 005 5 Sika Klemme fuse terminal
X1:29E 005 5 Sika Klemme fuse terminal
11

X1:300 005 7 Wago Zentralelektrik Wago ebox

X1:301 005 11 Wago Zentralelektrik Wago ebox
X1:302 003 13 Wago Zentralelektrik Wago ebox
X1:303 005 8 Wago Zentralelektrik Wago ebox
570 700 37

X1:30A 011 4 Sika Klemme fuse terminal

X1:30E 011 4 Sika Klemme fuse terminal
X1:31A 011 18 Sika Klemme fuse terminal
X1:31E 002 17 SIKA KLEMME fuse terminal
X1:31E 011 18 Sika Klemme fuse terminal
106

X1:321 010 6 Wago Zentralelektrik Wago ebox

X1:322 010 8 Wago Zentralelektrik Wago ebox
924 X1:323 010 7 Wago Zentralelektrik BOMAG
Wago ebox 008 911 53
Name Bl. Pf. Benennung title TYP
X1:324

X1:326
010
Wiring diagram 570 700 37
X1:325 010
010
7
6
7
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago ebox
Wago ebox
Wago ebox
19.3
X1:327 010 11 Wago Zentralelektrik Wago ebox
X1:328 010 11 Wago Zentralelektrik Wago ebox
X1:329 010 10 Wago Zentralelektrik Wago ebox
X1:32A 002 17 Sika Klemme fuse terminal
X1:32E 002 17 Sika Klemme fuse terminal
X1:330 010 10 Wago Zentralelektrik Wago ebox
X1:331 010 11 Wago Zentralelektrik Wago ebox
X1:332 010 11 Wago Zentralelektrik Wago ebox
X1:333 010 14 Wago Zentralelektrik Wago ebox
X1:334 010 14 Wago Zentralelektrik Wago ebox
X1:335 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
28.08.2006
Werner
28.08.2006

X1:336 007 9 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:337 007 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:338 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:339 007 5 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:33A 013 6 Sika Klemme fuse terminal
X1:33E 002 17 SIKA KLEMME fuse terminal
X1:33E 013 6 Sika Klemme fuse terminal
X1:340 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:341 011 18 Wago Zentralelektrik Wago ebox
X1:342 011 18 Wago Zentralelektrik Wago ebox
X1:343 008 4 Wago Zentralelektrik Wago ebox
X1:343 010 5 Wago Zentralelektrik Wago ebox
X1:344 010 4 Wago Zentralelektrik Wago ebox
X1:345 010 4 Wago Zentralelektrik Wago ebox
X1:346 010 3 Wago Zentralelektrik Wago ebox
X1:347 010 5 Wago Zentralelektrik Wago ebox
X1:348 010 5 Wago Zentralelektrik Wago ebox
X1:349 009 18 Wago Zentralelektrik Wago ebox
X1:349 009 19 Wago Zentralelektrik Wago ebox
X1:349 009 19 Wago Zentralelektrik Wago ebox
X1:349 010 17 Wago Zentralelektrik Wago ebox
X1:34A 011 14 Sika Klemme fuse terminal
X1:34E 011 14 Sika Klemme fuse terminal
X1:350 010 13 Wago Zentralelektrik Wago ebox
X1:351 010 12 Wago Zentralelektrik Wago ebox
X1:352 010 12 Wago Zentralelektrik Wago ebox
X1:353 010 13 Wago Zentralelektrik Wago ebox
X1:354 010 13 Wago Zentralelektrik Wago ebox
X1:355 011 19 Wago Zentralelektrik Wago ebox
component listing

X1:356 011 14 Wago Zentralelektrik Wago ebox

X1:357 008 17 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:358 008 13 Wago Zentralelektrik Wago ebox

X1:359 008 14 Wago Zentralelektrik Wago ebox
X1:35A 009 2 Sika Klemme fuse terminal
X1:35E 009 2 Sika Klemme fuse terminal
X1:363 010 15 Wago Zentralelektrik Wago ebox
X1:364 010 19 Wago Zentralelektrik Wago ebox
X1:364 011 14 Wago Zentralelektrik Wago ebox
X1:36A 013 9 Sika Klemme fuse terminal
X1:36E 013 9 Sika Klemme fuse terminal
X1:371 003 16 Wago Zentralelektrik Wago ebox
X1:372 014 19 Wago Zentralelektrik Wago ebox
X1:372 014 20 Wago Zentralelektrik Wago ebox
X1:373 012 15 Wago Zentralelektrik Wago ebox
X1:374 012 15 Wago Zentralelektrik Wago ebox
X1:375 012 3 Wago Zentralelektrik Wago ebox
X1:376 012 3 Wago Zentralelektrik Wago ebox
X1:377 012 19 Wago Zentralelektrik Wago ebox
X1:378 014 10 Wago Zentralelektrik Wago ebox
X1:381 013 19 Wago Zentralelektrik Wago ebox
X1:382 013 18 Wago Zentralelektrik Wago ebox
X1:383 013 17 Wago Zentralelektrik Wago ebox
X1:391/1 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:391/2 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:392/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:392/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:393/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:393/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:394/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:394/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:395/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:395/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:397/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:397/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:398/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:398/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:399/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:399/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
7

X1:400/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:400/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:401/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:401/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:402/1 009 7 Wago Zentralelektrik Wago ebox
11

X1:402/2 009 7 Wago Zentralelektrik Wago ebox

X1:403/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:403/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:404/1 009 14 Wago Zentralelektrik Wago ebox
570 700 37

X1:404/2 009 14 Wago Zentralelektrik Wago ebox

X1:405/1 009 15 Wago Zentralelektrik Wago ebox
X1:405/2 009 15 Wago Zentralelektrik Wago ebox
X1:406/1 010 2 Wago Zentralelektrik Wago ebox
X1:406/2 010 2 Wago Zentralelektrik Wago ebox
107

X1:407/1 010 3 Wago Zentralelektrik Wago ebox

X1:407/2 010 3 Wago Zentralelektrik Wago ebox
008 911 53
X1:408/1 010 2 Wago Zentralelektrik BOMAG
Wago ebox 925
Name Bl. Pf. Benennung title TYP

19.3 X1:408/2
X1:409/1
X1:409/2
010
010
010
2
2
2
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago ebox
Wago ebox
Wago ebox
Wiring diagram 570 700 37
X1:41/1 008 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:41/2 008 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:410/1 009 9 Wago Zentralelektrik Wago ebox
X1:410/2 009 9 Wago Zentralelektrik Wago ebox
X1:411/1 009 10 Wago Zentralelektrik Wago ebox
X1:411/2 009 10 Wago Zentralelektrik Wago ebox
X1:412/1 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:412/2 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:413/1 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:413/2 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:414/1 013 14 Wago Zentralelektrik Wago ebox
Seis
28.08.2006
Werner
28.08.2006

X1:414/2 013 14 Wago Zentralelektrik Wago ebox

X1:42/1 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:42/2 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:43/1 010 8 Wago Zentralelektrik Wago ebox
X1:43/2 010 8 Wago Zentralelektrik Wago ebox
X1:44/1 010 4 Wago Zentralelektrik Wago ebox
X1:44/2 010 4 Wago Zentralelektrik Wago ebox
X1:45/1 010 11 Wago Zentralelektrik Wago ebox
X1:45/2 010 11 Wago Zentralelektrik Wago ebox
X1:46/1 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:46/2 007 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:47/1 010 13 Wago Zentralelektrik Wago ebox
X1:47/2 010 13 Wago Zentralelektrik Wago ebox
X2:A 010 18 Datenschnittstelle data interface
X2:B 010 18 Datenschnittstelle data interface
X2:G 009 11 Datenschnittstelle data interface
X2:H 009 10 Datenschnittstelle data interface
X2:J 002 11 Datenschnittstelle data interface
X2:N 002 11 Datenschnittstelle data interface
X2:U 009 11 Datenschnittstelle data interface
X2:V 010 15 Datenschnittstelle data interface
X3:A 008 3 Stecker Handgas connector hand throttle
X3:B 008 2 Stecker Handgas connector hand throttle
X3:C 008 2 Stecker Handgas connector hand throttle
X4:A 004 15 EMR Diagnose EMRdiagnosis
X4:B 004 17 EMR Diagnose EMRdiagnosis
X4:F 004 16 EMR Diagnose EMRdiagnosis
X4:G 004 16 EMR Diagnose EMRdiagnosis
X4:H 004 15 EMR Diagnose EMRdiagnosis
component listing

X4:K 004 17 EMR Diagnose EMRdiagnosis

X4:M 004 16 EMR Diagnose EMRdiagnosis
Bauteilliste

X5:1 005 7 Deutsch Stecker Senso Deutsch Connector sensor

X6:1 004 10 Wago Zentralelektrik Wago ebox
X6:2 004 10 Wago Zentralelektrik Wago ebox
X6:3 004 11 Wago Zentralelektrik Wago ebox
X6:4 004 11 Wago Zentralelektrik Wago ebox
X6:5 004 15 Wago Zentralelektrik Wago ebox
X6:6 004 15 Wago Zentralelektrik Wago ebox
X6:7 004 16 Wago Zentralelektrik Wago ebox
X6:8 004 16 Wago Zentralelektrik Wago ebox
X6:9 004 16 Wago Zentralelektrik Wago ebox
X6:10 004 17 Wago Zentralelektrik Wago ebox
X7:1 014 9 Stecker Rops connector on rops
X7:2 014 9 Stecker Rops connector on rops
X7:3 014 9 Stecker Rops connector on rops
X7:4 014 9 Stecker Rops connector on rops
X7:5 013 16 Stecker Rops connector on rops
X7:6 013 16 Stecker Rops connector on rops
X8:1 012 3 Pumpenstecker Kabine connector pump cabin;
X8:2 012 3 Pumpenstecker Kabine connector pump cabin;
X9:1 007 5 Stecker Schalter Rich connector direction switch
X9:2 007 9 Stecker Schalter Rich connector direction switch
X9:3 007 7 Stecker Schalter Rich connector direction switch
X9:4 007 5 Stecker Schalter Rich connector direction switch
X9:5 007 5 Stecker Schalter Rich connector direction switch
X9:6 007 6 Stecker Schalter Rich connector direction switch
XS 002 15 Steckdose Socket
X10:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X10:B 004 6 AMP Stecker Gaspedal AMP connector throttle
X10:C 004 6 AMP Stecker Gaspedal AMP connector throttle
X11:1 011 18 Schnittstelle Sitz connector drivers seat
X11:2 011 18 Schnittstelle Sitz connector drivers seat
X12:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X12:B 004 8 AMP Stecker Gaspedal AMP connector throttle
X12:C 004 7 AMP Stecker Gaspedal AMP connector throttle
X13:1 008 17 Stecker Stufenschalte connector speed range switch
X13:2 008 18 Stecker Stufenschalte connector speed range switch
X13:3 008 14 Stecker Stufenschalte connector speed range switch
8

X14:4 013 15 Stecker Motor connector engine

X14:5 013 16 Stecker Motor connector engine
X14:6 002 6 Motorschnittstelle engine interface
X14:7 002 6 Motorschnittstelle engine interface
X14:8 005 7 Motorschnittstelle engine interface
11

X14:9 003 9 Motorschnittstelle engine interface

X14:10 006 12 Stecker Motor connector engine
X14:11 006 12 Stecker Motor connector engine
X15:A 010 18 Stecker Lehne links connector arm rest lh.
570 700 37

X15:B 010 18 Stecker Lehne links connector arm rest lh.

X15:C 010 19 Stecker Lehne links connector arm rest lh.
X17:1 013 16 Stecker Klimakupplung connector clima clutch
X17:2 013 16 Stecker Klimakupplung connector clima clutch
X18:1 013 16 Stecker Druckschalter connector pressure switch
108

X18:2 013 16 Stecker Druckschalter connector pressure switch

X19:1 013 13 Stecker Heizventil connector heating valve
926 X19:2 013 13 Stecker Heizventil BOMAG
connector heating valve 008 911 53
Name Bl. Pf. Benennung title TYP
X21:1

X22:1
011
Wiring diagram 570 700 37
X21:2 011
013
19
19
10
Schnittstelle Sitz
Schnittstelle Sitz
Stecker Luftklappe
connector drivers seat
connector drivers seat
connector air flap
19.3
X22:2 013 11 Stecker Luftklappe connector air flap
X23:1 013 14 Stecker Sensor connector sensor
X23:2 013 14 Stecker Sensor connector sensor
X24:1 013 15 Stecker Sensor connector sensor
X24:2 013 15 Stecker Sensor connector sensor
X25:A 013 19 Stecker Lüfter connector blower
X25:B 013 18 Stecker Lüfter connector blower
X25:C 013 18 Stecker Lüfter connector blower
X26:1 013 9 Stecker Klimasteuerun connector climacontrol
X26:2 013 9 Stecker Klimasteuerun connector climacontrol
X26:3 013 11 Stecker Klimasteuerun connector climacontrol
Seis
28.08.2006
Werner
28.08.2006

X26:4 013 10 Stecker Klimasteuerun connector climacontrol

X26:5 013 16 Stecker Klimasteuerun connector climacontrol
X26:6 013 12 Stecker Klimasteuerun connector climacontrol
X26:7 013 12 Stecker Klimasteuerun connector climacontrol
X26:8 013 15 Stecker Klimasteuerun connector climacontrol
X26:9 013 13 Stecker Klimasteuerun connector climacontrol
X26:10 013 10 Stecker Klimasteuerun connector climacontrol
X26:11 013 11 Stecker Klimasteuerun connector climacontrol
X26:12 013 13 Stecker Klimasteuerun connector climacontrol
X26:13 013 13 Stecker Klimasteuerun connector climacontrol
X26:14 013 13 Stecker Klimasteuerun connector climacontrol
X27:1 013 14 Stecker Klimasteuerun connector climacontrol
X27:2 013 14 Stecker Klimasteuerun connector climacontrol
X27:3 013 15 Stecker Klimasteuerun connector climacontrol
X27:4 013 15 Stecker Klimasteuerun connector climacontrol
X28:1 011 6 Stecker Radsensor connector wheel sensor
X28:2 011 6 Stecker Radsensor connector wheel sensor
X28:3 011 7 Stecker Radsensor connector wheel sensor
X28:4 011 7 Stecker Radsensor connector wheel sensor
X29:1 013 6 Stecker Zyklon Connector cyclone
X29:2 013 6 Stecker Zyklon Connector cyclone
X30:A 011 6 Verbindungsstecker Se connector sensor
X30:B 011 6 Verbindungsstecker Se connector sensor
X30:C 011 7 Verbindungsstecker Se connector sensor
X31:A 011 11 Verbindungsstecker An connector gauge
X31:B 011 9 Verbindungsstecker An connector gauge
X31:C 011 10 Verbindungsstecker An connector gauge
X33:1 011 4 Schmieranlage lubrication system
X33:2 011 4 Schmieranlage lubrication system
component listing

X34:1 011 4 Schmieranlage lubrication system

X34:2 011 4 Schmieranlage lubrication system
Bauteilliste

X34:3 011 3 Schmieranlage lubrication system

X34:4 011 3 Schmieranlage lubrication system
X34:5 011 4 Schmieranlage lubrication system
X35:1 009 13 Stecker Warnsummer connector warning buzzer
X35:2 009 13 Stecker Warnsummer connector warning buzzer
X36:1 008 7 Stecker Poti connector potentiometer
X36:2 008 6 Stecker Poti connector potentiometer
X36:3 008 7 Stecker Poti connector potentiometer
X39:A 008 7 Stecker Deceleratorpe connector decelerator pedal
X39:B 008 6 Stecker Deceleratorpe connector decelerator pedal
X39:C 008 6 Stecker Deceleratorpe connector decelerator pedal
X40:1 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:2 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:3 008 9 Stecker Deceleratorpe connector decelerator pedal
X40:4 008 7 Stecker Deceleratorpe connector decelerator pedal
X40:5 008 8 Stecker Decelelratorp connector decelerator pedal
X40:6 008 7 Stecker Deceleratorpe connector decelerator pedal
X41:1 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:2 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:3 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:4 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:5 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:6 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:8 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:9 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:10 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:11 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:12 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X42:1 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:2 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:4 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:5 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:6 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X17.1:1 004 2 2pol SPT 2pole SPT
X17.1:2 004 2 2pol SPT 2pole SPT
X27.1:4 004 18 Motor / 42pol EPC engine / 42pole EPC
X27.1:6 004 19 Motor / 42pol EPC engine / 42pole EPC
9

X27.1:7 004 19 Motor / 42pol EPC engine / 42pole EPC

X27.1:11 004 14 Motor / 42pol EPC engine / 42pole EPC
X27.1:12 004 6 Motor / 42pol EPC engine / 42pole EPC
X27.1:13 004 8 Motor / 42pol EPC engine / 42pole EPC
X27.1:14 004 8 Motor / 42pol EPC engine / 42pole EPC
11

X27.1:15 004 9 Motor / 42pol EPC engine / 42pole EPC

X27.1:18 004 7 Motor / 42pol EPC engine / 42pole EPC
X27.1:19 004 5 Motor / 42pol EPC engine / 42pole EPC
X27.1:20 004 4 Motor / 42pol EPC engine / 42pole EPC
570 700 37

X27.1:21 004 10 Motor / 42pol EPC engine / 42pole EPC

X27.1:22 004 11 Motor / 42pol EPC engine / 42pole EPC
X27.1:23 004 10 Motor / 42pol EPC engine / 42pole EPC
X27.1:24 004 7 Motor / 42pol EPC engine / 42pole EPC
X27.1:25 004 4 Motor / 42pol EPC engine / 42pole EPC
109

X27.1:26 004 5 Motor / 42pol EPC engine / 42pole EPC

X27.1:27 004 5 Motor / 42pol EPC engine / 42pole EPC
008 911 53
X27.1:28 004 11 Motor / 42pol EPC BOMAG
engine / 42pole EPC 927
Name Bl. Pf. Benennung title TYP

19.3 X27.1:29
X27.1:30
X27.1:33
004
004
004
11
7
6
Motor / 42pol EPC
Motor / 42pol EPC
Motor / 42pol EPC
engine / 42pole EPC
engine / 42pole EPC
engine / 42pole EPC
Wiring diagram 570 700 37
X27.1:34 004 12 Motor / 42pol EPC engine / 42pole EPC
X27.1:35 004 12 Motor / 42pol EPC engine / 42pole EPC
X27.1:36 004 14 Motor / 42pol EPC engine / 42pole EPC
X27.1:37 004 13 Motor / 42pol EPC engine / 42pole EPC
X27.1:39 004 17 Motor / 42pol EPC engine / 42pole EPC
X27.1:40 004 16 Motor / 42pol EPC engine / 42pole EPC
X27.1:41 004 16 Motor / 42pol EPC engine / 42pole EPC
X27.1:42 004 15 Motor / 42pol EPC engine / 42pole EPC
X27.2:10 004 3 12pol EPC 12pole EPC
X27.2:11 004 3 12pol EPC 12pole EPC
XD2.1:2 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
Seis
28.08.2006
Werner
28.08.2006

XD2.1:3 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH

XD2.1:5 004 18 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:6 004 18 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:8 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:9 004 5 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:10 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:11 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:13 004 11 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:20 004 14 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:22 004 10 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:29 004 5 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:30 004 10 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:33 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:34 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:35 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:38 004 11 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:39 004 13 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:40 004 15 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:52 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:53 004 15 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:54 004 12 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:59 004 8 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:60 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:61 004 8 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:62 004 5 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:77 004 6 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:78 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:79 004 6 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:89 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
component listing

XD2.2:3 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH

XD2.2:4 004 19 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
Bauteilliste

XD2.2:5 004 19 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH

XD2.2:7 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:8 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:9 004 8 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:10 004 8 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:15 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:18 004 6 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:19 004 9 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:23 004 10 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:24 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:25 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:26 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:27 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:28 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:32 004 6 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:33 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:34 004 10 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:35 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:36 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.3:3 004 15 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:4 004 12 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:6 004 13 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:7 004 14 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:8 004 18 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:12 004 14 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:13 004 12 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:14 004 16 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:15 004 16 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:16 004 17 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH

Y17 007 6 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y17 007 8 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y92 010 6 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. max. 1,1A
Y93 010 7 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. max. 1,1A
Y102 010 11 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A
11

Y102 010 12 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A

Y108 010 8 Magnetventil Schaufel Heben solenoid valve, lifting shovel max. 1,1A
Y109 010 9 Magnetventil Schaufel Senken solenoid valve, let down shovel max. 1,1A
Y110 010 19 Magnetventil Schaufel oeffnen solenoid valve, open shovel max. 1,1A
570 700 37

Y111 010 18 Magnetventil Schaufel Schließen solenoid valve, close shovel max. 1,1A
Y132 007 14 Magnetventil Radmotor vorn links Solenoid valve, wheel motor front lh. max. 0,6A
Y133 007 16 Magnetventil Radmotor vorn rechts Solenoid valve, wheel motor front rh. max. 0,6A
Y134 007 17 Magnetventil Radmotor hinten links Solenoid valve, wheel motor rear lh. max. 0,6A
Y135 007 19 Magnetventil Radmotor hinten rechts Solenoid valve, wheel motor rear rh. max. 0,6A
110

Y138 013 13 Magnetveentil Heizung Solenoid valve, heating unit 0,42A

Y147 004 12 Injektor A1 jet pump A1
928 Y148 004 14 Injektor A2 BOMAG
jet pump A2 008 911 53
Name Bl. Pf. Benennung title TYP
Y149

Y151
004
Wiring diagram 570 700 37
Y150 004
004
13
17
16
Injektor A3
Injektor B1
Injektor B2
jet pump A3
jet pump B1
jet pump B2
19.3
Y152 004 16 Injektor B3 jet pump B3
Y166 004 14 Injektor A4 jet pump A4
Y167 004 18 Injektor B4 jet pump B4
Seis
28.08.2006
Werner
28.08.2006
component listing
Bauteilliste
11
11
570 700 37
111

008 911 53 BOMAG 929

008 911 53 BOMAG 930
404

402
408

394
400
403
405
406
407
409
414

392
398

393
395
396
397
399
412

401
410
413
415

391
411

K77 K77
H07

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
057 513 10

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
057 664 11 057 664 11
057 564 17

057 564 37
057 564 22 057 564 30
057 564 23
1x6qmm
1x6qmm

Seis

153 131 1x6qmm

Versorgung Kabine 1
Werner

154 132
155 133 1x6qmm Versorgung Kabine 1x6qmm
2
10.07.2006
28.08.2006

156 134
K11

157 135 1x6qmm Masse Kabine 3

158 136
057 543 08

1x6qmm Masse Kabine 4

159 137
160 138 Masse Schutzbelüftung 5
161 139
057 564 29

162 140 6
163 141
164 142 7
165 143
1x2,5qmm
1x4qmm

1x6qmm
1x6qmm

166 144 8
057 564 35

167 145 9
K05

168 146
15A
169 147 Klimatronik Konvekta 1x1,5qmm F50 20
170 148 Zigarettenanzünder + 30A
171 149 1x1,5qmm F89 21
Tachograph / BC 672 EB
057 564 19
K22

172 150 Schutzbelüftung 22

30A
206 201 Leistung Steuerung 5x0,75qmm F67 27 1x4qmm
207 202
Schutzbelüftung
208 203 28
209 204 15A
Instrumente 1x1,5qmm
K90

F24 29
210 205
Schmieranlage + 10A
226 221 1x1,5qmm F16 30
Tachograph / BC 672 EB
227 222 15A
Fahrersitz 1x1,5qmm F29 31 1x2,5qmm
228 223
K48

10A
229 224 EDC7 Steuerung (15) 1x1,5qmm F122 32
230 225
K11

10A
235 231 Zykon Abscheider 1x1,5qmm F31 33 1x2,5qmm
236 232 15A
K61

Signalhörner 1x1,5qmm F23 34

237 233
238 234 10A
Fahren und Bremse 1x1,5qmm F25 35
257 241 10A
258 242 Klimatronik Konvekta 1x1,5qmm F33
057 268 42

36
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259 243
260 244 37
261 245 45 41
262 246 45 41
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263 247 46 42
264 248 46 42

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265 249 47 43
057 564 25

266 250 47 43
057 564 36

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057 564 21

267 251 48 44
057 543 12

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268 252 48 44
057 564 38

269 253 61
270 254
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62
271 255
057 500 57

63
057 664 96

272 256 64
K146

300 291 65
301 292 66
302 292
293 67
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303 294 68
304 295 69
305 296 70
306 297 71
307 298 72

057 565 39
308 299 84 81
343 321 85 82

057 565 36
057 668 71

344 322 86 83
057 564 24

345 323 92 87
346 324 93 88
347 325 94 89
348 326 95 90
349 327 96 91
057 564 26

350 328 104 101

057 565 40
351 329 105 102

057 565 38
352 330 106 103
353 331 115 107
354 332 116 108
355 333 117 109
356 334 118 110
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357 335 119 111

358 336 119 111
057 555 96

359 337 120 112

360 338 121 113
361 339 122 114

057 565 37
362 340 125 123
363 341 126 124

057 565 35
364 342
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375 371 130 128

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376 372
377 373 6 1
378 374 7 2
057 556 04 (Kappe/cap)

057 665 63
383 381 8 3

057 665 61
384 382 9 4

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057 199 46
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570 700 37
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28.08.2006
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10.07.2006
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28.08.2006
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008 911 53
Wiring diagram 570 700 37

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10.07.2006
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S/N 101 570 571 012 ⇔ 101 570 571 025 BC772 RS-2
S/N 101 570 581 035 ⇔ 101 570 581 074 BC772 RB-2
S/N 101 570 591 009 ⇔ 101 570 591 018 BC672 RB-2
S/N 101 570 821 008 ⇔ 101 570 821 025 BC972 RB-2
S/N 101 570 831 022 ⇔ 101 570 831 040 BC1172 RB-2

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^*& 008
&?^ 911 53
& $%
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Wiring diagram 570 700 39
~ ??~
??~
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~
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$%
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>$&>
>$&>
?^~

19.4
~ ??~ | <| >$&>|
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??~ < >$&>
??~ <| >$&>|
??~ ~ <~ >$&>~
??~ <~ >$&>~

[
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008 911
53 BOMAG
959
008 911 53 BOMAG 960
~?~

~?
~?

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~??
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Wiring diagram 570 700 39 19.4
008 911 53
Wiring diagram 570 700 39

|?

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~
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19.4

961
[ %> >
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962
19.4

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008 911 53
Wiring diagram 570 700 39

< $% %<[<

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19.5 Wiring diagram 570 700 42

008 911 53 BOMAG 963

19.5 Wiring diagram 570 700 42

S/N Wiring diagram 570 700 42

S/N 101 570 571 026 ⇔ 101 570 571 028 BC772 RS-2
S/N 101 570 581 075 ⇔ 101 570 581 129 BC772 RB-2
S/N 101 570 591 019 ⇔ 101 570 591 035 BC672 RB-2
S/N 101 570 821 026 ⇔ 101 570 821 046 BC972 RB-2
S/N 101 570 831 041 ⇔ 101 570 831 059 BC1172 RB-2

964 BOMAG 008 911 53

Inhaltsverzeichnis: BC 772...1172 RB / TIER III

008 911 53
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing no.
001 570 700 42 Stromlaufplan Circuit Diagram
002 570 700 42 Versorgung, Zigarettenanzünder supply, cigarette lighter
003 570 700 42 Zündschloß, Starter ignition switch, starter
004 570 700 42 DEUTZ Steuergerät EDC 7 f. 6 und 8Zylindermot. DEUTZ controller EDC 7 for 6 and 8zylinder engine
005 570 700 42 Instrumente indicators
Wiring diagram 570 700 42

006 570 700 42 Anzeigen, Störmeldungen monitoring, failure indication

007 570 700 42 Fahrpumpen, Radmotoren, Startfreigabe driving pumps, weehl motors, starting release
008 570 700 42 Fahrstufen, Bremse, Verzögerungspedal speed ranges, brakes, decelerator device
009 570 700 42 Versorgung Steuerung, Warnsummer, Override supply controllers, warning buzzers, override
010 570 700 42 Lenkung und Arbeitshydraulik steering and working hydraulic system
011 570 700 42 Hupe, Schmieranlage, Tachograph, Sitzfunktionen horn, lubrication systhem, tachograph, seat funktions
012 570 700 42 Heizung und Belüftung heating and ventilation
013 570 700 42 Schutzbelüftung, Zyklon Abscheider, Klimatronik protected vent. system, cyclone separator, air cond.
014 570 700 42 Kabine und Anbauteile cabin and attachmentparts
101 570 700 42 Bauteilliste component listing
201 570 700 42 Schaltkasten ebox

BOMAG
301 570 700 42 Lokalisierungsgrafik Steckverbinder Draufsicht localization graphic connectors top view

06.08.2007
001 001
Werner Stromlaufplan 570 700 42
06.08.2007
19.5

965
circuit diagram 001
Seis
966
Zuleitung Steuerung Pin 54 30/54S 9:2
Zuleitung Steuerung Pin 5660 30/5660S
9:2

2,5qmm
Kabine K30
14:2
19.5

4qmm
geschaltetes "15/54"

2x6qmm
Batteriespannung 30 3:1

6qmm
15/54 X1:6
Zündschloß "15/54" 3:1

Einspeisepunkte für Versorgung

2,5qmm
4qmm
2x6qmm
6qmm
6qmm
Sicherungespotential K11:87!
X1:241 X1:242
X1:31E
X1:33E

0,11A
0,075A
X1:241
11:7
1 86 K61:87a 5:9 F24 K11:87 5:1
5:1
R10
1 220_O
K61 X1:298
F00 250A

057 665 63
2 2,5qmm X1:32E
2 85 X1:243
1x25qmm F122
10A
Anlassehauptleitung: 2x70qmm B+ 3:1 D+ 6:2
Ladeleitung 2x 10qmm oder 1x25qmm X1:32A
X1:81 1
X1:259

BOMAG
+ E21
X1:202
9:13
8:10

G01 2
11 21 31 41 51 61
S01
Batterie X14:6

0,075A
5A
Bei Steckdosenbetrieb je nach Stecker bis 16A möglich!
battery
max. 10A

2:10 13:10
Zigarettenanzünder Steckdose
cigarette lighter socket

06.08.2007
1 1

008 911 53
Wiring diagram 570 700 42

Werner Versorgung, Zigarettenanzünder 570 700 42

06.08.2007
Seis supply, cigarette lighter 002
2:15 30 30 4:1
2:11 15/54
6qmm
2:6 B+ B+ 4:1 X1:23E
Anlasserhauptleitung 2x70qmm F13
30A

008 911 53
X1:23A

6qmm

Zündstartschalter
012 30 ignition switch
S00
01

50a 15/54

4qmm
1,5qmm

X1:293
Wiring diagram 570 700 42

X1:302

X1:8 X1:9

30
K05
7:2
87 87a

X1:7

BOMAG
2,5qmm
X14:9 X1:371
0,2A

0,2A

86 86
30 50 2 K11 K32
M01
M V47
85 85
1

X1:256 X1:70

2:20 31 31 4:1

2:17 14:6

Starter
starter
Anzugswicklung KHD = 73A
Haltewicklung KHD = 12A

06.08.2007
1 1 570 700 42
Werner Zündschloß, Starter
06.08.2007
19.5

967
Seis ignition switch, starter 003
968
30 30
3:20 13:1
B+ Pedal
3:5 X1:24E 6:7
XS
B124 2:19
19.5

1 + 1 elektronisches Fußpdal Diagnosestecker

F48 F93 elektronic foot pedal diagnosis
86 86 86 X22
80A 25A K15 K146 K60
2 F78
2 S119 H04 1 H70 1
13
X1:24A S118

X4:A
X4:H
X4:G
X4:M
X4:F
X4:K
X4:B
2 2 Fehlertaster Motor
85 85 85
4qmm B46

4qmm
4qmm
14 failure push button engine

Williams Codierung
sw rt ws or gn bl

X1:92
X1:93
X1:94
1
R24

X1:62
X1:64
X1:65
X1:71
2 X1:255

X10:B
X10:C
X10:A
X12:A
X12:C
X12:B
X6:1 X1:250
X6:2 X1:244
X6:3 X1:270
X6:4 X1:269
10 kOhm
2 3 1 EMR
RPM 2:19
9:2
Option
option

X6:5
X6:6
X6:7
X6:8
X6:9
X6:10

X1:231
X1:232
X1:233
5V EDC 8:2
Handgas
8:2
4x2,5qmm Dachkurve AGND EDC "31" 4x2,5qmm
8:2

Sensor Wasserabscheider
sender water separator
"30"
Fehler EMR
Vers. Meldeleuchte
Glühen
Temperatur
Motoröldruck
"15"
CAN 1H
CAN 1L
CAN 2H
CAN 2L
ISO KLinie

S2 S1

Fehler Motor
failure engine
Wasserabsch.
water separator

X1:235
X1:236
X1:237

XD2.1:3
XD2.1:9
XD2.1:6
XD2.1:5

XD2.1:2
XD2.1:8
XD2.1:11

XD2.1:61
XD2.1:13
XD2.1:10

XD2.1:79
XD2.1:77
XD2.1:33
XD2.1:60
XD2.1:59
XD2.1:30
XD2.1:39
XD2.1:53
XD2.1:35

XD2.1:62
XD2.1:29
XD2.1:78
XD2.1:38
XD2.1:20
XD2.1:52
XD2.1:89

XD2.1:22
XD2.1:54
XD2.1:40
XD2.1:34

X27.2:11
X27.2:10
A48 EDC7 Steuerung
4qmm

X17.1:1
X17.1:2
X1:5

BOMAG
50i
K14 K2
4:4

3:20 31 31 5:1

4:2 6:2 6:2 6:3 Injektor B3

06.08.2007
1 1

008 911 53
Wiring diagram 570 700 42

Werner DEUTZ Steuergerät EDC 7 f. 6 und 8Zylindermot. 570 700 42

06.08.2007
Seis 066_9 DEUTZ controller EDC 7 for 6 and 8zylinder engine 004
2:20 K11:87 K11:87 9:1

X1:29E

F24
15A

008 911 53
X1:29A
2:13 F24 F24 6:1
2:11 K61:87a K61:87a 6:7
X1:294 X1:295 X1:298

5 1 4 3 5 1
Wiring diagram 570 700 42

P00 +
E02 P14 + E22 P02 + E03 P03 + E01 P01 + E46 P12 +
1 1 1 1 1
_t _t n Q
2 2 2 2 2
G G G G

Modul 1
module 1
Modul 2
module 2
Modul 3
module 3
3 2 4 1 5 3 4

BOMAG
X1:300 X1:303 X1:301 X1:296
X1:291 X1:148 X1:292 X1:228

X14:8

X5:1

1 2
B53 1 1
R04 R03

2 2
X1:299 W X1:229
2:8
31 31
4:20 6:1

Kühlmitteltemperatur Motordrehzahl Tankanzeige

collant temperature trancducer, motor speed level gauge

Hydrauliköltemperatur Betriebsstundenzähler Voltmeter

hydraulic oil temperature engine hour meter volt meter

06.08.2007
1 1 570 700 42
Werner Instrumente
06.08.2007
19.5

969
Seis indicators 005
970
F24 F24
5:20 9:1
D+ ESX 9:15 Abschmieren
2:9 11:2
Lüfter 1.GANG
12:14 30 30 9:7
19.5

K133 K48 2.GANG 9:7

9:9 7:3
87 87a 87 87a
X1:101 X1:104
X1:89 X1:84 X1:90 X1:91 X1:123

X1:125
X1:126

X1:124

rt
rt
ws/vi
br/rt
br
br/sw
sw
vi

vi
ws/bl
br/or
br
ws/vi
or X1:102 X1:105 or
1 2 0/3a 4 8 A15 A15 16 11 17 18 9

6 3 7 5 20 19 14 15 12 13 10

bl
bl
gr

sw
br/or

ws/rt

ws/gr
ws/br
ws/br
ws/gr

ws/gn
ws/gn

X1:106

X1:115
X1:119

X1:118
X1:121

X1:120
X1:122

X1:87 X1:88 X1:85 X1:86

X1:392/2 V02 2 1 X1:392/1 X1:397/1 1 2 V07 X1:397/2
X0:18 X0:45
Fehler
X1:394/2 V04 2 1 X1:394/1 X1:398/1 1 2 V08 X1:398/2
X1:109 X1:117

X0:52 X0:50 X1:108 X1:116

Fehler
X1:393/2 V03 2 1 X1:393/1 X1:399/1 1 2 V09 X1:399/2

20s
Fehler
X0:19 X0:13
X1:111

X1:395/2 V05 2 1 X1:395/1 X1:400/1 1 2 V10 X1:400/2

Steuerung
Gaspedal
X0:11 X0:10
Pedal X1:401/1 1 2 V11 X1:401/2
X1:112

X1:82 X1:83 4:19 X0:6 Fehler

D+
X1:403/1 1 2 V13 X1:403/2
X1:113

X1:114

X0:36 X0:51

ESX
X14:10 X1:210

BOMAG
5:20 K61:87a K61:87a 14:11
15

20s
20s
2min
K113

X1:103
30 30
3 3 3 3 1 1 3 K113 2 2 2 2 2 1 +
K146 B55 B03 B116 B129 B24 B20 B121 B122 B22 B21 B42 B05
4:13 6:11 B19
Q P P B25 P P Q P
87a 87 4 4 4 4 2 2 4 87 87a 1 1 1 1 1 2

X14:11

X1:181
X1:182
X1:182
X1:191
X1:191

X1:181

X1:183
X1:187
X1:185
X1:186
X1:183

31
X1:184
X1:184

X1:205

5:20 31 7:1
Speisepumpe Speisepumpe Zwischengetr.
6:14
Speisepumpe Speisepumpe

Rücklauffilter nur BC 972 RB

return flow filter only acc. to BC 972 RB

Modul 1: Motorfunktionen Modul 2: Maschinenfunktionen

module 1: engine functions module 2: maschine functions

06.08.2007
1 1

008 911 53
Wiring diagram 570 700 42

Werner Anzeigen, Störmeldungen 570 700 42

06.08.2007
Seis monitoring, failure indication 006
DEC 1 8:4
X1:338 X1:262 S04:12 8:10
X1:335 2 1
X1:46/2 X1:46/1
X9:4 X9:1 FM6

008 911 53
1
R32 X1:42/1
1k
2

1 1
R33 1 R34 R35 1 FM2
2k 1k 3k3 2
2 2 2

Fahrtrichtungsschalter nicht belegt X1:42/2

switch, travel direction V0R 33 13 24 44 not used
S31 X1:336
34 14 23 43
Wiring diagram 570 700 42

X9:5 X9:6 X9:3 X9:2

X1:339

X1:340 X1:337

Richtung
AGND
8,5V
Ain

X1:412/1 X1:413/1

X0:1
13 9

X0:32
X0:23
X0:29

1 1
V23 V25 K77 K77 ESX Steuerung
9:17 9:17
2 2 14 10

X0:22
X0:21
X0:46
X0:47
X0:48
X0:43

X1:412/2 X1:413/2

BOMAG
Vorwärts

Rückwärts
vorne Links
hinten Links

vorne rechts
hinten rechts

br nicht bei
X1:221 X1:223 X1:135 X1:157
V38 BC 672772
not used for
rt BC 672772

X1:149 X1:153 X1:131 X1:133 X1:155

200 ... 600mA
200 ... 600mA
200 ... 600mA
200 ... 600mA

86 86 H14
K05 K48 + 1 1 1 1 1 1 1 1
V34 Y17 V35 Y17 V32 Y16 V33 Y16 Y132 Y133 Y134 Y135

85 85 2 2 2 2 2 2 2 2

1,08A
1,08A
1,08A
1,08A

X1:70 X1:70 X1:188

06.08.2007
1 1 570 700 42
Werner Fahrpumpen, Radmotoren, Startfreigabe
06.08.2007
19.5

971
Seis driving pumps, weehl motors, starting release 1 007
972
F25 9:1

X1:343 X1:261
19.5

X40:6
X40:2
X13:3
5V EDC DEC 1
X13:1
X13:2

4:8 7:19 decelerator pedal R20 R21 R22 R23

1 k_O 1 k_O 1 k_O 1 k_O
Nur für BC 671771 RB/RS
only acc. to BC 671771 RB/RS

bl gr
KD1 KD2
S161

ws
sw
rt
ge
gn
vi
or
bei Option
Schalter Fahrstufen
switch speed ranges

X3:B
acc.to option
X40:3

decelerator pedal

Verbindung entfällt
connection not applied

X40:1
Fahrtverzögerungspedal
X1:359
X1:263

X42:5
X42:6
X41:11
X41:6
X41:4 X39:B
X41:3 X39:C
X41:5 X39:A
X41:1 X40:4
X41:2 X40:5
S04:11
8:11
Zusatzelektronik
A78

Bremse
high=Bremse auf
8,5V
AGND
Fahrstufen
additional electronic

X41:9

X42:1
X41:8

X42:2
X42:4
X41:10

X41:12
X0:1
X0:7

BOMAG
X0:23

X0:40
ESX Steuerung
X36:1
X0:62

X0:61
1

X3:C
R43

X3:A
499 _O
2
Handgas 5 k_O K77
4:8 8 7 S04:11

Bremse
AGND EDC X36:2 S120
4:8 9:17 8:10 X1:170
1./2. Fahrstufe

1 X1:151
R44

1,25A
1,25A

499 _O
1 2 Y04 1 Y03 1
H81 X36:3 V31 V37
2 2 2

X1:234
Nur für BC 671771 RB/RS
only acc. to BC 671771 RB/RS

31 X1:152 X1:192
7:20 31 9:1

Meldeleuchte Verzögerungsfunktion Magnetventil Bremse Stufenumschaltung

06.08.2007
1 1

008 911 53
Wiring diagram 570 700 42

Werner Fahrstufen, Bremse, Verzögerungspedal 570 700 42

06.08.2007
Seis speed ranges, brakes, decelerator device 1 008
K11:87 K11:87 11:1
5:20

X1:35E

F25
10A

008 911 53
X1:35A
F25 F25 10:1
8:20
2:19 30/54S 2,5qmm 6:6 ESX

2:19 30/5660S 4qmm

X1:26E
F24
6:20 X1:27E
RPM F84
4:8
10A

F67
30A X1:26A
30
K90
X1:27A
X1:257 9:4

2,5qmm
Elektronik
87 87a
Wiring diagram 570 700 42

X1:66
X2:H
X1:67
X2:G
S01

X2:U

5x0,75qmm
Leistung
2:17
22
X1:349
X1:349
X1:349

X1:258 X1:404/2 X1:405/2

X1:207
+UE/Dios
+UB/Dios
+UB/Dios

Drehzahl
CAN2
CAN2+
RxD
TxD
+ + + + + +

1x0,75qmm
2 2
V14 V15
1 1

X0:5
X0/1:3
X0/1:9

X0:4

X0:16
X0/1:10

X0:56
X0:57
X0:59
X0:60
X0:33
X0:53

X0:58

X0:28
X0:54
ESX Steuerung X1:404/1 X1:405/1 ESX Dios Modul

X0:2
X0:24
X0:25
X0:3
X0:44
1. Gang 2. Gang Summer
X0/1:11
X0/1:4

BOMAG
6:19 1.GANG
2.GANG
6:19
GND/Dios

X1:402/1 X1:410/1 X1:411/1 1

Relais Override
Motorabstellung
V42
Gehäuse Dios Modul

1 1 1 2
V12 V21 V22
2 2 2 KLIMA
GND für Knotenaddresse Dios

X1:402/2 X1:410/2 X1:411/2

X35:1
K90 86 K22 86 86 + K77/1 86 K77 86
H07
0,7A

K133
X1:185
X1:186

X1:184

85 85 85 X35:2 85 85

0,075
0,075
0,075
0,021A
0,021A

31 X1:70 X1:70 X1:70 X1:70 X1:70 X1:70

8:20 31 10:1

9:17 2:17 6:10

10:5 8:11
10:5 7:6
Lampentest Warnsummer
warning buzzer 10:5 7:5

10:5

06.08.2007
1 1 570 700 42
Werner Versorgung Steuerung, Warnsummer, Override
06.08.2007
19.5

973
Seis supply controllers, warning buzzers, override 1 009
974
F25 X15:A
9:20
X1:349
Schild/Schaufel 1=senken / 2=heben 3=schließen / 4=öffnen
blade/shovel 1=let down / 2=lift 3=close / 4=open
1=Links /2=Rechts 1
19.5
BR/BN

1=left /2=right Achse 3/4 mit Kontakten

BR/BN
BR/BN
1 1 B169 B170 1 1 3 3
S70 4 1015 nur bei Schaufel
axle 3/4 with contacts B08
S71 1 2 2 LI RE 3 2 4
2 2 4 1015 only acc. to shovel X15:B

BL/BU

BL/BU
WS/WHT
WS/WHT
JoyStick
2
sieht Metall wenn Lehne unten

joystick X1:363
Initiator Armlehne

3 2 5 4 7 6 1 3 2 5 4 6 7 1 14 13 12 15 11 10 16 8 9
SW/BK
BL/BU

X2:A X2:B

X2:V

X1:346
X1:345
X1:344
X1:347
X1:348
X1:343
X1:321
X1:325
X1:326
X1:324
X1:323
X1:322
X1:330
X1:329
X1:328
X1:331
X1:332
X1:327
X1:352
X1:351
X1:350
X1:353
X1:354
X1:334
X1:333
CAN Bus LED display

Sensoren Lenkanschlag
sens. steering stop limit
CAN bus LED display X1:63

X1:44/2 X1:45/2 X1:47/2 + P18 X1:61

2 X1:43/2 2 2
FM4 2 FM5 FM7 X1:68
1 FM3 1 1
1 057 664 08

X1:44/1 X1:43/1 X1:45/1 X1:47/1 X1:69

AGND F1 F2
8,5V

lenken
CAN+ X1:364

CAN

links
rechts
lenken
AGND
8,5V
heben/
senken
senken
heben
auf/zu
schließen
öffnen
Schwim.
Lehne

links
rechts
X0:1
X0/1:1

X0:9

X0:8
X0/1:2

X0:15
X0:31
X0:17
X0:12

X0:14
X0:41

X0:39
X0:30
X0:35
X0:37

X0:38
X0:23
X0:27
X0:26

X0:34

ESX Steuerung ESX Dios Modul

BOMAG
X0:64
X0:49
X0:20
X0:42
X0:63
X0:65
X0:66
X0:67
X0:68
X0:55
X0/1:5
X0/1:6

9:15

20 19 2 R36 1 Gehäuse
housing

heben
K77/1 47_O 390 mA

senken

lenken li

lenken re.

X1:406/2
Schwimmst.
9:15
öffnen/Dios

0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA

14 13 2 R38 1
schließen/Dios

K77/1 47_O 390 mA

X1:407/2
9:15 R40
10 9 2 1
K77/1 47_O 390 mA
X1:141 X1:143

X1:408/2
9:15 R42 X1:137 X1:139
8 7 2 1 X1:159 X1:161 X1:163 X1:165

X1:409/2
X1:308 K77/1 47_O 390 mA Y92 1 Y93 1 Y108 1 Y109 1 Y102 1 Y102 1 Y111 1 Y110 1
2 2 2 2
1,08A
1,08A

2 2
2 2 2 2 2 2

V19
V16
V17

V18
X1:189
X1:181
X1:182
X1:183
X1:187
X1:188

1 1 1 1
X1:160 X1:162 X1:164 X1:166 X1:138 X1:140 X1:142 X1:144
31
9:20 31 11:1

Lenken rechts Schild senken

steering right let down blade

X1:409/1
X1:406/1
X1:407/1

X1:408/1
Lenken links Schwimmstellung Schaufel schließen
floating position close shovel
steering left
Schwimmstellung Schaufel öffnen
Schild heben
lift blade floating position open shovel

06.08.2007
1 1

008 911 53
Wiring diagram 570 700 42

Werner Lenkung und Arbeitshydraulik 570 700 42

06.08.2007
Seis steering and working hydraulic system 010
9:20 K11:87 K11:87 13:1
Abschmieren
6:19
X1:30E X1:34E X1:31E

F16 F23 F29

008 911 53
10A 15A 15A

X1:172
X1:30A X1:34A X1:31A

X1:171 Zusatzanzeige Geschwindigkeit

additional speedometer X1:341 X1:245

3A
X31:A
X34:4 1 2 86 30 S25 23
4 (+) K13
LA 15 K13
E04 1 E04 1 11:14
M08
P09 85 87 87a 24
M 8 (S) 2 2
Wiring diagram 570 700 42

Zentralschmieranlage
central lubrication system 3 () X1:246
Z 31 X31:B X31:C X1:355

X34:3 5

X33:1
X33:2
X11:1 X21:1
7,5A

+ sw
M10 R06
X30:A M
B7 A2 ge

X1:173
X1:174
K13:87
2,5A

14:19
X1:248 X28:1 Versorgung über F89
X1:356 Signalhörner Kabine
X1:241 A1 A3
br sw
2:13
23 1

BOMAG
S27 B15 3
8 S29 23
X28:3 B3 A5 S03 2 ge
Taster Schmieranlage X30:C R06
4 P09 V46
switch, lubrication system 24 X28:4
B52 bl 2 ws
4 6 1 9 1 24 br
B4 A6
X1:272 X28:2
A16

Initiator Schmierkolben
proximity switch lubrication piston
Lieferumfang GRAMMER
delivery equipment GRAMMER

X30:B 7 8 9 2 X11:2 X21:2

Im Lenkjoystick
in steering joystick

X1:190 X1:191 X1:364 X1:256

X1:342
10:20 31 31 13:1

11:16

Sensor Radmotor HL Tachograph Sitz mit Kompressor und Schalter

06.08.2007
1 1 570 700 42
Werner Hupe, Schmieranlage, Tachograph, Sitzfunktionen
06.08.2007
19.5

975
Seis horn, lubrication systhem, tachograph, seat funktions 011
976
K32:30 K32:87
14:2 14:3
F41:4
14:8
19.5

F40 G F90 F F02 F

Box 2 Box 2 Box 1
10A
7 5A
6 10A
6

X1:374
X1:265
2,5 qmm

123 13 31 42 24
1 2 3 12 11 13 14 16
Stufenschalter Frischluft
switch, fresh air
S44
5 7 11 3 1 10 14 32 41 23

Regel aus = 0,2A S28 X1:266 X1:267 X1:268

E30 Kleine Stufe = 0,3A
mittleter Stufe = 0,5A
große Stufe = 1A 1 1
Power Stufe = 1,7A R26 R27
Heizung Anlaufstrom beim Start = 4,2A
22 Ohm
10 Ohm

Heating
Schaltuhr Heizung 2 6 8 9 4 12 2 2
heater timer Lüfter
6:6
X1:373
10 9 5 6 8 7 4 15
X1:377

BOMAG
X8:1

2,5 qmm
15/54
30
87a
in

X1:375
X1:226
A53 n
1
Y14
max. 0,75A

20s; n kleiner 1300 1/min

2 20s; rpm lower 1300 1/min
X1:227 8s; n=0 1/min
8s; rpm=0 1/min S +
X1:376
M17 M

X8:2

15/54

K31
14:1
Kraftstoffpumpe Überwachung Lüfter Frischluft Lüfter
fuel pump heating unit monitoring blower blower fresh air

06.08.2007
1 1

008 911 53
Wiring diagram 570 700 42

Werner Heizung und Belüftung 570 700 42

06.08.2007
Seis heating and ventilation 012
30
4:19
F24
9:6 Raumtemperatursensor
K11:87 sensor ambient temperature
11:20
X1:36E
Ausblastemperatursensor
F33 sensor outlet temperature X1:20E

008 911 53
X1:28E X1:22E X1:33E
10A
F50
F123 F94 F31 15A
X1:36A
10A
B29 B118 X1:20A
X1:28A X1:22A X1:33A
30 + +
K62

wird durch D+ aktiviert

2:10 nicht belegt
87 87a not used X1:253 X1:383 X1:381
Versorgung für Schutzbelüftungsanlage

Bel.
X1:251 X1:249

X23:1
X24:1

X23:2
X24:2

15/54
D+
Absicherung und Verkabelung nach Angabe X25:B X25:A
Hersteller der Schutzbelüftungsanlage
supply for protected ventilation system ge rt
Lüftermodul
Wiring diagram 570 700 42

X26:6
X26:7
fuse and wiring acc. to supplier PWM +

X26:13
X26:12
X26:14
blower module

X26:1
X27:1

X26:3
X27:3
X26:5

X27:2
of protected ventilation system

X26:4
A65 Klimatronik X27:4 A53

M+ M

X26:2
X26:10
X26:11
X26:9
X26:8
br gn sw
X25:C
1

31
V43 X1:247

Ventil
2 X1:129
Kupplung

1
B117 _t Thermostat Vereisungsschutz
X22:1 X22:2 thermostat antiicing device
X1:252 2
optional
X1:130 E37 +

BOMAG
optional X1:127 2
X1:146
X7:6 X18:1 VD V36
1
4 Druckschalter

3A
pressure switch
B75 P
LP 3 HP
X29:1 X19:1 X1:414/2
or X7:5 X18:2
+ Y138 1 2 X1:147
X1:201
M26 M V26 X14:4 X17:1
0,42A

2 1
sw 2 1
X1:414/1
X19:2
X1: X29:2 V48 Y15
1 2
X1:382
1,75A

X1:70 X1:272 X1:128

X1:205 X14:5 X17:2
11:20 31 31 14:1

Zyklon Abscheider Magnetventil Heizen Magnetkupplung Verdampferlüfter

cyclone separator solenid valve heating magnetic clutch blower evaporator

Zusatzausrüstung Klimatronik KONVEKTA

Option klimatronic KONVEKTA

06.08.2007
1 1 570 700 42
Werner Schutzbelüftung, Zyklon Abscheider, Klimatronik
06.08.2007
19.5

977
Seis protected vent. system, cyclone separator, air cond. 013
978
K30 K13:87
2:19 2x6qmm
11:16
19.5

X1:2 X1:1

2x6qmm
12:9 K32:30

F41:4 Kamera
camera
12:9 + 123 3 2 1 012 7 2
F126 S22
P32 01
S16 3,75A
S53 1 1 2 S45 1 S38 1 S137 1 S26 1 1

S128
01
S20 5 1 8 5 S21 5 4
4
5 3 4 5 5 5 5 5

X1:72
K61:87a rt
X1:145 15 J S 86
6:9 ge

1,5A
Impulsgeber

Spannungswandler
voltage transformer
X7:1 X7:2 sw A57 Interval switch
2,5A

+24 +12 3 4
E56 31 31b
24V E16 1 E23 1 E25 1 E29 1 1 1

BOMAG
A107

X1:378
B11

2,9A
2,9A
2,9A
0,6A
2,9A
12V
2 2 2 2 2 2

Rundumkennleuchte
rotary beacon
U01 E32
A12 15 53a 31b 53
2,5A

31b
53
53a

+ + B51 E17 1 R77 R77 R77 R77 + +

E24 1 E26 1 E29 1 + E57 1 P15 4 1
1 1 1 1

2,9A
M04 M M06 M M05 M M07 M B28

2,9A
2,9A
0,6A
2,9A
B51 31
2 2,9A 2 2 2 2
Radio 2 2 2 2 31 31 2

X1:150
1,7A
1,7A
1,7A
1,7A
7,9A
2,5A
3,3A
2,5A

radio
K31
12:19 Scheinwerfer vorn X7:3 X7:4 Bildschirm Spiegelheizung Wischer vorn Wischer hinten Signalhorn
2x6qmm
head lights front monitor mirror heating wiper, front wiper, rear warning horn

X1:3 X1:4 Scheinwerfer links/rechts Innenleuchten 1 1 Wascherpumpe Wascherpumpe

head lights lh./rh. inside light, cabin E28 E27 washer pump washer pump
2,9A 2,9A

X1:189
X1:189
2 2

31 X1:190 X1:190 31
13:20

Scheinwerfer Motorraum
head lights, engine area

Arbeitsscheinwerfer hinten
working head lights, rear

06.08.2007
1 1

008 911 53
Wiring diagram 570 700 42

Werner Kabine und Anbauteile 570 700 42

06.08.2007
Seis cabin and attachmentparts 014
Name Bl. Pf. Benennung title TYP
A12

A15
014
Wiring diagram 570 700 42
A15 006
006
2
7
13
Radio
Ueberwachungsmodul
Ueberwachungsmodul
Radio
monitoring module
monitoring module
19.5
A16 011 9 Elektronik Tachograph Electronic system, tachograph
A48 004 9 Elektronische Motorsteuerung Electronic engine management
A53 012 14 Modul Luefterueberwachung Modul blower monitoring
A53 013 18 Modul Luefterueberwachung Modul blower monitoring
A57 014 14 Intervallschalter Scheibenwischer Interval switch, wiper
A65 013 14 Steuerung Klimatronik Controller klimatronic
A78 008 3 Zusatzelektronik Additional control unit
A107 014 11 Umschaltbox switch box

B03 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B05 006 18 Druckschalter Bremse Pressure switch, brake
Seis
06.08.2007
Werner
06.08.2007

B08 010 19 Naeherungsinitiator Fahrhebel ’0’Stell. Proximity switch, travel lever ’0’ pos. max. 1,08A
B11 014 19 Signalhorn Warning horn 2,5A
B15 011 6 Aufnehmer Geschwindigkeit Transducer, speed
B19 006 19 Magnetsensor Verschmutzung Magnetic sensor, contamination
B20 006 13 Temperaturschalter Hydraulikoel Temperature switch, hydraulic oil
B21 006 17 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B22 006 16 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B24 006 12 Schwimmerschalter Hydraulikoel Float switch, hydraulic oil
B25 006 11 Druckschalter Ruecklauffilter Pressure switch, return flow filter
B28 014 20 Signalhorn Warning horn 2,5A
B29 013 14 Raumthermostat Room thermostat
B42 006 17 Differenzdruckschalter Hydraulikoel Hydraulic oil pressure differential switch
B51 014 2 Lautsprecher Radio Speaker radio
B51 014 3 Lautsprecher Radio Speaker radio
B52 011 4 Naeherungsinitiator Schmierkolben Proximity switch, lubrication piston
B53 005 6 Temperaturgeber Kuehlmittel Temperature switch, collant
B55 006 3 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B75 013 16 Kuehlmitteldruck coolant pressure
B88 004 5 Druckgeber Motoroel Sender, engine oil pressure
B113 004 7 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 004 8 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B116 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner
B117 013 15 Thermostat Klimaanlage Thermostar, air conditioning
B118 013 15 Temperaturfühler Auslaß Temperature sender outlet
B121 006 15 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B122 006 15 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B124 004 3 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 004 6 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B129 006 12 Druckschalter Verteilergetriebe pressure switch power takeoff gear
component listing

B130 004 9 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2

B133 004 11 Sensor Ladeluftdruck / temperatur sesnor charging air prssure / temperature
Bauteilliste

B169 010 7 Näherungsinitiator Lenkzylinder links proximity switch steering cylinder left
B170 010 8 Näherungsinitiator Lenkzylinder rechts proximity switch steering cylinder right

E01 005 14 Beleuchtung Tankanzeige Illumination, level gauge

E02 005 5 Beleuchtung Temperaturanzeige Illumination, temperature gauge
E03 005 10 Beleuchtung Drehzahlmesser Illumination, rpm meter
E04 011 10 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E04 011 11 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E16 014 4 Scheinwerfer links Head light, lh. 55W
E17 014 4 Scheinwerfer rechts Head light, rh. 55W
E20 002 12 Zigarettenanzuender Cigarette lighter
E21 002 12 Beleuchtung Zigarettenanzuender Illumination, cigarette lighter
E22 005 7 Beleuchtung Temperaturanzeige Hydr.oel Illumination, temp. gauge, hydraulic oil
E23 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E24 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E25 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E26 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E27 014 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E28 014 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E29 014 7 Innenleuchte Kabine Inside light, cabin 15W
E29 014 8 Innenleuchte Kabine Inside light, cabin 15W
E30 012 3 Heizgeraet Heating unit
E32 014 8 Kennleuchte Warning light 70W
E37 013 18 Klimaverdampfer Air conditioning, evaporator
E46 005 15 Beleuchtung Voltmeter Illumination volt meter
E56 014 9 Scheinwerfer Motorraum rechts Head light, engine area rh. 55W
E57 014 9 Scheinwerfer Motorraum links Head light, engine area lh. 55W
ESX 006 9 Elektronisches Steuergeraet Electronic system, control unit
ESX 007 12 Elektronisches Steuergeraet Electronic system, control unit
ESX 008 10 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 5 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 18 Elektronisches Steuergeraet Electronic system, control unit
ESX 010 9 Elektronisches Steuergeraet Electronic system, control unit max. 1,08A
ESX 010 19 Elektronisches Steuergeraet Electronic system, control unit 0,2A

F00 002 2 Hauptsicherung Batterie Fuse, main, battery 250A

F02 012 12 Ersatzsicherung Fuse, spare 10A
1

F05 002 15 Sicherung Steckdose Fuse, socket 30A

F13 003 9 Sicherung Startschalter Fuse, starter switch 30A
F16 011 4 Sicherung Zentralschmieranlage Fuse, central lubrication system 10A
F23 011 14 Sicherung Signalhorn Fuse, warning horn 15A
F24 005 5 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A
11

F25 009 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F27 014 16 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 10A
F28 014 18 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 10A
F29 011 18 Sicherung Kompressor Sitzverstell. Fuse, compr., seat height adjustm. 15A
570 700 42

F31 013 6 Sicherung Kabinenluefter Fuse, cabin ventilator 10A

F33 013 9 Sicherung Klimageraet Fuse, air conditioning 10A
F40 012 3 Sicherung Kabinenheizung Fuse, heating unit cab 10A
F41 014 8 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A
F42 014 7 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
101

F48 004 2 Sicherung Gluehanlage Fuse, glow plug system 80A

F49 014 1 Sicherung Spannungswandler Fuse, voltage transformer 10A
008 911
F50 53 013 19 Sicherung Klimageraet BOMAG
Fuse, air conditioning 15A 979
Name Bl. Pf. Benennung title TYP

19.5 F66
F67
F84
014
009
009
4
7
13
Sicherung Scheinwerfer vorne
Sicherung Steuerung (Potential 30)
Sicherung Steuerung (Klemme 54)
Fuse, head light front
Fuse, controller (pot.30)
Fuse, controller (Pin 54)
15A
Wiring diagram 570 700 42
30A
10A
F85 014 6 Sicherung, Scheinwerfer vorne Fuse, head light front 20A
F86 014 10 Sicherung, Scheinwerfer hinten Fuse, head lights rear 15A
F89 002 12 Sicherung, Zigarettenanzuender Fuse, cigarette lighter 30A
F90 012 8 Sicherung, Ansteuerung Fuse, actuation 5A
F93 004 4 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F94 013 3 Sicherung Schutzbelueftung Fuse, protected ventilation syst.
F98 014 13 Sicherung Spiegelheizung fuse,mirror heating 10A
F99 014 9 Sicherung Motorraumbeleuchtung fuse, illumination engine area 15A
FM1 008 13 Platinensicherung Multifuse 0,2A
FM2 007 19 Platinensicherung Multifuse 0,2A
FM3 010 9 Platinensicherung Multifuse 0,2A
Seis
06.08.2007
Werner
06.08.2007

FM4 010 5 Platinensicherung Multifuse 0,2A

FM5 010 11 Platinensicherung Multifuse 0,2A
FM6 007 7 Platinensicherung Multifuse 0,2A
FM7 010 14 Platinensicherung Multifuse 0,2A
F122 002 17 Sicherung EMR Fuse, EMR 10A
F123 013 2 Sicherung Schutzbelüftungsanlage Fuse, protected ventilation system
F125 014 11 Vorsicherung prefusing 10A
F126 014 11 Sicherung Rückfahrkamera Fuse, back up camera system 2A

G01 002 2 Batterie Battery

G02 002 5 Generator Generator 28V/80A
G03 002 2 Batterie Battery

H04 004 10 Meldeleuchte Betriebsstoerung Indicator light, breakdown

K05 007 2 Relais Startstrom Relay, starting current BOSCHW

K62 002 10 Relais D+ Relay, D+ BOSCHW

K77 009 17 Relais Override Relay, override SDS/SF4
Bauteilliste

K90 009 4 Relais, Meldeleuchte Stoerung SPS Relay, indicat.light brake down SPS BOSCHW
K113 006 11 Zeitrelais Timing relay BOSCHW
K133 009 9 Relais Test Relay, test BOSCHW
K146 004 13 Relais Kühlmitteltemperatur relay, coolant temperature BOSCHW
K77/1 009 15 Relais Override Relay, override SDS/SF4

M01 003 9 Starter Starter

P00 005 12 Betriebsstundenzaehler Operating hour meter

R02 004 2 Gluehkerze Glow plug

R21 008 15 Widerstand Resistor 1 KOHM

R22 008 16 Widerstand Resistor 1 KOHM
R23 008 17 Widerstand Resistor 1 KOHM
R24 004 5 Widerstand Resistor 10 kOHM
R26 012 17 Widerstand Resistor 22 OHM
11

R27 012 18 Widerstand Resistor 10 OHM

R32 007 5 Widerstand Resistor 1 kOhm
R33 007 5 Widerstand Resistor 2 kOhm
R34 007 6 Widerstand Resistor 1 kOhm
570 700 42

R35 007 8 Widerstand Resistor 3,3 kOhm

R36 010 6 Widerstand Resistor 47 OHM
R38 010 6 Widerstand Resistor 47 OHM
R40 010 6 Widerstand Resistor 47 OHM
R42 010 6 Widerstand Resistor 47 OHM
102

R43 008 7 Widerstand Resistor 499Ohm

R44 008 7 Widerstand Resistor 499Ohm
980 R77 014 12 Widerstandsheizung Aussenspiegel BOMAG
Resistor heating outside mirror 40W 008 911 53
Name Bl. Pf. Benennung title TYP
R77

R77
014 13 Widerstandsheizung Aussenspiegel
Wiring diagram 570 700 42
R77 014 13 Widerstandsheizung Aussenspiegel
014 14 Widerstandsheizung Aussenspiegel
Resistor heating outside mirror
Resistor heating outside mirror
Resistor heating outside mirror
40W
40W
40W
19.5
S00 003 9 Startschalter Starter switch MERIT
S01 002 17 Schalter NOT AUS Switch, emergency off NOTAUSH
S01 002 17 Schalter NOT AUS Switch, emergency off
S02 008 16 Fahrstufenschalter Switch, speed range selector
S02 008 19 Fahrstufenschalter Switch, speed range selector
S03 011 14 Taster Signalhorn Push button, warning horn
S04 008 10 Bremsschalter Switch, brake
S16 014 5 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 014 14 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 18 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
Seis
06.08.2007
Werner
06.08.2007

S22 014 16 Schalter Scheibenwascher vorne Switch, windscreen washer, front

S25 011 19 Schalter Fahrersitzheizung Switch, heating, operator’s seat
S26 014 10 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
S27 011 3 Taster Zentralschmieranlage Push botton, central lubrication system
S28 012 8 Schalter Kabinenheizung Switch, cabin heating
S29 011 18 Schalter Fahrersitz Hoehenverstellung Switch, operator’s seat height adjustm.
S30 002 2 Batterietrennschalter Switch, battery disconnect
S31 007 5 Schalter Fahrtrichtung Switch, travel direction
S38 014 8 Schalter Kennleuchte Switch, warning light
S44 012 17 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 4 Schalter Arbeitsbeleuchtung Switch, working lights
S70 010 10 Schalter Schubsschild Switch, dozer blade WAGO
S71 010 4 Schalter Lenkung Switch, steering max. 1,08A
S118 004 18 Schalter Fehlerdiagnose Switch, fault diagnosis
S119 004 6 Elektronisches Fusspedal Electronic foot pedal
S120 008 7 Schalter Motordrehzahl Switch, engine speed 5 kOhm
S128 014 13 Schalter Spiegelheizung Switch, mirror heating
S137 014 9 Schalter Motorraumbeleuchtung Switch, illumination engine area
S160 008 4 Schalter Aktivierung Verzögerungspedal Switch, enable decelerator pedal
S161 008 6 Verzögerungspedal decelerator pedal

U01 014 1 Spannungswandler Voltage transformer

V01 002 7 Diode Diode WAGO

V02 006 7 Diode Diode WAGO
V03 006 7 Diode Diode WAGO
V04 006 7 Diode Diode WAGO
V05 006 7 Diode Diode WAGO
component listing

V07 006 12 Diode Diode WAGO

V08 006 12 Diode Diode WAGO
Bauteilliste

V09 006 12 Diode Diode WAGO

V10 006 12 Diode Diode WAGO
V11 006 12 Diode Diode WAGO
V12 009 7 Diode Diode WAGO
V13 006 12 Diode Diode WAGO
V14 009 14 Diode Diode Wago
V15 009 15 Diode Diode Wago
V16 010 3 Diode Diode WAGO
V17 010 4 Diode Diode WAGO
V18 010 3 Diode Diode WAGO
V19 010 2 Diode Diode WAGO
V21 009 9 Diode Diode WAGO
V22 009 10 Diode Diode WAGO
V23 007 2 Diode Diode WAGO
V25 007 3 Diode Diode WAGO
V26 013 14 Diode Diode WAGO
V31 008 10 Diode Diode Lütze
V32 007 9 Diode Diode Lütze
V33 007 11 Diode Diode Lütze
V34 007 5 Diode Diode Lütze
V35 007 7 Diode Diode Lütze
V36 013 19 Diode Diode FE5B
V37 008 13 Diode Diode Lütze
V38 007 2 Diode Diode FE5B KabeldiodeDiode
V42 009 13 Diode (A2) Diode (A2) Diodenmodul
V43 013 6 Diode (A3) Diode (A3) Diodenmodul
V46 011 15 Diode (A6) Diode (A6) Diodenmodul
V47 003 12 Diode (A7) Diode (A7) Diodenmodul
V48 013 15 Diode (A8) Diode (A8) Diodenmodul

X0/1:1 010 19 DIOS STECKER Dios connector

X0/1:2 010 19 DIOS STECKER Dios connector
X0/1:3 009 18 DIOS STECKER Dios connector
X0/1:4 009 19 DIOS STECKER Dios connector
X0/1:5 010 18 DIOS STECKER Dios connector
X0/1:6 010 19 DIOS STECKER Dios connector
X0/1:9 009 19 DIOS STECKER Dios connector
3

X0/1:10 009 19 DIOS STECKER Dios connector

X0/1:11 009 18 DIOS STECKER Dios connector
X0:1 007 10 ESX STECKER esx connector
X0:1 008 13 ESX STECKER esx connector
X0:1 010 8 ESX STECKER esx connector
11

X0:2 009 4 ESX STECKER esx connector

X0:3 009 9 ESX STECKER esx connector
X0:4 009 10 ESX STECKER esx connector
X0:5 009 11 ESX STECKER esx connector
570 700 42

X0:6 006 9 ESX STECKER esx connector

X0:7 008 14 ESX STECKER esx connector
X0:8 010 4 ESX STECKER esx connector
X0:9 010 8 ESX STECKER esx connector
X0:10 006 10 ESX STECKER esx connector
103

X0:11 006 9 ESX STECKER esx connector

X0:12 010 15 ESX STECKER esx connector
008 911
X0:13 53 006 10 ESX STECKER BOMAG
esx connector 981
Name Bl. Pf. Benennung title TYP

19.5 X0:14
X0:15
X0:16
010
010
009
7
8
4
ESX STECKER
ESX STECKER
ESX STECKER
esx connector
esx connector
esx connector
Wiring diagram 570 700 42
X0:17 010 14 ESX STECKER esx connector
X0:18 006 9 ESX STECKER esx connector
X0:19 006 9 ESX STECKER esx connector
X0:20 010 9 ESX STECKER esx connector
X0:21 007 10 ESX STECKER esx connector
X0:22 007 8 ESX STECKER esx connector
X0:23 007 11 ESX STECKER esx connector
X0:23 008 13 ESX STECKER esx connector
X0:23 010 9 ESX STECKER esx connector
X0:24 009 6 ESX STECKER esx connector
X0:25 009 7 ESX STECKER esx connector
Seis
06.08.2007
Werner
06.08.2007

X0:26 010 17 ESX STECKER esx connector

X0:27 010 16 ESX STECKER esx connector
X0:28 009 6 ESX STECKER esx connector
X0:29 007 19 ESX STECKER esx connector
X0:30 010 10 ESX STECKER esx connector
X0:31 010 13 ESX STECKER esx connector
X0:32 007 7 ESX STECKER esx connector
X0:33 009 9 ESX STECKER esx connector
X0:34 010 14 ESX STECKER esx connector
X0:35 010 12 ESX STECKER esx connector
X0:36 006 9 ESX STECKER esx connector
X0:37 010 16 ESX STECKER esx connector
X0:38 010 5 ESX STECKER esx connector
X0:39 010 6 ESX STECKER esx connector
X0:40 008 10 ESX STECKER esx connector
X0:41 010 12 ESX STECKER esx connector
X0:42 010 10 ESX STECKER esx connector
X0:43 007 19 ESX STECKER esx connector
X0:44 009 13 ESX STECKER esx connector
X0:45 006 10 ESX STECKER esx connector
X0:46 007 14 ESX STECKER esx connector
X0:47 007 16 ESX STECKER esx connector
X0:48 007 17 ESX STECKER esx connector
X0:49 010 8 ESX STECKER esx connector
X0:50 006 10 ESX STECKER esx connector
X0:51 006 10 ESX STECKER esx connector
X0:52 006 9 ESX STECKER esx connector
X0:53 009 9 ESX STECKER esx connector
X0:54 009 13 ESX STECKER esx connector
component listing

X0:55 010 17 ESX STECKER esx connector

X0:56 009 7 ESX STECKER esx connector
Bauteilliste

X0:57 009 8 ESX STECKER esx connector

X0:58 009 8 ESX STECKER esx connector
X0:59 009 8 ESX STECKER esx connector
X0:60 009 9 ESX STECKER esx connector
X0:61 008 10 ESX STECKER esx connector
X0:62 008 14 ESX STECKER esx connector
X0:63 010 12 ESX STECKER esx connector
X0:64 010 7 ESX STECKER esx connector
X0:65 010 15 ESX STECKER esx connector
X0:66 010 16 ESX STECKER esx connector
X0:67 010 16 ESX STECKER esx connector
X0:68 010 16 ESX STECKER esx connector
X1: 013 2 Wago Zentralelektrik Wago ebox
X1:1 014 7 Wago Zentralelektrik Wago ebox
X1:2 014 7 Wago Zentralelektrik Wago ebox
X1:3 014 2 Wago Zentralelektrik Wago ebox
X1:4 014 2 Wago Zentralelektrik Wago ebox
X1:5 004 20 Wago Zentralelektrik Wago ebox
X1:6 002 17 Wago Zentralelektrik Wago ebox
X1:7 003 9 Wago Zentralelektrik Wago ebox
X1:8 003 9 Wago Zentralelektrik Wago ebox
X1:9 003 9 Wago Zentralelektrik Wago ebox
X1:61 010 19 Wago Zentralelektrik Wago ebox
X1:62 004 15 Wago Zentralelektrik Wago ebox
X1:63 010 19 Wago Zentralelektrik Wago ebox
X1:64 004 16 Wago Zentralelektrik Wago ebox
X1:65 004 16 Wago Zentralelektrik Wago ebox
X1:66 009 10 Wago Zentralelektrik Wago ebox
X1:67 009 11 Wago Zentralelektrik Wago ebox
X1:68 010 19 Wago Zentralelektrik Wago ebox
X1:69 010 19 Wago Zentralelektrik Wago ebox
X1:70 002 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 003 16 Wago Zentralelektrik Wago ebox
X1:70 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:70 009 4 Wago Zentralelektrik Wago ebox
X1:70 009 6 Wago Zentralelektrik Wago ebox
4

X1:70 009 9 Wago Zentralelektrik Wago ebox

X1:70 009 13 Wago Zentralelektrik Wago ebox
X1:70 009 15 Wago Zentralelektrik Wago ebox
X1:70 009 17 Wago Zentralelektrik Wago ebox
X1:70 013 6 Wago Zentralelektrik Wago ebox
11

X1:71 004 17 Wago Zentralelektrik Wago ebox

X1:72 014 11 Wago Zentralelektrik Wago ebox
X1:81 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:82 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
570 700 42

X1:83 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:84 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:85 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:86 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:87 006 2 WAGO ZENTRALELEKTRIK WAGO EBOX
104

X1:88 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:89 006 2 WAGO ZENTRALELEKTRIK WAGO EBOX
982 X1:90 006 3 WAGO ZENTRALELEKTRIK BOMAG
WAGO EBOX 008 911 53
Name Bl. Pf. Benennung title TYP
X1:91

X1:93
006
Wiring diagram 570 700 42
X1:92 004
004
4
12
13
WAGO ZENTRALELEKTRIK
Wago Zentralelektrik
Wago Zentralelektrik
WAGO EBOX
Wago ebox
Wago ebox
19.5
X1:94 004 14 Wago Zentralelektrik Wago ebox
X1:101 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:102 006 9 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:103 006 5 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:104 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:105 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:106 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:108 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:109 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:110 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:111 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
06.08.2007
Werner
06.08.2007

X1:112 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:113 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:114 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:115 006 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:116 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:117 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:118 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:119 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:120 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:121 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:122 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:123 006 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:124 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:125 006 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:126 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:127 013 13 Wago Zentralelektrik Wago ebox
X1:128 013 13 Wago Zentralelektrik Wago ebox
X1:129 013 15 Wago Zentralelektrik Wago ebox
X1:130 013 15 Wago Zentralelektrik Wago ebox
X1:131 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:132 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:133 007 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:134 007 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:135 007 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:136 007 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:137 010 12 Wago Zentralelektrik Wago ebox
X1:138 010 12 Wago Zentralelektrik Wago ebox
X1:139 010 13 Wago Zentralelektrik Wago ebox
X1:140 010 13 Wago Zentralelektrik Wago ebox
component listing

X1:141 010 18 Wago Zentralelektrik Wago ebox

X1:142 010 18 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:143 010 19 Wago Zentralelektrik Wago ebox

X1:144 010 19 Wago Zentralelektrik Wago ebox
X1:145 014 9 Wago Zentralelektrik Wago ebox
X1:146 013 15 Wago Zentralelektrik Wago ebox
X1:147 013 15 Wago Zentralelektrik Wago ebox
X1:148 005 8 Wago Zentralelektrik Wago ebox
X1:149 007 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:150 014 10 Wago Zentralelektrik Wago ebox
X1:151 008 10 Wago Zentralelektrik Wago ebox
X1:152 008 10 Wago Zentralelektrik Wago ebox
X1:153 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:154 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:155 007 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:156 007 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:157 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:158 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:159 010 7 Wago Zentralelektrik Wago ebox
X1:160 010 7 Wago Zentralelektrik Wago ebox
X1:161 010 8 Wago Zentralelektrik Wago ebox
X1:162 010 8 Wago Zentralelektrik Wago ebox
X1:163 010 9 Wago Zentralelektrik Wago ebox
X1:164 010 9 Wago Zentralelektrik Wago ebox
X1:165 010 10 Wago Zentralelektrik Wago ebox
X1:166 010 10 Wago Zentralelektrik Wago ebox
X1:170 008 14 Wago Zentralelektrik Wago ebox
X1:171 011 4 Wago Zentralelektrik Wago ebox
X1:172 011 3 Wago Zentralelektrik Wago ebox
X1:173 011 3 Wago Zentralelektrik Wago ebox
X1:174 011 4 Wago Zentralelektrik Wago ebox
X1:181 006 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:181 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:181 010 15 Wago Zentralelektrik Wago ebox
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:182 010 16 Wago Zentralelektrik Wago ebox
X1:183 006 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:183 006 19 WAGO ZENTRALELEKTRIK WAGO EBOX
5

X1:183 010 16 Wago Zentralelektrik Wago ebox

X1:184 006 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:184 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:184 009 18 Wago Zentralelektrik Wago ebox
X1:185 006 17 WAGO ZENTRALELEKTRIK WAGO EBOX
11

X1:185 009 19 Wago Zentralelektrik Wago ebox

X1:186 006 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:186 009 19 Wago Zentralelektrik Wago ebox
X1:187 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
570 700 42

X1:187 010 16 Wago Zentralelektrik Wago ebox

X1:188 007 4 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:188 010 17 Wago Zentralelektrik Wago ebox
X1:189 010 15 Wago Zentralelektrik Wago ebox
X1:189 014 9 Wago Zentralelektrik Wago ebox
105

X1:189 014 9 Wago Zentralelektrik Wago ebox

X1:190 011 6 Wago Zentralelektrik Wago ebox
008 911
X1:19053 014 10 Wago Zentralelektrik BOMAG
Wago ebox 983
Name Bl. Pf. Benennung title TYP

19.5 X1:190
X1:191
X1:191
014
006
006
11
15
15
Wago Zentralelektrik
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
Wago ebox
WAGO EBOX
WAGO EBOX
Wiring diagram 570 700 42
X1:191 011 7 Wago Zentralelektrik Wago ebox
X1:192 008 14 Wago Zentralelektrik Wago ebox
X1:201 013 15 Wago Zentralelektrik Wago ebox
X1:202 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:205 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:205 013 15 Wago Zentralelektrik Wago ebox
X1:207 009 4 Wago Zentralelektrik Wago ebox
X1:20A 013 19 Sika Klemme fuse terminal
X1:20E 013 19 Sika Klemme fuse terminal
X1:210 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:21A 002 12 Sika Klemme fuse terminal
Seis
06.08.2007
Werner
06.08.2007

X1:21E 002 12 Sika Klemme fuse terminal

X1:221 007 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:222 007 14 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:223 007 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:224 007 16 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:226 012 3 Wago Zentralelektrik Wago ebox
X1:227 012 3 Wago Zentralelektrik Wago ebox
X1:228 005 15 Wago Zentralelektrik Wago ebox
X1:229 005 15 Wago Zentralelektrik Wago ebox
X1:22A 013 3 Sika Klemme fuse terminal
X1:22E 013 3 Sika Klemme fuse terminal
X1:231 004 6 Wago Zentralelektrik Wago ebox
X1:232 004 6 Wago Zentralelektrik Wago ebox
X1:233 004 7 Wago Zentralelektrik Wago ebox
X1:234 008 5 Wago Zentralelektrik Wago ebox
X1:235 004 6 Wago Zentralelektrik Wago ebox
X1:236 004 6 Wago Zentralelektrik Wago ebox
X1:237 004 7 Wago Zentralelektrik Wago ebox
X1:23A 003 9 Sika Klemme fuse terminal
X1:23E 002 3 Sika Klemme fuse terminal
X1:23E 003 9 Sika Klemme fuse terminal
X1:241 002 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:242 002 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:243 002 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:244 004 10 Wago Zentralelektrik Wago ebox
X1:245 011 19 Wago Zentralelektrik Wago ebox
X1:246 011 19 Wago Zentralelektrik Wago ebox
X1:247 013 15 Wago Zentralelektrik Wago ebox
X1:248 011 3 Wago Zentralelektrik Wago ebox
component listing

X1:249 013 10 Wago Zentralelektrik Wago ebox

X1:24A 004 4 Sika Klemme fuse terminal
Bauteilliste

X1:24E 004 4 Sika Klemme fuse terminal

X1:250 004 10 Wago Zentralelektrik Wago ebox
X1:251 013 9 Wago Zentralelektrik Wago ebox
X1:252 013 13 Wago Zentralelektrik Wago ebox
X1:253 013 17 Wago Zentralelektrik Wago ebox
X1:255 004 18 Wago Zentralelektrik Wago ebox
X1:256 002 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:256 003 12 Wago Zentralelektrik Wago ebox
X1:256 011 15 Wago Zentralelektrik Wago ebox
X1:257 009 13 Wago Zentralelektrik Wago ebox
X1:258 009 13 Wago Zentralelektrik Wago ebox
X1:259 002 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:25A 002 15 Sika Klemme fuse terminal
X1:25E 002 15 Sika Klemme fuse terminal
X1:260 002 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:261 008 10 Wago Zentralelektrik Wago ebox
X1:262 007 18 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:262 008 10 Wago Zentralelektrik Wago ebox
X1:263 008 10 Wago Zentralelektrik Wago ebox
X1:265 012 18 Wago Zentralelektrik Wago ebox
X1:266 012 17 Wago Zentralelektrik Wago ebox
X1:267 012 18 Wago Zentralelektrik Wago ebox
X1:268 012 19 Wago Zentralelektrik Wago ebox
X1:269 004 11 Wago Zentralelektrik Wago ebox
X1:26A 009 13 Sika Klemme fuse terminal
X1:26E 009 13 Sika Klemme fuse terminal
X1:270 004 11 Wago Zentralelektrik Wago ebox
X1:272 011 3 Wago Zentralelektrik Wago ebox
X1:272 013 9 Wago Zentralelektrik Wago ebox
X1:27A 009 7 Sika Klemme fuse terminal
X1:27E 009 7 Sika Klemme fuse terminal
X1:28A 013 2 Sika Klemme fuse terminal
X1:28E 013 2 Sika Klemme fuse terminal
X1:291 005 7 Wago Zentralelektrik Wago ebox
X1:292 005 11 Wago Zentralelektrik Wago ebox
X1:293 003 10 Wago Zentralelektrik Wago ebox
X1:294 005 5 Wago Zentralelektrik Wago ebox
6

X1:295 005 7 Wago Zentralelektrik Wago ebox

X1:296 005 15 Wago Zentralelektrik Wago ebox
X1:298 002 11 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:298 005 11 Wago Zentralelektrik Wago ebox
X1:299 004 20 Wago Zentralelektrik Wago ebox
11

X1:299 005 5 Wago Zentralelektrik Wago ebox

X1:29A 005 5 Sika Klemme fuse terminal
X1:29E 005 5 Sika Klemme fuse terminal
X1:300 005 7 Wago Zentralelektrik Wago ebox
570 700 42

X1:301 005 11 Wago Zentralelektrik Wago ebox

X1:302 003 13 Wago Zentralelektrik Wago ebox
X1:303 005 8 Wago Zentralelektrik Wago ebox
X1:308 010 2 Wago Zentralelektrik Wago ebox
X1:30A 011 4 Sika Klemme fuse terminal
106

X1:30E 011 4 Sika Klemme fuse terminal

X1:31A 011 18 Sika Klemme fuse terminal
984 X1:31E 002 17 SIKA KLEMME BOMAG
fuse terminal 008 911 53
Name Bl. Pf. Benennung title TYP
X1:31E

X1:322
011
Wiring diagram 570 700 42
X1:321 010
010
18
7
9
Sika Klemme
Wago Zentralelektrik
Wago Zentralelektrik
fuse terminal
Wago ebox
Wago ebox
19.5
X1:323 010 8 Wago Zentralelektrik Wago ebox
X1:324 010 8 Wago Zentralelektrik Wago ebox
X1:325 010 7 Wago Zentralelektrik Wago ebox
X1:326 010 8 Wago Zentralelektrik Wago ebox
X1:327 010 12 Wago Zentralelektrik Wago ebox
X1:328 010 11 Wago Zentralelektrik Wago ebox
X1:329 010 11 Wago Zentralelektrik Wago ebox
X1:32A 002 17 Sika Klemme fuse terminal
X1:32E 002 17 Sika Klemme fuse terminal
X1:330 010 10 Wago Zentralelektrik Wago ebox
X1:331 010 12 Wago Zentralelektrik Wago ebox
Seis
06.08.2007
Werner
06.08.2007

X1:332 010 12 Wago Zentralelektrik Wago ebox

X1:333 010 15 Wago Zentralelektrik Wago ebox
X1:334 010 15 Wago Zentralelektrik Wago ebox
X1:335 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:336 007 9 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:337 007 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:338 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:339 007 5 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:33A 013 6 Sika Klemme fuse terminal
X1:33E 002 17 SIKA KLEMME fuse terminal
X1:33E 013 6 Sika Klemme fuse terminal
X1:340 007 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:341 011 18 Wago Zentralelektrik Wago ebox
X1:342 011 18 Wago Zentralelektrik Wago ebox
X1:343 008 4 Wago Zentralelektrik Wago ebox
X1:343 010 6 Wago Zentralelektrik Wago ebox
X1:344 010 5 Wago Zentralelektrik Wago ebox
X1:345 010 4 Wago Zentralelektrik Wago ebox
X1:346 010 4 Wago Zentralelektrik Wago ebox
X1:347 010 5 Wago Zentralelektrik Wago ebox
X1:348 010 6 Wago Zentralelektrik Wago ebox
X1:349 009 18 Wago Zentralelektrik Wago ebox
X1:349 009 19 Wago Zentralelektrik Wago ebox
X1:349 009 19 Wago Zentralelektrik Wago ebox
X1:349 010 17 Wago Zentralelektrik Wago ebox
X1:34A 011 14 Sika Klemme fuse terminal
X1:34E 011 14 Sika Klemme fuse terminal
X1:350 010 14 Wago Zentralelektrik Wago ebox
X1:351 010 13 Wago Zentralelektrik Wago ebox
component listing

X1:352 010 13 Wago Zentralelektrik Wago ebox

X1:353 010 14 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:354 010 14 Wago Zentralelektrik Wago ebox

X1:355 011 19 Wago Zentralelektrik Wago ebox
X1:356 011 14 Wago Zentralelektrik Wago ebox
X1:357 008 17 Wago Zentralelektrik Wago ebox
X1:358 008 13 Wago Zentralelektrik Wago ebox
X1:359 008 14 Wago Zentralelektrik Wago ebox
X1:35A 009 2 Sika Klemme fuse terminal
X1:35E 009 2 Sika Klemme fuse terminal
X1:363 010 16 Wago Zentralelektrik Wago ebox
X1:364 010 20 Wago Zentralelektrik Wago ebox
X1:364 011 14 Wago Zentralelektrik Wago ebox
X1:36A 013 9 Sika Klemme fuse terminal
X1:36E 013 9 Sika Klemme fuse terminal
X1:371 003 16 Wago Zentralelektrik Wago ebox
X1:372 014 19 Wago Zentralelektrik Wago ebox
X1:372 014 20 Wago Zentralelektrik Wago ebox
X1:373 012 15 Wago Zentralelektrik Wago ebox
X1:374 012 15 Wago Zentralelektrik Wago ebox
X1:375 012 3 Wago Zentralelektrik Wago ebox
X1:376 012 3 Wago Zentralelektrik Wago ebox
X1:377 012 19 Wago Zentralelektrik Wago ebox
X1:378 014 10 Wago Zentralelektrik Wago ebox
X1:381 013 19 Wago Zentralelektrik Wago ebox
X1:382 013 18 Wago Zentralelektrik Wago ebox
X1:383 013 17 Wago Zentralelektrik Wago ebox
X1:391/1 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:391/2 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:392/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:392/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:393/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:393/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:394/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:394/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:395/1 006 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:395/2 006 6 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:397/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:397/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
7

X1:398/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:398/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:399/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:399/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:400/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
11

X1:400/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:401/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:401/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:402/1 009 7 Wago Zentralelektrik Wago ebox
570 700 42

X1:402/2 009 7 Wago Zentralelektrik Wago ebox

X1:403/1 006 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:403/2 006 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:404/1 009 14 Wago Zentralelektrik Wago ebox
X1:404/2 009 14 Wago Zentralelektrik Wago ebox
107

X1:405/1 009 15 Wago Zentralelektrik Wago ebox

X1:405/2 009 15 Wago Zentralelektrik Wago ebox
008 911 53
X1:406/1 010 3 Wago Zentralelektrik BOMAG
Wago ebox 985
Name Bl. Pf. Benennung title TYP

19.5 X1:406/2
X1:407/1
X1:407/2
010
010
010
3
4
4
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago ebox
Wago ebox
Wago ebox
Wiring diagram 570 700 42
X1:408/1 010 3 Wago Zentralelektrik Wago ebox
X1:408/2 010 3 Wago Zentralelektrik Wago ebox
X1:409/1 010 2 Wago Zentralelektrik Wago ebox
X1:409/2 010 2 Wago Zentralelektrik Wago ebox
X1:41/1 008 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:41/2 008 13 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:410/1 009 9 Wago Zentralelektrik Wago ebox
X1:410/2 009 9 Wago Zentralelektrik Wago ebox
X1:411/1 009 10 Wago Zentralelektrik Wago ebox
X1:411/2 009 10 Wago Zentralelektrik Wago ebox
X1:412/1 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX
Seis
06.08.2007
Werner
06.08.2007

X1:412/2 007 2 WAGO ZENTRALELEKTRIK WAGO EBOX

X1:413/1 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:413/2 007 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:414/1 013 14 Wago Zentralelektrik Wago ebox
X1:414/2 013 14 Wago Zentralelektrik Wago ebox
X1:42/1 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:42/2 007 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:43/1 010 9 Wago Zentralelektrik Wago ebox
X1:43/2 010 9 Wago Zentralelektrik Wago ebox
X1:44/1 010 5 Wago Zentralelektrik Wago ebox
X1:44/2 010 5 Wago Zentralelektrik Wago ebox
X1:45/1 010 11 Wago Zentralelektrik Wago ebox
X1:45/2 010 11 Wago Zentralelektrik Wago ebox
X1:46/1 007 8 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:46/2 007 7 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:47/1 010 14 Wago Zentralelektrik Wago ebox
X1:47/2 010 14 Wago Zentralelektrik Wago ebox
X2:A 010 19 Datenschnittstelle data interface
X2:B 010 19 Datenschnittstelle data interface
X2:G 009 11 Datenschnittstelle data interface
X2:H 009 10 Datenschnittstelle data interface
X2:J 002 11 Datenschnittstelle data interface
X2:N 002 11 Datenschnittstelle data interface
X2:U 009 11 Datenschnittstelle data interface
X2:V 010 15 Datenschnittstelle data interface
X3:A 008 3 Stecker Handgas connector hand throttle
X3:B 008 2 Stecker Handgas connector hand throttle
X3:C 008 2 Stecker Handgas connector hand throttle
X4:A 004 15 EMR Diagnose EMRdiagnosis
component listing

X4:B 004 17 EMR Diagnose EMRdiagnosis

X4:F 004 16 EMR Diagnose EMRdiagnosis
Bauteilliste

X4:G 004 16 EMR Diagnose EMRdiagnosis

X4:H 004 15 EMR Diagnose EMRdiagnosis
X4:K 004 17 EMR Diagnose EMRdiagnosis
X4:M 004 16 EMR Diagnose EMRdiagnosis
X5:1 005 7 Deutsch Stecker Senso Deutsch Connector sensor
X6:1 004 10 Wago Zentralelektrik Wago ebox
X6:2 004 10 Wago Zentralelektrik Wago ebox
X6:3 004 11 Wago Zentralelektrik Wago ebox
X6:4 004 11 Wago Zentralelektrik Wago ebox
X6:5 004 15 Wago Zentralelektrik Wago ebox
X6:6 004 15 Wago Zentralelektrik Wago ebox
X6:7 004 16 Wago Zentralelektrik Wago ebox
X6:8 004 16 Wago Zentralelektrik Wago ebox
X6:9 004 16 Wago Zentralelektrik Wago ebox
X6:10 004 17 Wago Zentralelektrik Wago ebox
X7:1 014 9 Stecker Rops connector on rops
X7:2 014 9 Stecker Rops connector on rops
X7:3 014 9 Stecker Rops connector on rops
X7:4 014 9 Stecker Rops connector on rops
X7:5 013 16 Stecker Rops connector on rops
X7:6 013 16 Stecker Rops connector on rops
X8:1 012 3 Pumpenstecker Kabine connector pump cabin;
X8:2 012 3 Pumpenstecker Kabine connector pump cabin;
X9:1 007 5 Stecker Schalter Rich connector direction switch
X9:2 007 9 Stecker Schalter Rich connector direction switch
X9:3 007 7 Stecker Schalter Rich connector direction switch
X9:4 007 5 Stecker Schalter Rich connector direction switch
X9:5 007 5 Stecker Schalter Rich connector direction switch
X9:6 007 6 Stecker Schalter Rich connector direction switch
XS 002 15 Steckdose Socket
X10:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X10:B 004 6 AMP Stecker Gaspedal AMP connector throttle
X10:C 004 6 AMP Stecker Gaspedal AMP connector throttle
X11:1 011 18 Schnittstelle Sitz connector drivers seat
X11:2 011 18 Schnittstelle Sitz connector drivers seat
X12:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X12:B 004 8 AMP Stecker Gaspedal AMP connector throttle
8

X12:C 004 7 AMP Stecker Gaspedal AMP connector throttle

X13:1 008 17 Stecker Stufenschalte connector speed range switch
X13:2 008 18 Stecker Stufenschalte connector speed range switch
X13:3 008 14 Stecker Stufenschalte connector speed range switch
X14:4 013 15 Stecker Motor connector engine
11

X14:5 013 16 Stecker Motor connector engine

X14:6 002 6 Motorschnittstelle engine interface
X14:7 002 6 Motorschnittstelle engine interface
X14:8 005 7 Motorschnittstelle engine interface
570 700 42

X14:9 003 9 Motorschnittstelle engine interface

X14:10 006 12 Stecker Motor connector engine
X14:11 006 12 Stecker Motor connector engine
X15:A 010 18 Stecker Lehne links connector arm rest lh.
X15:B 010 18 Stecker Lehne links connector arm rest lh.
108

X15:C 010 20 Stecker Lehne links connector arm rest lh.

X17:1 013 16 Stecker Klimakupplung connector clima clutch
986 X17:2 013 16 Stecker Klimakupplung BOMAG
connector clima clutch 008 911 53
Name Bl. Pf. Benennung title TYP
X18:1

X19:1
013
Wiring diagram 570 700 42
X18:2 013
013
16
16
13
Stecker Druckschalter
Stecker Druckschalter
Stecker Heizventil
connector pressure switch
connector pressure switch
connector heating valve
19.5
X19:2 013 13 Stecker Heizventil connector heating valve
X21:1 011 19 Schnittstelle Sitz connector drivers seat
X21:2 011 19 Schnittstelle Sitz connector drivers seat
X22:1 013 10 Stecker Luftklappe connector air flap
X22:2 013 11 Stecker Luftklappe connector air flap
X23:1 013 14 Stecker Sensor connector sensor
X23:2 013 14 Stecker Sensor connector sensor
X24:1 013 15 Stecker Sensor connector sensor
X24:2 013 15 Stecker Sensor connector sensor
X25:A 013 19 Stecker Lüfter connector blower
X25:B 013 18 Stecker Lüfter connector blower
Seis
06.08.2007
Werner
06.08.2007

X25:C 013 18 Stecker Lüfter connector blower

X26:1 013 9 Stecker Klimasteuerun connector climacontrol
X26:2 013 9 Stecker Klimasteuerun connector climacontrol
X26:3 013 11 Stecker Klimasteuerun connector climacontrol
X26:4 013 10 Stecker Klimasteuerun connector climacontrol
X26:5 013 16 Stecker Klimasteuerun connector climacontrol
X26:6 013 12 Stecker Klimasteuerun connector climacontrol
X26:7 013 12 Stecker Klimasteuerun connector climacontrol
X26:8 013 15 Stecker Klimasteuerun connector climacontrol
X26:9 013 13 Stecker Klimasteuerun connector climacontrol
X26:10 013 10 Stecker Klimasteuerun connector climacontrol
X26:11 013 11 Stecker Klimasteuerun connector climacontrol
X26:12 013 13 Stecker Klimasteuerun connector climacontrol
X26:13 013 13 Stecker Klimasteuerun connector climacontrol
X26:14 013 13 Stecker Klimasteuerun connector climacontrol
X27:1 013 14 Stecker Klimasteuerun connector climacontrol
X27:2 013 14 Stecker Klimasteuerun connector climacontrol
X27:3 013 15 Stecker Klimasteuerun connector climacontrol
X27:4 013 15 Stecker Klimasteuerun connector climacontrol
X28:1 011 6 Stecker Radsensor connector wheel sensor
X28:2 011 6 Stecker Radsensor connector wheel sensor
X28:3 011 7 Stecker Radsensor connector wheel sensor
X28:4 011 7 Stecker Radsensor connector wheel sensor
X29:1 013 6 Stecker Zyklon Connector cyclone
X29:2 013 6 Stecker Zyklon Connector cyclone
X30:A 011 6 Verbindungsstecker Se connector sensor
X30:B 011 6 Verbindungsstecker Se connector sensor
X30:C 011 7 Verbindungsstecker Se connector sensor
X31:A 011 11 Verbindungsstecker An connector gauge
component listing

X31:B 011 9 Verbindungsstecker An connector gauge

X31:C 011 10 Verbindungsstecker An connector gauge
Bauteilliste

X33:1 011 4 Schmieranlage lubrication system

X33:2 011 4 Schmieranlage lubrication system
X34:1 011 4 Schmieranlage lubrication system
X34:2 011 4 Schmieranlage lubrication system
X34:3 011 3 Schmieranlage lubrication system
X34:4 011 3 Schmieranlage lubrication system
X34:5 011 4 Schmieranlage lubrication system
X35:1 009 13 Stecker Warnsummer connector warning buzzer
X35:2 009 13 Stecker Warnsummer connector warning buzzer
X36:1 008 7 Stecker Poti connector potentiometer
X36:2 008 6 Stecker Poti connector potentiometer
X36:3 008 7 Stecker Poti connector potentiometer
X39:A 008 7 Stecker Deceleratorpe connector decelerator pedal
X39:B 008 6 Stecker Deceleratorpe connector decelerator pedal
X39:C 008 6 Stecker Deceleratorpe connector decelerator pedal
X40:1 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:2 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:3 008 9 Stecker Deceleratorpe connector decelerator pedal
X40:4 008 7 Stecker Deceleratorpe connector decelerator pedal
X40:5 008 8 Stecker Decelelratorp connector decelerator pedal
X40:6 008 7 Stecker Deceleratorpe connector decelerator pedal
X41:1 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:2 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:3 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:4 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:5 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:6 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:8 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:9 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:10 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:11 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:12 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X42:1 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:2 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:4 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:5 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:6 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
9

X17.1:1 004 2 2pol SPT 2pole SPT

X17.1:2 004 2 2pol SPT 2pole SPT
X27.1:4 004 18 Motor / 42pol EPC engine / 42pole EPC
X27.1:6 004 19 Motor / 42pol EPC engine / 42pole EPC
X27.1:7 004 19 Motor / 42pol EPC engine / 42pole EPC
11

X27.1:11 004 14 Motor / 42pol EPC engine / 42pole EPC

X27.1:12 004 6 Motor / 42pol EPC engine / 42pole EPC
X27.1:13 004 8 Motor / 42pol EPC engine / 42pole EPC
X27.1:14 004 8 Motor / 42pol EPC engine / 42pole EPC
570 700 42

X27.1:15 004 9 Motor / 42pol EPC engine / 42pole EPC

X27.1:18 004 7 Motor / 42pol EPC engine / 42pole EPC
X27.1:19 004 5 Motor / 42pol EPC engine / 42pole EPC
X27.1:20 004 4 Motor / 42pol EPC engine / 42pole EPC
X27.1:21 004 10 Motor / 42pol EPC engine / 42pole EPC
109

X27.1:22 004 11 Motor / 42pol EPC engine / 42pole EPC

X27.1:23 004 10 Motor / 42pol EPC engine / 42pole EPC
008 911 53
X27.1:24 004 7 Motor / 42pol EPC BOMAG
engine / 42pole EPC 987
Name Bl. Pf. Benennung title TYP

19.5 X27.1:25
X27.1:26
X27.1:27
004
004
004
4
5
5
Motor / 42pol EPC
Motor / 42pol EPC
Motor / 42pol EPC
engine / 42pole EPC
engine / 42pole EPC
engine / 42pole EPC
Wiring diagram 570 700 42
X27.1:28 004 11 Motor / 42pol EPC engine / 42pole EPC
X27.1:29 004 11 Motor / 42pol EPC engine / 42pole EPC
X27.1:30 004 7 Motor / 42pol EPC engine / 42pole EPC
X27.1:33 004 6 Motor / 42pol EPC engine / 42pole EPC
X27.1:34 004 12 Motor / 42pol EPC engine / 42pole EPC
X27.1:35 004 12 Motor / 42pol EPC engine / 42pole EPC
X27.1:36 004 14 Motor / 42pol EPC engine / 42pole EPC
X27.1:37 004 13 Motor / 42pol EPC engine / 42pole EPC
X27.1:39 004 17 Motor / 42pol EPC engine / 42pole EPC
X27.1:40 004 16 Motor / 42pol EPC engine / 42pole EPC
X27.1:41 004 16 Motor / 42pol EPC engine / 42pole EPC
Seis
06.08.2007
Werner
06.08.2007

X27.1:42 004 15 Motor / 42pol EPC engine / 42pole EPC

X27.2:10 004 3 12pol EPC 12pole EPC
X27.2:11 004 3 12pol EPC 12pole EPC
XD2.1:2 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:3 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:5 004 18 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:6 004 18 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:8 004 4 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:9 004 5 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:10 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:11 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:13 004 11 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:20 004 14 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:22 004 10 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:29 004 5 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:30 004 10 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:33 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:34 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:35 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:38 004 11 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:39 004 13 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:40 004 15 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:52 004 16 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:53 004 15 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:54 004 12 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:59 004 8 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:60 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:61 004 8 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.1:62 004 5 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
component listing

XD2.1:77 004 6 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH

XD2.1:78 004 7 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
Bauteilliste

XD2.1:79 004 6 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH

XD2.1:89 004 17 EDC7 / 89pol BOSCH EDC7 / 89pol BOSCH
XD2.2:3 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:4 004 19 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:5 004 19 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:7 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:8 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:9 004 8 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:10 004 8 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:15 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:18 004 6 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:19 004 9 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:23 004 10 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:24 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:25 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:26 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:27 004 5 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:28 004 4 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:32 004 6 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:33 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:34 004 10 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:35 004 7 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.2:36 004 11 EDC7 / 36pol BOSCH EDC7 / 36pol BOSCH
XD2.3:3 004 15 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:4 004 12 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:6 004 13 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:7 004 14 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:8 004 18 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:12 004 14 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:13 004 12 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:14 004 16 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:15 004 16 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH
XD2.3:16 004 17 EDC7 / 16pol BOSCH EDC7 / 16pol BOSCH

Y14 012 3 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit

Y15 013 16 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 1,75A
Y16 007 10 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y16 007 12 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y17 007 6 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
11

Y17 007 8 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y92 010 7 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. max. 1,1A
Y93 010 8 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. max. 1,1A
Y102 010 12 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A
570 700 42

Y102 010 13 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A

Y108 010 9 Magnetventil Schaufel Heben solenoid valve, lifting shovel max. 1,1A
Y109 010 10 Magnetventil Schaufel Senken solenoid valve, let down shovel max. 1,1A
Y110 010 19 Magnetventil Schaufel oeffnen solenoid valve, open shovel max. 1,1A
Y111 010 18 Magnetventil Schaufel Schließen solenoid valve, close shovel max. 1,1A
110

Y132 007 14 Magnetventil Radmotor vorn links Solenoid valve, wheel motor front lh. max. 0,6A
Y133 007 16 Magnetventil Radmotor vorn rechts Solenoid valve, wheel motor front rh. max. 0,6A
988 Y134 007 17 Magnetventil Radmotor hinten links BOMAG
Solenoid valve, wheel motor rear lh. 008
max. 0,6A 911 53
Name Bl. Pf. Benennung title TYP
Y135

Y147
007
Wiring diagram 570 700 42
Y138 013
004
19
13
12
Magnetventil Radmotor hinten rechts
Magnetveentil Heizung
Injektor A1
Solenoid valve, wheel motor rear rh.
Solenoid valve, heating unit
jet pump A1
max. 0,6A
0,42A 19.5
Y148 004 14 Injektor A2 jet pump A2
Y149 004 13 Injektor A3 jet pump A3
Y150 004 17 Injektor B1 jet pump B1
Y151 004 16 Injektor B2 jet pump B2
Y152 004 16 Injektor B3 jet pump B3
Y166 004 14 Injektor A4 jet pump A4
Y167 004 18 Injektor B4 jet pump B4
Seis
06.08.2007
Werner
06.08.2007
component listing
Bauteilliste
11
11
570 700 42
111

008 911 53 BOMAG 989

008 911 53 BOMAG 990
404

402
408

394
400
403
405
406
407
409
414

392
398

393
395
396
397
399
412

401
410
413
415

391
411

K77 K77
H07

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
057 513 10

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
057 664 11 057 664 11
057 564 17

057 564 37
057 564 22 057 564 30
057 564 23
1x6qmm
1x6qmm

Seis

153 131 1x6qmm

Versorgung Kabine 1
Werner

154 132
155 133 1x6qmm Versorgung Kabine 1x6qmm
2
06.08.2007
06.08.2007

156 134
K11

157 135 1x6qmm Masse Kabine 3

158 136
057 543 08

1x6qmm Masse Kabine 4

159 137
160 138 Masse Schutzbelüftung 5
161 139
057 564 29

162 140 6
163 141
164 142 7
165 143
1x2,5qmm
1x4qmm

1x6qmm
1x6qmm

166 144 8
057 564 35

167 145 9
K05

168 146 15A

169 147 Klimatronik Konvekta 1x1,5qmm F50 20
170 148 Zigarettenanzünder + 30A
171 149 1x1,5qmm F89 21
Tachograph / BC 672 EB
057 564 19
K22

172 150 Schutzbelüftung 22

30A
206 201 Leistung Steuerung 5x0,75qmm F67 27 1x4qmm
207 202
Schutzbelüftung
208 203 28
209 204 15A
Instrumente 1x1,5qmm
K90

F24 29
210 205
Schmieranlage + 10A
226 221 1x1,5qmm F16 30
Tachograph / BC 672 EB
227 222 15A
Fahrersitz 1x1,5qmm F29 31 1x2,5qmm
228 223
K48

10A
229 224 EDC7 Steuerung (15) 1x1,5qmm F122 32
230 225
K11

10A
235 231 Zykon Abscheider 1x1,5qmm F31 33 1x2,5qmm
236 232 15A
K61

Signalhörner 1x1,5qmm F23 34

237 233
238 234 10A
Fahren und Bremse 1x1,5qmm F25 35
257 241 10A
258 242 Klimatronik Konvekta 1x1,5qmm F33
057 268 42

36
K62

259 243
260 244 37
261 245 45 41
262 246 45 41
K133

263 247 46 42
264 248 46 42

ebox
265 249 47 43
057 564 25

266 250 47 43
057 564 36

Schaltkasten
057 564 21

267 251 48 44
057 543 12

1 2 1 2 1 2 1 2
1 2 1 2 1 2 1 2

268 252 48 44
057 564 38

269 253 61
270 254
K15

62
271 255
057 500 57

63
057 664 96

272 256 64
K146

300 291 65
301 292 66
302 292
293 67
K60

303 294 68
304 295 69
305 296 70
306 297 71
307 298 72

057 565 39
308 299 84 81
343 321 85 82

057 565 36
057 668 71

344 322 86 83
057 564 24

345 323 92 87
346 324 93 88
347 325 94 89
348 326 95 90
349 327 96 91
057 564 26

350 328 104 101

057 565 40
351 329 105 102

057 565 38
352 330 106 103
353 331 115 107
354 332 116 108
355 333 117 109
356 334 118 110
X2:AV

357 335 119 111

358 336 119 111
057 555 96

359 337 120 112

360 338 121 113
361 339 122 114

057 565 37
362 340 125 123
363 341 126 124

057 565 35
364 342
129 127
data interface

375 371 130 128

Datenschnittstelle

376 372
377 373 6 1
378 374 7 2
057 556 04 (Kappe/cap)

057 665 63
383 381 8 3

057 665 61
384 382 9 4

X6:1..10
057 555 98

10 5

1
X6
2 R42 1 2 R10 1
47_O 220_O
2 R40 1 2 R27 1
47_O 10_O

1
057 564 43

057 199 46
diagnosis EMR
Diagnose EMR
X4:
2 R38 1 2 R26 1
47_O 22_O
2 R36 1 2 2 2 2 2 2 2 2
LU Motor
47_O
P18
8 7 6 5 4 3 2 1

057 664 03
1 1
1 1 1 1 1 1

LU Motor

570 700 42
057 664 08

V48
V47
V46
V45
V44
V43
V42
V41

201
057 665 62
Wiring diagram 570 700 42 19.5
008 911 53
Wiring diagram 570 700 42

X28
X4
X2
X17

X1
X30
X15
X3
X11
X35
X7 X21
X18
X13 X39
X23 X9
X26 X12 X40
X0
X19 X27 X10
X16 X31 X42 X36

BOMAG
X22 X41
X29 X24 X8
X14 X18
X17 X27.1 X25

X27.2
D2.1

X33
D2.2 D2.3
X34

06.08.2007
1 1 570 700 42
Werner Lokalisierungsgrafik Steckverbinder Draufsicht
06.08.2007
19.5

991
Seis localization graphic connectors top view 301
992
19.5

X18

X29

X23
X31 X11 X15 X13
X16 X41
X21
X4 X42
X36
X2 X19 X15 X26 X9
X0
X27

X24
X18 X22
X1

X30 X25 X12 X39

X35
X3 X10 X40

D2.2 X34
X17 X27.1
D2.1 X27.2

BOMAG
D2.3 X33

X14

X28

06.08.2007
1 1

008 911 53
Wiring diagram 570 700 42

Werner Lokalisierungsgrafik Steckverbinder Seitenansicht 570 700 42

06.08.2007
Seis localization graphic connectors side view 302
19.6 Wiring diagram 570 700 44

008 911 53 BOMAG 993

19.6 Wiring diagram 570 700 44

S/N Wiring diagram 570 700 44

S/N 101 570 571 029 ⇔ 101 570 571 ... BC772 RS-2
S/N 101 570 581 130 ⇔ 101 570 581 ... BC772 RB-2
S/N 101 570 591 036 ⇔ 101 570 591 ... BC672 RB-2
S/N 101 570 821 047 ⇔ 101 570 821 ... BC972 RB-2
S/N 101 570 831 060 ⇔ 101 570 831 ... BC1172 RB-2

994 BOMAG 008 911 53

Inhaltsverzeichnis: BC 672...11722 RB/EB/RS

008 911 53
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing no.
001 570 700 44 Stromlaufplan Circuit Diagram
002 570 700 44 Versorgung, Zigarettenanzünder supply, cigarette lighter
003 570 700 44 Zündschloß, Starter ignition switch, starter
004 570 700 44 DEUTZ Steuergerät EDC 7 f. 6 und 8Zylindermot. DEUTZ controller EDC 7 for 6 and 8zylinder engine
005 570 700 44 Anzeigen, Störmeldungen BAUSER Geräte monitoring, failure indication BAUSER units
Wiring diagram 570 700 44

006 570 700 44 Fahrpumpen, Radmotoren, Startfreigabe driving pumps, weehl motors, starting release
007 570 700 44 Fahrstufen, Bremse, Verzögerungspedal speed ranges, brakes, decelerator device
008 570 700 44 Versorgung Steuerung, Warnsummer, Override supply controllers, warning buzzers, override
009 570 700 44 Lenkung und Arbeitshydraulik steering and working hydraulic system
010 570 700 44 Hupe, Schmieranlage, Tachograph, Sitzfunktionen horn, lubrication systhem, tachograph, seat funktions
011 570 700 44 Heizung und Belüftung heating and ventilation
012 570 700 44 Schutzbelüftung, Zyklon Abscheider, Klimatronik protected vent. system, cyclone separator, air cond.
013 570 700 44 Kabine und Anbauteile cabin and attachmentparts
101 570 700 44 Bauteilliste component listing
201 570 700 44 Schaltkasten ebox
301 570 700 44 Lokalisierungsgrafik Steckverbinder Draufsicht localization graphic connectors top view

BOMAG
04.06.2008
001 001
Werner Stromlaufplan 570 700 44
04.06.2008
19.6

995
circuit diagram 001
Seis
996
Zuleitung Steuerung Pin 54 30/54S 8:2
Zuleitung Steuerung Pin 5660 30/5660S
8:2

2,5qmm
Kabine K30
13:2
19.6

4qmm
geschaltetes "15/54"

2x6qmm
Batteriespannung 30 3:1

6qmm
15/54 X1:6
Zündschloß "15/54" 3:1

Einspeisepunkte für Versorgung

2,5qmm
4qmm
2x6qmm
6qmm
6qmm
Sicherungespotential K11:87!
X1:241 X1:242
X1:31E
X1:33E

0,11A
0,075A
X1:241
10:7
1 86 K61:87a 5:9 F24 K11:87 5:1
5:12
R10
1 220_O
K61 X1:298
F00 250A

057 665 63
2 2,5qmm X1:32E
2 85 X1:243
1x25qmm F122
10A
Anlassehauptleitung: 2x70qmm B+ 3:1
Ladeleitung 2x 10qmm oder 1x25qmm X1:32A
X1:81 1
X1:259

BOMAG
+ E21
X1:202
8:13
7:10

G01 2
11 21 31 41 51 61
S01
Batterie X14:6

0,075A
5A
Bei Steckdosenbetrieb je nach Stecker bis 16A möglich!
battery
max. 10A

12 22 32 42 52 62
B+ D+
+ 86 E20 1 2 X1:260 NotAus Schalter
28V/80A + emergancy shut off
G03 G02 K62 XS
24V 30

85 K22 8:9
B W
87a 87
X2:N X2:J EMR
S30 3 X14:7 4:15
W XS
Trennschalter 5:2 4:18
switch battery disconnect
4
X1:70 X1:256
31 31 3:1

2:10 12:10
Zigarettenanzünder Steckdose
cigarette lighter socket

04.06.2008
1 1

008 911 53
Wiring diagram 570 700 44

Werner Versorgung, Zigarettenanzünder 570 700 44

04.06.2008
Seis supply, cigarette lighter 002
2:15 30 30 4:1
2:11 15/54
6qmm
2:6 B+ B+ 4:1 X1:23E
Anlasserhauptleitung 2x70qmm F13
30A

008 911 53
X1:23A

6qmm

Zündstartschalter
012 30 ignition switch
S00
01

50a 15/54

4qmm
1,5qmm

X1:293
Wiring diagram 570 700 44

X1:302

X1:8 X1:9

30
K05
6:2
87 87a

X1:7

BOMAG
2,5qmm
X14:9 X1:371
0,2A

0,2A

86 86
30 50 2 K11 K32
M01
M V47
85 85
1

X1:256 X1:70

2:20 31 31 4:1

2:17 13:6

Starter
starter
Anzugswicklung KHD = 73A
Haltewicklung KHD = 12A

04.06.2008
1 1 570 700 44
Werner Zündschloß, Starter
04.06.2008
19.6

997
Seis ignition switch, starter 003
998
30 30
3:20 12:1
B+ Pedal
3:5 X1:24E 5:7
XS
B124 2:19
19.6

1 + 1 elektronisches Fußpdal Diagnosestecker

F48 F93 elektronic foot pedal diagnosis
86 86 86 X22
80A 25A K15 K146 K60
2 F78
2 S119 H04 1 H70 1
13
X1:24A S118

X4:A
X4:H
X4:G
X4:M
X4:F
X4:K
X4:B
2 2 Fehlertaster Motor
85 85 85
4qmm B46

4qmm
4qmm
14 failure push button engine

Williams Codierung
sw rt ws or gn bl

X1:92
X1:93
X1:94
1
R24

X1:62
X1:64
X1:65
X1:71
2 X1:255

X10:B
X10:C
X10:A
X12:A
X12:C
X12:B
X6:1 X1:250
X6:2 X1:244
X6:3 X1:270
X6:4 X1:269
10 kOhm
2 3 1 EMR
RPM 2:19
8:2
Option
option

X6:5
X6:6
X6:7
X6:8
X6:9
X6:10

X1:231
X1:232
X1:233
5V EDC 7:2
Handgas
7:2
4x2,5qmm Dachkurve AGND EDC "31" 4x2,5qmm
7:2

Sensor Wasserabscheider
sender water separator
"30"
Fehler EMR
Vers. Meldeleuchte
Glühen
Temperatur
Motoröldruck
"15"
CAN 1H
CAN 1L
CAN 2H
CAN 2L
ISO KLinie

S2 S1

Fehler Motor
failure engine
Wasserabsch.
water separator

X1:235
X1:236
X1:237

XD2.1:3
XD2.1:9
XD2.1:6
XD2.1:5

XD2.1:2
XD2.1:8
XD2.1:11

XD2.1:61
XD2.1:13
XD2.1:10

XD2.1:79
XD2.1:77
XD2.1:33
XD2.1:60
XD2.1:59
XD2.1:30
XD2.1:39
XD2.1:53
XD2.1:35

XD2.1:62
XD2.1:29
XD2.1:78
XD2.1:38
XD2.1:20
XD2.1:52
XD2.1:89

XD2.1:22
XD2.1:54
XD2.1:40
XD2.1:34

X27.2:11
X27.2:10
A48 EDC7 Steuerung
4qmm

X17.1:1
X17.1:2
X1:5

BOMAG
50i
K14 K2
4:4

3:20 31 31 5:1

4:2 5:3 5:4 5:4 Injektor B3

04.06.2008
1 1

008 911 53
Wiring diagram 570 700 44

Werner DEUTZ Steuergerät EDC 7 f. 6 und 8Zylindermot. 570 700 44

04.06.2008
Seis 070 DEUTZ controller EDC 7 for 6 and 8zylinder engine 004
4:20

999 BOMAG 008 911 53

2:8
2:20

31
W

25
2

X1:103 X1:301 X1:292

K11:87

R03
2
1
4

X1:229 Tankgeber X1:296 X1:90

level gauge X1:228
4:12
3
12

87a Vorglühen X1:89 X1:91

87
30

glow system
4:13
8

K15 K146

87a X1:87
Kühlmitteltemperatur
87
30

collant temperature
Seis
4:14
K60

87a X1:88
11

Werner

Motoröldruck
87
30

engine oil pressure

01.07.2008
01.07.2008

20s
15

Kühlmittelfüllstand X1:85
Q
B55

coolant tank X1:82

4
3

X1:181
Modul 1: Motorfunktionen
16

X1:86
module 1: engine functions

Luftfilter rechts
P
B03
Lüfter

air cleaner rh.

X1:83
4
3
ESX

X1:182
10

X1:298
Luftfilter links
P
X1:394/2
X1:392/2

X1:395/2
X1:393/2

air cleaner lh.

B116
8:15
11:16

4
3

X1:182
4:19
V05 2
V03 2
V04 2
V02 2
15A
F24

X1:29A
X1:29E

X1:101
1
1
1
1
A15

Pedal
2
1

X1:395/1
X1:393/1
X1:394/1
X1:392/1

X0:6
X0:11
X0:19
X0:52
X0:18
X0:36

ESX Steuerung
2:11 K61:87a

P
B129
X0:45
X0:50

X0:51
X0:10
X0:13

2
1

20s
X14:11

Verteilergetriebe
X14:10

X1:205 power takeoff gear

Q
B24
K61:87a

2
1

20s
Hydrauliköl min.
X1:181 hydraulic oil min.
B20
X1:210

4
3
2min
X1:403/1
X1:400/1
13:11

X1:398/1
X1:399/1
X1:397/1

X1:401/1

Hydrauliköltemp.
hydraulic oil temp.
X1:187
5:19
1
1
1
1
1
1
2:13

87
K113
F24

30
26

monitoring, failure indication BAUSER units

87a
A81

X1:104

Anzeigen, Störmeldungen BAUSER Geräte

1
2
Diff.drucksch.
2 V13 X1:403/2
2 V11 X1:401/2
2 V10 X1:400/2
2 V09 X1:399/2
2 V08 X1:398/2
2 V07 X1:397/2

pressure. diff.
12

Speisepumpe
X1:191 X1:116
Voltmeter

B121 B122

1
2
volt meter
Diff.drucksch. X1:108

Speisepumpe
pressure. diff.
13

X1:191 X1:117

nur BC 972/1172 RB
6:3
K48

X1:109

B22

1
2
10

X1:118
30

Diff.drucksch.

only acc. to BC 972/1172 RB

pressure. diff.
87a

Speisepumpe
X1:184 X1:123

B21

1
2
11

Diff.drucksch. X1:119
pressure diff.

Speisepumpe
X1:184 X1:111 X1:124

B42

1
2
8

X1:120
Diff.drucksch. I
pressure diff.

P
X1:185 X1:112 X1:125

Zwischengetr.
B05

module 2: maschine functions

2
1
9

Modul 2: Maschinenfunktionen
X1:122
Bremsdruck
X1:186 brake pressure X1:114 X1:126

+
25

B19
Verschmutzungssensor X1:121
contamination sensor

1
X1:183 X1:113

R04

2
1
1
Hydrauliköltemperatur X1:303
indicator light, hydr.oil temp.
X1:148

X5:2
X5:1
B53
Kühlmitteltemperatratur X1:300

2
1

1
collant temperature
X14:12 X1:291

X14:8
Abschmieren

5:12
X1:106

P
2.GANG 8:2
1.GANG 8:2

B25
10:2

4
3
X1:110
Rücklauffilter

31
K113 15
return flow filter
X1:183
120s switch on delay

570 700 44
120s anzugsverzögert

005
F24 8:1
Wiring diagram 570 700 44

31 6:1
K11:87 8:1
19.6
1000
DEC 1 7:4
X1:338 X1:262 S04:12 7:10
X1:335 2 1
19.6

X1:46/2 X1:46/1
X9:4 X9:1 FM6

1
R32 X1:42/1
1k
2

1 1
R33 1 R34 R35 1 FM2
2k 1k 3k3 2
2 2 2

Fahrtrichtungsschalter nicht belegt X1:42/2

switch, travel direction V0R 33 13 24 44 not used
S31 X1:336
34 14 23 43
X9:5 X9:6 X9:3 X9:2
X1:339

X1:340 X1:337

Richtung
AGND
8,5V
Ain

X1:412/1 X1:413/1

X0:1
13 9

X0:32
X0:23
X0:29

1 1
V23 V25 K77 K77 ESX Steuerung
8:17 8:17
2 2 14 10

X0:22
X0:21
X0:46
X0:47
X0:48
X0:43

BOMAG
X1:412/2 X1:413/2

Vorwärts

Rückwärts
vorne Links
hinten Links

vorne rechts
hinten rechts

br nicht bei
X1:221 X1:223 X1:135 X1:157
V38 BC 572772
not used for
rt BC 672772

X1:149 X1:153 X1:131 X1:133 X1:155

200 ... 600mA
200 ... 600mA
200 ... 600mA
200 ... 600mA

86 86 H14
K05 K48 + 1 1 1 1 1 1 1 1
V34 Y17 V35 Y17 V32 Y16 V33 Y16 Y132 Y133 Y134 Y135

85 85 2 2 2 2 2 2 2 2

1,08A
1,08A
1,08A
1,08A

X1:70 X1:70 X1:188

X1:222 X1:224 X1:136 X1:158
31 X1:154 X1:132 X1:134 X1:156
5:20 31 7:1
TandemPumpe TandemPumpe TandemPumpe TandemPumpe
3:9 5:14 rechts 2 rechts 4 links 1 links 3 Prop. Ventil Rad vorne li. Prop. Ventil Rad hinten re.
prop. valve weehl front lh. prop. valve weehl rear rh.
stromlos = qmax stromlos = qmax
Prop. Ventil Rad vorne re.
Ventile Fahrpumpe rückwärts Ventile Fahrpumpe vorwärts prop. valve weehl front rh.
solenoid valves, travel direction backw. solenoid valves, travel direction forw.
stromlos = qmax
Warnsummer Rückwärtsfahrt stromlos = Rückwärtsfahrt nicht aktiv stromlos = Vorwärtsfahrt nicht aktiv
buzzer, back up alarm strom = Rückwärtsfahrt aktiv strom = Vorwärtsfahrt aktiv
Prop. Ventil Rad hinten li.
prop. valve weehl rear lh.
stromlos = qmax

04.06.2008
1 1

008 911 53
Wiring diagram 570 700 44

Werner Fahrpumpen, Radmotoren, Startfreigabe 570 700 44

04.06.2008
Seis driving pumps, weehl motors, starting release 1 006
F25 8:1

X1:343 X1:261
31 X1:358
S01
2:17

008 911 53
Aktivierung Verzögerungspedal X1:357
32
enable decelerator pedal 6:19 S04:12 X1:41/2
X1:262 23
S02
12 123
S160 0 1 43 23 Bremsschalter 1 S02 Schalter Fahrstufen
S04 brake switch FM1 switch speed ranges
01
2 24
11 Komplett 872 701 02
44 24
X1:41/1
Verzögerungspedal

X40:6
X40:2
X13:3
5V EDC DEC 1
X13:1
X13:2

4:8 6:19 decelerator pedal R20 R21 R22 R23

1 k_O 1 k_O 1 k_O 1 k_O
bl gr
KD1 KD2
S161
Nur für BC 672772 RB/RS/EB
only acc. to BC 672772 RB/RS/EB
Wiring diagram 570 700 44

ws
rt
sw
ge
gn
vi
or
bei Option
Schalter Fahrstufen
switch speed ranges

X3:B
acc.to option
X40:3

decelerator pedal

Verbindung entfällt
connection not applied

X40:1
Fahrtverzögerungspedal
X1:359
X1:263

X42:5
X42:6
X41:11
X41:6
X41:4 X39:B
X41:3 X39:C
X41:5 X39:A
X41:1 X40:4
X41:2 X40:5
S04:11
7:11
Zusatzelektronik
A78

Bremse
high=Bremse auf
8,5V
AGND
Fahrstufen
additional electronic

X41:9

X42:1
X41:8

X42:2
X42:4
X41:10

X41:12
X0:1
X0:7

X0:23

X0:40
ESX Steuerung

BOMAG
X36:1
X0:62

X0:61
1

X3:C
R43

X3:A
499 _O
2
Handgas 5 k_O K77
4:8 8 7 S04:11

Bremse
AGND EDC X36:2 S120
4:8 8:17 7:10 X1:170
1./2. Fahrstufe

1 X1:151
R44

1,25A
1,25A

499 _O
1 2 Y04 1 Y03 1
H81 X36:3 V31 V37
2 2 2

X1:234
Nur für BC 672772 RB/RS/EB
only acc. to BC 672772 RB/RS/EB

31 X1:152 X1:192
6:20 31 8:1

Meldeleuchte Verzögerungsfunktion Magnetventil Bremse Stufenumschaltung

04.06.2008
1 1 570 700 44
Werner Fahrstufen, Bremse, Verzögerungspedal
04.06.2008
19.6

1001
Seis speed ranges, brakes, decelerator device 1 007
K11:87

1002
K11:87 10:1
5:20

X1:35E
19.6

F25
10A

X1:35A
F25 F25 9:1
7:20
2:19 30/54S 2,5qmm 5:5 ESX

2:19 30/5660S 4qmm

X1:26E
F24
5:20 X1:27E
RPM F84
4:8
10A

F67
30A X1:26A
30
K90
X1:27A
X1:257 8:7

2,5qmm
Elektronik
87 87a
21

X1:66
X2:H
X1:67
X2:G
S01

X2:U

5x0,75qmm
Leistung
2:17
22
X1:349
X1:349
X1:349

X1:258 X1:404/2 X1:405/2

X1:207
+UE/Dios
+UB/Dios
+UB/Dios

Drehzahl
CAN2
CAN2+
RxD
TxD
+ + + + + +

1x0,75qmm
2 2
V14 V15
1 1

X0:5
X0/1:3
X0/1:9

X0:4

X0:16
X0/1:10

X0:56
X0:57
X0:59
X0:60
X0:33
X0:53

X0:58

X0:28
X0:54
ESX Steuerung X1:404/1 X1:405/1 ESX Dios Modul

BOMAG
X0:25
X0:3
X0:2
X0:24
X0:44
Summer
X0/1:11
X0/1:4

1. Gang
2. Gang
GND/Dios

1.GANG
5:18
1

Relais Override
2.GANG

Motorabstellung
5:18 V42
Gehäuse Dios Modul

KLIMA
GND für Knotenaddresse Dios

X35:1
K90 86 K22 86 + K77/1 86 K77 86
H07
0,7A
X1:185
X1:186

X1:184

85 85 X35:2 85 85

0,075
0,075
0,021A
0,021A

31 X1:70 X1:70 X1:70 X1:70 X1:70

7:20 31 9:1

8:17 2:17
9:5 7:11
9:5 6:6
Warnsummer
warning buzzer 9:5 6:5

9:5

04.06.2008
1 1

008 911 53
Wiring diagram 570 700 44

Werner Versorgung Steuerung, Warnsummer, Override 570 700 44

04.06.2008
Seis supply controllers, warning buzzers, override 1 008
F25 X15:A
8:20
X1:349
Schild/Schaufel 1=senken / 2=heben 3=schließen / 4=öffnen
blade/shovel 1=let down / 2=lift 3=close / 4=open
1=Links /2=Rechts 1

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